High-integration type insulation battery box

Abstract

The invention relates to a high-integration type insulating battery box which comprises a bottom plate, a box body, a box cover and an internal partition plate, the bottom plate is of a plate-shaped structure with a preset thickness and is used for supporting the box body, the box cover and the internal partition plates; the box body is a shell with an upper opening and a lower opening and is arranged at the top of the bottom plate; the box cover is of a plate-shaped structure with a preset thickness and is arranged at the top of the box body, and a containing cavity is formed among the bottom plate, the box body and the box cover; the internal partition plate is arranged in the box body, and is arranged at the top of the bottom plate to divide the accommodating chamber into more than two spaces; the bottom plate, the box body, the box cover and the internal partition plates are all made of Kevlar composite materials with PMI and Kevlar honeycombs as sandwiches, and the technical problem that electromagnetic interference affects electronic components in the battery box and affects the structural integrity and durability of the battery box body is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy battery packs, and specifically to a highly integrated insulated battery box. Background Art

[0002] At present, the layout space left for the battery pack in flying cars is very limited. It is necessary to arrange 150 - 200 kWh of electricity in the extreme space to achieve a cruising time of 30 - 40 minutes, which poses high requirements for the integration of the battery box. At the same time, inside the battery box, on the one hand, the battery management system needs to monitor the status of all battery cells, and on the other hand, the battery management system needs to control the high - voltage distribution box to control the on - off of the battery box and the main circuit, resulting in redundant wiring harnesses. Once there is a short - circuit or open - circuit at a certain point in the wiring harness of the battery box, the battery system will be unable to operate, and the entire battery system is at risk of being scrapped, and it requires professional operation and is difficult to repair.

[0003] The existing battery box bodies for electric flying cars are mostly made of Q325 steel and aluminum alloy materials, and high - voltage plugs and communication plugs are set on the shell. Both of these two types of materials are conductive materials. On the one hand, they cannot effectively isolate electromagnetic interference from affecting the electronic components inside the battery box, and on the other hand, in a specific chemical environment, these two materials are prone to electrochemical corrosion, affecting the structural integrity and durability of the battery box body. Summary of the Invention

[0004] In view of this, the present application provides a highly integrated insulated battery box, which solves the above problems by changing the overall preparation material of the battery box.

[0005] According to one aspect of the present application, there is provided a highly integrated insulated battery box, including a bottom plate, a box body, a box cover and internal partitions; the bottom plate is a plate - shaped structure with a preset thickness, used to support the box body, the box cover and the internal partitions; the box body is a shell with openings at both the top and bottom, and the box body is arranged on the top of the bottom plate; the box cover is a plate - shaped structure with a preset thickness, arranged on the top of the box body, and an accommodation chamber is formed between the bottom plate, the box body and the box cover; the internal partitions are arranged inside the box body and on the top of the bottom plate, dividing the accommodation chamber into two or more spaces; the materials of the bottom plate, the box body, the box cover and the internal partitions are all Kevlar composite materials with PMI and Kevlar honeycomb as the sandwich.

[0006] In a possible implementation manner, the laying methods of the box cover, the box body and the internal partitions are all: first lay the first Kevlar fiber cloth layer, lay PMI on the first Kevlar fiber cloth layer, and lay the second Kevlar fiber cloth layer on the PMI.

[0007] In a possible implementation, the first Kevlar fiber cloth layer is a 4-layer 250 g / m 3 Kevlar fiber cloth, the thickness of the PMI is 3 mm, and the second Kevlar fiber cloth layer is a 4-layer 250 g / m 3 Kevlar fiber cloth; the laying angles of the 4 layers of Kevlar fiber cloth in the first Kevlar fiber cloth layer and the 4 layers of Kevlar fiber cloth in the second Kevlar fiber cloth layer from top to bottom are all: 0°, 45°, 90°, 0°.

[0008] In a possible implementation, the laying method of the bottom plate is: first lay the third Kevlar fiber cloth layer, lay the PMI on the third Kevlar fiber cloth layer, and lay the fourth Kevlar fiber cloth layer on the PMI.

[0009] In a possible implementation, the third Kevlar fiber cloth layer is a 6-layer 250 g / m 3 Kevlar fiber cloth, the thickness of the PMI is 3 mm, and the fourth Kevlar fiber cloth is a 6-layer 250 g / m 3 Kevlar fiber cloth; the laying angles of the 6 layers of Kevlar fiber cloth in the third Kevlar fiber cloth layer and the 6 layers of Kevlar fiber cloth in the fourth Kevlar fiber cloth layer from top to bottom are all: 0°, 45°, 90°, 45°, 0°, 0°.

[0010] In a possible implementation, the space includes a first space for placing an external battery module and a second space for placing electrical components.

[0011] In a possible implementation, the internal partition is vertically arranged at the top of the bottom plate.

[0012] In a possible implementation, a high-voltage plug, a communication plug, a high-voltage indicator light, and a fan are arranged on the box body; a plurality of through holes are formed in the front wall of the box body, and the high-voltage plug, the communication plug, and the high-voltage indicator light are all arranged on the front wall of the box body through the through holes; the through holes are also arranged on the right side wall of the box body, and a plurality of them are arranged along the length direction of the right side wall of the box body; the number of the fans is multiple and is the same as the number of the through holes on the right side wall of the box body, and the fans are arranged on the box body through the through holes on the right side wall of the box body.

[0013] In a possible implementation, it further includes a high-voltage power distribution module, a BMS module, an IMD module, and an FPC wire harness assembly; the high-voltage power distribution module, the BMS module, and the IMD module are all arranged in the second space; the FPC wire harness assembly is arranged inside the battery module; the BMS module is connected to the battery module through the FPC wire harness assembly, the BMS module is connected to the high-voltage power distribution module, and the IMD module is connected to the battery module.

[0014] In a possible implementation, the bottom plate is in a cuboid structure, the box body is in a trapezoidal structure, and one side of the top cover extends downward by a preset distance.

[0015] Advantages of the present invention: By providing a bottom plate, a box body, a box cover, and internal partitions; the bottom plate is a plate-like structure with a preset thickness, installed inside an external electric flying vehicle, and used to support the box body, the box cover, and the internal partitions. Through such a setting, the box body, the box cover, and the internal partitions can be fixed inside the electric flying vehicle; the box body is a shell with openings at both the top and bottom, and the box body is arranged on the top of the bottom plate. Through such a setting, the box cover is a plate-like structure with a preset thickness, arranged on the top of the box body, and an accommodation chamber is formed between the bottom, the box body, and the box cover, used to accommodate the battery module and electrical components; the internal partition is arranged inside the box body, and the internal partition is vertically arranged on the top of the bottom plate, dividing the accommodation chamber into two spaces. The first space is used to place the external battery module, and the second space is used to place electrical components. With such a setting, the battery module is used to supply power to the external electric flying vehicle, and the electrical components connect the battery module and the external electric flying vehicle, enabling the external electric flying vehicle to generate power; the materials of the bottom plate, the box body, the box cover, and the internal partitions are all Kevlar composite materials with PMI and Kevlar honeycomb as the sandwich. The strength of Kevlar fiber is very high, and PMI is a high dynamic load structural material. Choosing PMI material and Kevlar honeycomb material as the sandwich materials for the composite layup can improve the bending strength of the bottom plate, the box body, the box cover, and the internal partitions, while ensuring the lightweight of the materials and enabling the bottom plate, the box body 103, the box cover, and the internal partitions to have high fatigue resistance.

[0016] [[ID=⑨]]Other features and aspects of the present application will become clear from the following detailed description of the exemplary embodiments with reference to the accompanying drawings. Description of the Drawings

[0017] The drawings included in the specification and constituting a part of the specification show the exemplary embodiments, features, and aspects of the present application together with the specification, and are used to explain the principles of the present application.

[0018] Figure 1 It is a three-dimensional view of the highly integrated insulation battery box according to the embodiment of the present invention;

[0019] Figure 2Schematic diagram of the box assembly provided by the embodiment of the present invention;

[0020] Figure 3 Load-displacement diagrams of three-point bending and shear tests for the composite materials of the box cover, box body and internal partition provided by the embodiment of the present invention;

[0021] Figure 4 Load-displacement diagrams of three-point bending and shear tests for the composite material of the bottom plate provided by the embodiment of the present invention;

[0022] Figure 5 Schematic diagram of the high-voltage power distribution module provided by the embodiment of the present invention;

[0023] Figure 6 Specific structure diagram of the battery module and FPC harness assembly provided by the embodiment of the present invention. Detailed implementation manners

[0024] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments.

[0025] Examples of the embodiments are shown in the accompanying drawings, where the same or similar symbols represent the same or similar elements or elements with the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to explain the present invention and should not be construed as a limitation of the present invention.

[0026] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention or simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0027] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "a plurality" means two or more unless otherwise specifically defined.

[0028] In the present invention, unless otherwise clearly defined and limited, terms such as "installation", "connection", "linkage", "fixation", "engagement", "hinge" shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral one; it may be a mechanical connection or an electrical connection; it may be a direct connection or an indirect connection through an intermediate medium, and it may be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0029] As Figures 1 to 6 shown, the highly integrated insulated battery box is applicable to an electric flying vehicle and includes a bottom plate 104, a box body 103, a box cover 101, and an internal partition 102; the bottom plate 104 is a plate-like structure with a preset thickness and is installed inside an external electric flying vehicle for supporting the box body 103, the box cover 101, and the internal partition 102; the box body 103 is a shell with openings at both the top and bottom, and the box body 103 is arranged on the top of the bottom plate 104; the box cover 101 is a plate-like structure with a preset thickness and is arranged on the top of the box body 103, and a receiving chamber is formed between the bottom plate 104, the box body 103, and the box cover 101; the internal partition 102 is arranged inside the box body 103 and is vertically arranged on the top of the bottom plate 104 to divide the receiving chamber into two spaces, the first space is for placing an external battery module, and the second space is for placing electrical components; the materials of the bottom plate 104, the box body 103, the box cover 101, and the internal partition 102 are all Kevlar composite materials with PMI and Kevlar honeycombs as the sandwich.

[0030] Specifically, the specific structure of the highly integrated insulation battery box includes a bottom plate 104, a box body 103, a box cover 101, and an internal partition 102; the bottom plate 104 is a plate-like structure with a preset thickness, installed inside an external electric flying vehicle, and is used to support the box body 103, the box cover 101, and the internal partition 102. Through such a setting, the box body 103, the box cover 101, and the internal partition 102 can be fixed inside the electric flying vehicle; the box body 103 is a shell with openings at both the top and bottom. The box body 103 is arranged on the top of the bottom plate 104. Through such a setting, the box cover 101 is a plate-like structure with a preset thickness, arranged on the top of the box body 103, and a receiving chamber is formed between the bottom plate 104, the box body 103, and the box cover 101, which is used to accommodate the battery module 6 and electrical components; the internal partition 102 is arranged inside the box body 103, and the internal partition 102 is vertically arranged on the top of the bottom plate 104, dividing the receiving chamber into two spaces. The first space is used to place the external battery module 6, and the second space is used to place electrical components. With such a setting, the battery module 6 is used to supply power to the external electric flying vehicle, and the battery module 6 and the external electric flying vehicle are connected through electrical components, enabling the external electric flying vehicle to generate power; the materials of the bottom plate 104, the box body 103, the box cover 101, and the internal partition 102 are all Kevlar composite materials with PMI and Kevlar honeycomb as the sandwich. The strength of Kevlar fiber is very high, and PMI is a high dynamic load structural material. PMI material and Kevlar honeycomb material are selected as the sandwich materials for the composite ply.

[0031] Among them, the laying methods of the box cover 101, the box body 103, and the internal partition 102 are all as follows: First, lay the first layer of Kevlar fiber cloth, lay PMI on the first layer of Kevlar fiber cloth, and lay the second layer of Kevlar fiber cloth on the PMI. The first layer of Kevlar fiber cloth is a 4-layer 250g / m 3 Kevlar fiber cloth, the thickness of PMI is 3mm, and the second layer of Kevlar fiber cloth is a 4-layer 250g / m 3 Kevlar fiber cloth. The laying angles of the 4 layers of Kevlar fiber cloth in the first layer of Kevlar fiber cloth and the 4 layers of Kevlar fiber cloth in the second layer of Kevlar fiber cloth from top to bottom are all: 0°, 45°, 90°, 0°. The laying method of the bottom plate 104 is: First, lay the third layer of Kevlar fiber cloth, lay PMI on the third layer of Kevlar fiber cloth, and lay the fourth layer of Kevlar fiber cloth on the PMI. The third layer of Kevlar fiber cloth is a 6-layer 250g / m 3 Kevlar fiber cloth, the thickness of PMI is 3mm, and the fourth layer of Kevlar fiber cloth is a 6-layer 250g / m 3Kevlar fiber cloth. The laying angles of the 6 layers of Kevlar fiber cloth in the third Kevlar fiber cloth layer and the 6 layers of Kevlar fiber cloth in the fourth Kevlar fiber cloth layer from top to bottom are all: 0°, 45°, 90°, 45°, 0°, 0°.

[0032] Further, in some embodiments, the lid 101101, the box body 103, and the internal partition 102 bear less force than the bottom plate 104 in the operating conditions of the flying car. The designed layup method from top to bottom is successively 250 g / m 3 4 layers of Kevlar fiber cloth, 3 mm thick PMI, 250 g / m 3 4 layers of Kevlar fiber cloth, and the angles of the Kevlar fiber cloth are successively 0°, 45°, 90°, 0°. The layup method of the bottom plate 104 from top to bottom is successively 250 g / m 3 6 layers of Kevlar fiber cloth, 3 mm thick PMI, 250 g / m 3 6 layers of Kevlar fiber cloth, and the angles of the Kevlar fiber cloth are successively 0°, 45°, 90°, 45°, 0°, 0°.

[0033] Further, 250 g / m 3 The strength of Kevlar fiber is very high, which can reach five times that of steel of the same mass, and the density is only one-fifth of that of steel. The 0° angle layup makes the material have very high strength and stiffness in the tensile direction, but the strength and toughness in the transverse direction are relatively low. The 90° angle layup makes the material have higher strength and toughness in the transverse direction, but the strength and stiffness in the tensile direction are relatively low. In the layup design of the Kevlar fiber cloth of the lid 101, the box body 103, and the internal partition 102 with angles of 0°, 45°, 90°, 0°, the 0° layer provides the maximum axial strength, and the 45° and 90° layers provide the transverse strength and toughness, enabling the composite material to better disperse and absorb energy when being impacted. The alternating use of the 0° and 90° layers increases the stability of the laminate, reduces the interlayer slip, and improves the stability of the overall structure. Arranging the 0° layer on the outermost layer can improve the out-of-plane performance of the composite laminate, such as impact resistance and compression resistance, and the fibers in the 0° direction provide the strongest in-plane support. In addition, arranging the 0° layer on the outer layer can more effectively bear cyclic loads, reduce the generation and propagation of fatigue cracks, and extend the service life of the material. Since the bottom plate 104 bears greater axial force, an additional layer of 45° and 0° layup is added in the layup design. The 0° layer is along the fiber direction and has the highest unidirectional tensile strength. When two layers of 0° fiber cloth are arranged adjacent to each other, the in-plane strength of the composite laminate in this direction is significantly improved.

[0034] Furthermore, when subjected to transverse bending, the bending moment M varies with the cross-sectional position. Generally, the maximum normal stress σmax occurs on the cross-section with the maximum bending moment and at the farthest distance from the neutral axis. Therefore, increasing the thickness of the material can significantly improve the bending stress of the material. Therefore, in order to improve the bending strength of the material while ensuring the lightweight of the material, PMI material and Kevlar honeycomb material are selected as the sandwich materials for the composite ply. Since the lid 101, the box body 103, and the internal partition 102 are less stressed, PMI material with high fatigue resistance and suitable for sandwich structures under high dynamic loads is selected as the sandwich. Since the bottom plate 104 is more stressed, Kevlar honeycomb material with excellent strength-to-weight ratio is selected as the sandwich.

[0035] Furthermore, the forming processes of the lid 101, the box body 103, the internal partition 102, and the bottom plate 104 are all vacuum bag molding. Three-point bending and shear tests are conducted on different ply designs to test the strength of the materials. Please refer to Figure 3 and Figure 4 , the load-displacement diagrams of the three-point bending and shear tests of the lid 101, the box body 103, the internal partition 102, and the bottom plate 104 are used to calculate the ply stiffness and shear strength. The ultimate tensile strength σ of the lid 101, the box body 103, and the internal partition 102 = maximum load / material cross-sectional area = 143 MPa, and the shear strength τ = maximum load / material cross-sectional area = 312.6 MPa. The ultimate tensile strength σ of the lid 101, the box body 103, and the internal partition 102 = maximum load / material cross-sectional area = 128 MPa, and the ultimate shear strength τ = maximum load / material cross-sectional area = 281.9 MPa. The ultimate tensile strength σ of the bottom plate 104 = maximum load / material cross-sectional area = 137 MPa, and the ultimate shear strength τ = maximum load / material cross-sectional area = 312.6 MPa. Please refer to the following table for the comparison of the material properties of the ply with the benchmark steel. It is concluded that the ply schemes of the lid 101, the box body 103, the internal partition 102, and the bottom plate 104 are equivalent to steel with a thickness of 0.9 mm, and the ply scheme of the bottom plate 104 is equivalent to steel with a thickness of 1.25 mm, showing good applicability.

[0036] Table 1

[0037]

[0038]

[0039] Through experiments, the lid 101, the box body 103, the internal partition 102, and the bottom plate 104 have good shear resistance and bending resistance, and can achieve the purpose of protecting the internal battery module 6 under the condition of full insulation.

[0040] In a possible implementation, a high-voltage plug 105, a communication plug 107, a high-voltage indicator light 106, and a fan 108 are provided on the box body 103; a plurality of through holes are formed in the front wall of the box body 103, and the high-voltage plug 105, the communication plug 107, and the high-voltage indicator light 106 are all arranged on the front wall of the box body through the through holes; the through holes are also arranged on the right side wall of the box body 103, and a plurality of them are arranged along the length direction of the right side wall of the box body 103; the number of fans 108 is multiple and the same as the number of through holes on the right side wall of the box body 103, and the fans 108 are arranged on the box body 103 through the through holes on the right side wall of the box body 103. It further includes a high-voltage power distribution module 2, a BMS module 3, an IMD module 4, and an FPC wire harness assembly 5; the high-voltage power distribution module 2, the BMS module 3, and the IMD module 4 are all arranged in the second space; the FPC wire harness assembly 5 is arranged inside the battery module 6; the BMS module 3 is connected to the battery module 6 through the FPC wire harness assembly 5, the BMS module 3 is connected to the high-voltage power distribution module 2, and the IMD module 4 is connected to the battery module 6.

[0041] Specifically, the box cover 101, the internal partition 102, the box body 103, the bottom plate 104, the high-voltage plug 105, the high-voltage indicator light 106, the communication plug 107, and the fan 108 form a box body assembly 1. The box body 103 is adhered to the bottom plate 104 by structural adhesive, and the internal partition 102 is adhered to the bottom plate 104 by structural adhesive to form a cavity in the battery box for placing the battery module 6. The box cover 101 is installed on the box body 103 by bolts to isolate the high voltage inside the battery box. The box cover 101, the internal partition 102, the box body 103, and the bottom plate 104 are all Kevlar composite materials with PMI or Kevlar honeycomb as the core, which can not only achieve electrical isolation but also play a role in fire prevention and chemical corrosion resistance. The internal partition 102 is provided with pores for heat dissipation and ventilation to prevent the temperature of the battery cells from being too high and also reduce the weight of the box body assembly 1. The box body 103 has openings for the fan 108 for forced air cooling, the high-voltage plug 105, the communication plug 107, and the high-voltage indicator light 106. The fan 108 is adhered to the opening of the box body 103 by structural adhesive for forced heat dissipation of the battery box. The high-voltage plug 105 is fixed to the opening of the box body 103 by bolts for outputting the high voltage inside the battery box. The communication plug 107 is fixed to the opening of the box body 103 by bolts for communicating with the upper-level flight control system. The high-voltage indicator light 106 is adhered to the opening of the box body 103 by structural adhesive for indicating whether the high-voltage circuit inside the battery box is connected.

[0042] Among them, it also includes a high-voltage power distribution module 2, a BMS module 3, an IMD module 4, an FPC harness assembly 5, and a battery module 6. The material of the box assembly 1 is Kevlar and PMI composite material. The high-voltage power distribution module 2 is installed inside the box assembly 1. The BMS module 3 is installed inside the box assembly 1. The BMS module 3 is connected to the battery module 6 through the FPC harness assembly 5. The BMS module 3 is connected to the high-voltage power distribution module 2 through a plug. The IMD module 4 is installed inside the box assembly 1 and is connected to the positive and negative electrodes of the battery. The FPC harness assembly 5 is installed inside the battery module 6, and the battery module 6 is installed inside the box assembly 1.

[0043] In some embodiments, please refer to Figure 5 , the high-voltage power distribution module 2 is designed in a modular form to improve the integration of the flying car battery system. The high-voltage power distribution module 2 includes an insulating housing 201, a positive relay 202, a negative relay 203, a pre-charge relay 208, a pre-charge resistor 210, a main fuse 205, a copper bar 209, and a current sensor 204. The positive relay 202, the negative relay 203, the pre-charge relay 208, the pre-charge resistor 210, the main fuse 205, and the current sensor 204 are all fixed inside the insulating housing 201 with bolts.

[0044] Further, in some embodiments, the positive relay 202 is connected to the total positive electrode of the battery module 6 through a high-voltage cable 207 and a bolt. The negative relay 203 is connected to the total negative electrode of the battery module 6 through a high-voltage cable 207 and a bolt. The positive relay 202 and the negative relay 203 cut off or connect the high voltage to the main circuit under the control of the BMS module 3. The pre-charge relay 208 is connected in series with the pre-charge resistor 210, and at the same time, the pre-charge relay 208 is connected in parallel with the negative relay 203 to prevent excessive current at the moment when the main circuit is connected, protecting the battery cells and the relay.

[0045] Further, in some embodiments, the high-voltage power distribution module 2 is connected to the BMS module 3, used to receive the control instructions transmitted by the BMS, and control the on-off of the positive relay 202, the negative relay 203, and the pre-charge relay 208 according to the control instructions, thereby controlling the on-off of the main circuit of the battery box. The current sensor 204 is connected in series with the positive relay 202, used to monitor the current in the main circuit of the battery box. The main fuse 205 is installed in the insulating fuse housing 206, connected in series between the negative relay 202 and the battery module 6, used to prevent excessive main circuit current and ensure the safety of the battery system. The copper bar 209 is fixed on the positive relay 202 and the negative relay 203 with bolts, connecting the high-voltage plug 105 and outputting high voltage.

[0046] In some embodiments, please refer to Figure 2, the BMS module 3 includes a BMS bracket and a BMS. The BMS is fixed inside the box assembly 1 through bolts and the BMS bracket, and is used to collect operating parameters such as the cell voltage, total voltage, and relay status of the battery box, estimate the state of charge parameter of the battery, and issue charge and discharge control instructions and fault alarms.

[0047] In some embodiments, refer to Figure 2 , the IMD module 4 includes an IMD bracket and an IMD. The IMD is fixed inside the box assembly 1 through bolts and the IMD bracket, and is used to monitor the insulation resistance of the high-voltage positive and negative poles of the battery box to the ground of the flying car body, avoiding the risk of electric shock to the driver.

[0048] In some embodiments, refer to Figure 6 , the FPC harness assembly 5 includes an FPC 501, a small fuse 502, and a thermistor 503, and is used to connect the BMS module 3 to the cells, and obtain the voltage and temperature of each cell in the battery box in real time. The FPC 501 is welded to the cell tab of the battery module 6 according to the corresponding pads by a welding process. The small fuse 502 is welded to the cell tab of the cell 602 of the FPC 501 by a welding process, and is used to prevent the current from being too large due to a short circuit of the cell 602 and damaging the circuit. The thermistor 503 is welded to the negative tab of the cell 602 of the FPC 501 by a welding process, and is used to measure the temperature at the negative tab of the cell 602. By simplifying the acquisition harness of the cell 602 into an FPC harness, the redundancy of the harness is greatly reduced, the reliability of the harness is improved, and the occupied space is reduced.

[0049] In some embodiments, refer to Figure 6 , the battery module 6 includes a cell 602, an insulating and flame-retardant foam 603, a module housing 601, an insulating cover plate 604, a collecting board 614, a positive electrode base 605, a positive electrode pin 606, a positive electrode copper bar 607, a positive electrode protective case 608, a negative electrode base 613, a negative electrode copper bar 612, a negative electrode connecting member 611, a high-voltage cable 609, and a negative electrode protective case 610. The cell 602 is installed in the cavity of the module housing 601, and the cells 602 in the battery module 6 are connected in series using an ultrasonic welding process. Compared with bolt-pressed tabs, the weight of the battery module 6 is reduced to a large extent. The insulating and flame-retardant foam 603 is sandwiched between adjacent cells 602 according to a certain rule, and is used to reduce the collision and vibration between adjacent cells 602 and protect the cells 602. The material of the module housing 601 is an epoxy material, which reduces the weight and improves the insulation performance of the battery module 6 at the same time.

[0050] Further, in some embodiments, the insulating cover plate 604 is disposed on the outer surface of the module housing 601 along the X direction from the open end of the module housing 601, and is used to enclose the cell 602 and the FPC harness assembly 5 in the inner cavity, further improving the insulation performance of the battery module 6.

[0051] Further, in some embodiments, the acquisition board 614 is fixed to the upper part of the insulating cover plate 604 by bolts and is connected to the FPC harness assembly 5 to collect the voltage and temperature signals of the battery cells 602, making better use of the limited space inside the battery box.

[0052] Further, in some embodiments, the positive electrode base 605 is fixed to the upper part of the insulating cover plate 604 by bolts, the positive electrode pin 606 is fixed to the upper part of the positive electrode base 605 by bolts, the positive electrode copper bar 607 is fixed to the upper part of the positive electrode pin 606 by bolts, the positive electrode tab of the battery cell 602 is clamped between the positive electrode pin 606 and the positive electrode copper bar 607, improving the stability of the series connection of the battery cells 602 and providing a socket for connecting to the previous battery module 6. The positive electrode protective case is fixed to the upper part of the insulating cover plate 604 by bolts, covering the conductive structures of the positive electrode pin 606 and the positive electrode copper bar 607, isolating the high voltage at the positive electrode tab and preventing the risk of short circuit or electric shock.

[0053] Further, in some embodiments, the negative electrode base 613 is fixed to the upper part of the insulating cover plate 604 by bolts, the negative electrode copper bar 612 is fixed to the upper part of the negative electrode base 613 by bolts, the negative electrode connecting part 611 is fixed to the upper part of the negative electrode copper bar 612 by bolts, the negative electrode tab of the battery cell 602 is clamped between the negative electrode copper bar 612 and the negative electrode connecting part 611, the high-voltage cable 609 is connected to the negative electrode connecting part 611 by bolts, and the other end of the high-voltage cable 609 is connected to the next battery module 6 to form a series-connected battery pack. The negative electrode protective case 610 is fixed to the upper part of the insulating cover plate 604 by bolts, covering the conductive structures of the negative electrode connecting part 611 and the negative electrode copper bar 612, isolating the high voltage at the negative electrode tab and preventing the risk of short circuit or electric shock.

[0054] In a possible implementation manner, the bottom plate 104 is of a cuboid structure, the box body 103 is of a trapezoidal structure, and one side of the top cover 101 extends downward by a preset distance.

[0055] Specifically, as Figure 2 shown, the bottom plate 104 is of a cuboid structure, the box body 103 is of a trapezoidal structure, making the second space smaller and capable of accommodating all the electrical components. In order for the top cover 101 to be adapted to the box body 103, one side of the top cover 101 extends downward by a preset distance. Such a setting can save the space of the external electric flying vehicle to a certain extent, but is not limited to the shape of this embodiment, and the shapes of the bottom plate 104, the box body 103 and the top cover 101 can be changed according to needs.

[0056] In this application, the bottom plate 104, the box body 103, the box cover 101 and the internal partition 102 are made of Kevlar and PMI composite materials, and the battery module 6 is fixed in the cavity of the internal partition 102. The wire harness for collecting the voltage and temperature of the battery cells is simplified into an FPC wire harness assembly 6, and the FPC wire harness assembly 6 is covered with an insulating cover plate 604, and the electrical components are enclosed in the cavity to complete the assembly of the battery module 6. The high-voltage power distribution module 2 is designed in a modular form, and the main electrical components are all fixed to the inside of the box body 103 with bolts. The battery management system is connected to the battery module 6 to collect the battery cell signals and is connected to the high-voltage power distribution module 2 to control the on / off of the main circuit. The acquisition board 614 of the battery management system is designed in the form of a flexible circuit board, and the high-voltage power distribution module 2 is designed in a modular way, which can simplify the redundant physical wire harness and realize more flexible space utilization. The fully insulated box body 103 improves the safety and durability of the battery pack.

[0057] As mentioned above, the above are only the preferred specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the scope disclosed by the present invention, according to the technical solution and concept of the present invention, makes equivalent substitutions or changes, and should be covered by the protection scope of the present invention.

Claims

1. A highly integrated insulated battery box, characterized in that, It includes a bottom plate, a box body, a box cover and internal partitions; The bottom plate is a plate-like structure with a preset thickness, and is used to support the box body, the box cover and the internal partitions; The box body is a shell with openings at both the top and bottom, and the box body is arranged on the top of the bottom plate; The box cover is a plate-like structure with a preset thickness, arranged on the top of the box body, and an accommodation chamber is formed between the bottom plate, the box body and the box cover; The internal partitions are arranged inside the box body, and the internal partitions are arranged on the top of the bottom plate, dividing the accommodation chamber into two or more spaces; The materials of the bottom plate, the box body, the box cover and the internal partitions are all Kevlar composite materials with PMI and Kevlar honeycomb as the sandwich; 2. The highly integrated insulated battery box according to claim 1, wherein The laying methods of the box cover, the box body and the internal partitions are all: first lay the first Kevlar fiber cloth layer, lay PMI on the first Kevlar fiber cloth layer, and lay the second Kevlar fiber cloth layer on the PMI; 3. The highly integrated insulated battery box according to claim 2, wherein The first Kevlar fiber cloth layer is a 4-layer 250 g / m 3 Kevlar fiber cloth, the thickness of the PMI is 3 mm, and the second Kevlar fiber cloth layer is a 4-layer 250 g / m 3 Kevlar fiber cloth; The laying angles of the 4 layers of Kevlar fiber cloth of the first Kevlar fiber cloth layer and the laying angles of the 4 layers of Kevlar fiber cloth of the second Kevlar fiber cloth layer from top to bottom are all: 0°, 45°, 90°, 0°; 4. The highly integrated insulated battery box according to claim 1, characterized in that, The laying method of the bottom plate is: first lay the third Kevlar fiber cloth layer, lay PMI on the third Kevlar fiber cloth layer, and lay the fourth Kevlar fiber cloth layer on the PMI; 5. The highly integrated insulated battery box according to claim 4, wherein, The third Kevlar fiber cloth layer is a 250 g / m² Kevlar fiber cloth with 6 layers. The thickness of the PMI is 3 mm. The fourth Kevlar fiber cloth is a 250 g / m² Kevlar fiber cloth with 6 layers; 3 The third Kevlar fiber cloth layer is a 250 g / m² Kevlar fiber cloth with 6 layers. The thickness of the PMI is 3 mm. The fourth Kevlar fiber cloth is a 250 g / m² Kevlar fiber cloth with 6 layers; 3 Kevlar fiber cloth; The laying angles of the 6 layers of Kevlar fiber cloth of the third Kevlar fiber cloth layer and the laying angles of the 6 layers of Kevlar fiber cloth of the fourth Kevlar fiber cloth layer from top to bottom are all: 0°, 45°, 90°, 45°, 0°, 0°; 6. The highly integrated insulated battery box according to any one of claims 1-5, characterized in that The spaces include a first space for placing an external battery module and a second space for placing electrical components; 7. The highly integrated insulated battery box according to any one of claims 1-5, characterized in that, The internal partitions are vertically arranged on the top of the bottom plate; 8. The highly integrated insulated battery box according to claim 1, characterized in that, A high-voltage plug, a communication plug, a high-voltage indicator light and a fan are arranged on the box body; A plurality of through holes are opened on the front wall of the box body, and the high-voltage plug, the communication plug and the high-voltage indicator light are all arranged on the front wall of the box body through the through holes; The through holes are also arranged on the right side wall of the box body, and a plurality of them are arranged along the length direction of the right side wall of the box body; The number of the fans is a plurality, and is the same as the number of the through holes on the right side wall of the box body, and the fans are arranged on the box body through the through holes on the right side wall of the box body; 9. The highly integrated insulated battery box according to claim 8, wherein, It also includes a high-voltage power distribution module, a BMS module, an IMD module and an FPC wire harness assembly; The high-voltage power distribution module, the BMS module and the IMD module are all arranged in the second space; The FPC wire harness assembly is arranged inside the battery module; The BMS module is connected to the battery module through the FPC wire harness assembly, the BMS module is connected to the high-voltage power distribution module, and the IMD module is connected to the battery module; 10. The highly integrated insulated battery box according to claim 1, characterized in that, The bottom plate is a cuboid structure, the box body is a trapezoidal structure, and one side of the top cover extends downward by a preset distance.

Images