Modularized power battery pack

Abstract

The invention discloses a modular power battery pack. The modular power battery pack adopts a highly integrated, lightweight and modular design. The battery pack is integrated with a battery box body, a battery cell module, a fuse, a pre-charging resistor, a pre-charging relay, a high-voltage connector, a slave control module, a BMS control module, a high-voltage connector, a low-voltage connector and other parts. The battery box body and the battery cell module are stacked in multiple layers, and the battery box body is integrally cast by adopting a high-strength aluminum alloy material, so that the energy density of the battery pack is effectively improved. Hoisting holes are reserved in the two side surfaces of the battery pack to realize integral hoisting, so that the assembly timeliness and the maintenance convenience are improved. Multi-pack parallel connection of the battery system is achieved, when one battery pack breaks down in the running process of the whole vehicle, the battery pack of the branch circuit is controlled to be cut off through the BMS to conduct pack throwing treatment, normal work of other battery packs is not affected, and the vehicle can continue to run.

Description

Technical Field

[0001] The present invention belongs to the field of new energy power batteries, and particularly relates to a modular power battery pack. Background Art

[0002] The current mainstream power battery system for new energy heavy-duty trucks in my country consists of a battery pack + battery frame. This complex battery pack design makes matching difficult and occupies space within the vehicle, impacting cargo capacity. The present invention provides a modular power battery pack that fully utilizes the space within the vehicle chassis. The modular battery pack features a multi-layer stacked modular housing with an integrated frame that allows for direct mounting to the vehicle frame. This addresses the current assembly difficulties associated with the battery + frame structure while effectively increasing the energy density of the battery system. The voltage of a single modular battery pack reaches the overall vehicle voltage platform, enabling the parallel connection of multiple power battery packs in a modular layout.

[0003] Existing technologies have problems: The power battery system uses a battery pack + battery frame structure, which has low system energy density and is heavy. The battery pack and power battery frame need to be installed layer by layer, with a large number of connecting bolts, which makes assembly time-consuming and maintenance difficult. Summary of the Invention

[0004] The purpose of the present invention is to provide a modular power battery pack to meet the development trend of new energy heavy trucks for modularization, lightweight and high integration of power battery systems. In order to make full use of the layout space of the whole vehicle, the modular battery pack adopts a multi-layer stacking assembly scheme, a lightweight box (integrated frame function), a high-density energy cell module and other measures to improve the energy density of the system. The battery pack integrates a BMS high-voltage box, and the voltage of a single pack reaches the platform voltage of the whole vehicle. The battery system realizes multiple packs in parallel. When a battery pack fails during the operation of the whole vehicle, the BMS control cuts off this branch battery pack for "dumping" processing, which does not affect the normal operation of other battery packs, and the vehicle can continue to drive. The modular battery pack is flexible in layout and can be arranged in the cabin, on both sides of the frame, in the middle of the frame, etc., to make full use of the layout space of the whole vehicle.

[0005] In order to solve the above problems existing in the prior art, the technical solution adopted by the present invention is:

[0006] A modular power battery pack, comprising: an upper guard plate, a battery cell group, a cooling manifold, and a BMS high-voltage box;

[0007] The top of the battery cell group is connected to an upper guard plate, and the battery cell group includes a plurality of battery cell layers stacked longitudinally, and the battery cell layer includes a battery box and a battery cell module located in the middle of the battery box;

[0008] A cross reinforcement plate is provided inside the battery box, an installation notch is provided between the cross reinforcement plate and the battery box, the battery box is also provided with an explosion-proof valve installation hole, a water cooling plate is provided at the bottom of the battery box, a bolt installation hole is provided at the lower part of the battery box, and a sealing gasket installation groove for installing a sealing gasket is provided at the upper part of the battery box; the sealing gasket is provided in the sealing gasket installation groove, and a threaded hole is provided in the sealing gasket installation groove, and the threaded hole is provided in a one-to-one correspondence with the bolt installation opening.

[0009] The battery boxes are connected by bolts. The bolt mounting holes of the upper battery box are aligned with the threaded holes of the lower battery box, and then the bolts are connected. The sealing gasket is also provided with holes for passing the bolts. The sealing gasket is placed between the two battery boxes to provide a sealing effect. In order to facilitate the passage of the bolts through the sealing gasket, corresponding holes are also provided on the sealing gasket.

[0010] The explosion-proof valve mounting hole is used for connecting the explosion-proof valve.

[0011] The battery cell module includes multiple electric chips, and the positive and negative electrodes of the multiple electric chips are connected in series in sequence by welding copper bars. The positive and negative electrodes of the battery cell module are both connected to the BMS high-voltage box.

[0012] Furthermore, the battery case is constructed from a lightweight, one-piece magnesium-aluminum alloy. Cross-reinforcement plates are installed inside the battery case to enhance overall strength. A water-cooling plate is installed at the bottom of the case, with an S-shaped water channel cast inside. This water channel features low water resistance, a large cooling area, and rapid heat dissipation. The S-shaped water channel is connected to the cooling inlet and outlet. Bolt mounting holes are located at the bottom of the case, while a gasket mounting slot and threaded holes are located at the top for connecting the upper battery modules. The front panel features explosion-proof valve mounting holes for installing the valve, cooling water inlets and outlets for installing the cooling manifold, and wiring holes for routing high-voltage busbars and signal acquisition cables. The rear panel features explosion-proof valve mounting holes for installing the valve, and lifting holes are located on both sides for lifting the battery modules. Separately installing the cell modules increases safety.

[0013] Furthermore, the battery cell module is composed of multiple battery cell layers, and the battery cell layers are composed of multiple electric chips connected by welding copper busbars without traditional connecting plates at both ends, which further improves the energy density; four battery cell modules are installed in the four partitions of the battery box, and then the positive bus copper bus, signal acquisition line, negative bus copper bus and other components are welded.

[0014] Furthermore, the water-cooling plate is internally provided with an S-shaped water channel, with a cooling water inlet and cooling water outlet at either end. The S-shaped water channel, cast within the water-cooling plate, features low water resistance, a large cooling and heat dissipation area, and rapid heat dissipation. The S-shaped water channel is connected to the cooling water inlet and cooling water outlet. The water-cooling plate is primarily used to cool electronic chips. The S-shaped water channel maximizes the water channel contact area and improves cooling efficiency.

[0015] Furthermore, it also includes a cooling converging water pipe, which includes a converging water inlet pipe and a converging water outlet pipe. The converging water inlet pipe is connected to the cooling water inlet through the water inlet, and the converging water inlet pipe is connected to the vehicle cooling system through the vehicle water inlet. The converging water outlet pipe is connected to the cooling water outlet through the water outlet, and the converging water outlet pipe is connected to the vehicle cooling system through the vehicle water outlet.

[0016] Furthermore, BMS high-voltage box: the high-voltage box integrates the positive high-voltage bus, fuse, pre-charge resistor, pre-charge relay, main positive relay, main negative relay, negative high-voltage bus, positive high-voltage connector and negative high-voltage connector, slave control module, low-voltage interface, control line, diagnostic interface, BMS control module, high-voltage box shell and end cover.

[0017] The beneficial effects of the present invention are:

[0018] 1. The battery modules of the present invention are installed in compartments within the battery box with adhesive coating on their bottoms. This partitioning has the beneficial effect of: if a battery module in one compartment fails, it can be repaired or replaced without affecting other compartments, resulting in low maintenance costs. Multiple battery cells are connected in series via copper busbars welded together to achieve the vehicle platform voltage. The busbars and signal acquisition cables connecting the same layers are routed through the reserved wiring holes in the battery box to form a battery module.

[0019] 2. The beneficial effect of the present invention using the above-mentioned multi-layer battery module stacking installation is that the upper and lower battery modules are connected by bolts, which is convenient for installation and disassembly. If a single-layer battery module fails, there is no need to disassemble the entire battery pack, and the maintenance cost is low.

[0020] 3. The beneficial effect of the present invention using the above-mentioned battery pack integrated BMS high-voltage box is that when a battery pack fails during the operation of the entire vehicle, the BMS controls the disconnection of this branch battery pack for "pack discarding" processing, which does not affect the normal operation of other battery packs and the vehicle can continue to drive.

[0021] 4. The present invention adopts a multi-layer stacking arrangement to improve the system energy density of the battery pack. The upper and lower layers are connected by bolts to achieve modular assembly, which is convenient for assembly and disassembly and has low maintenance costs. The battery pack is flexible in layout, saving space for the entire vehicle layout, and can be hoisted as a whole, with high assembly efficiency. The battery pack is integrated with a BMS high-voltage box. The voltage of a single pack reaches the voltage of the entire vehicle platform to achieve high-voltage redundancy. The battery system realizes multiple packs in parallel. When a battery pack fails during the operation of the entire vehicle, the BMS control cuts off the branch battery pack for "pack ejection" processing, which does not affect the normal operation of other battery packs, and the vehicle can continue to drive. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a structural schematic diagram of the present invention.

[0023] Figure 2 It is an exploded view of the present invention.

[0024] Figure 3 It is a schematic diagram of the battery box structure of the present invention.

[0025] Figure 4 for Figure 3 A partial enlarged view of part A.

[0026] Figure 5 This is a cross-sectional view of the water-cooling plate of the battery box in the present invention.

[0027] Figure 6 Schematic diagram of the single-layer battery module structure in the present invention Figure 1 .

[0028] Figure 7 Schematic diagram of the single-layer battery module structure in the present invention Figure 2 .

[0029] Figure 8 for Figure 7 A partial enlarged view of part B.

[0030] Figure 9 This is a schematic diagram of the installation of the confluence water pipe in the present invention.

[0031] In the figure: 1-upper guard plate; 2-battery box; 201-cross reinforcement plate; 202-water cooling plate; 203-bolt mounting hole; 204-sealing gasket mounting slot; 205-threaded hole; 206-explosion-proof valve mounting hole; 207-cooling water inlet; 208-cooling water outlet; 209-wiring hole; 211-lifting hole; 3-explosion-proof valve; 4-cooling confluence water pipe; 401-confluence water inlet pipe; 402-confluence water outlet pipe; 403-water inlet; 404-water outlet; 405-vehicle water inlet; 406-vehicle water outlet; 5-BMS high-voltage box; 6-battery cell module; 601-electric chip; 602-positive busbar; 603-signal acquisition line; 604-negative busbar; 605-welding busbar; 7-sealing gasket. DETAILED DESCRIPTION

[0032] The present invention will be further described below with reference to the accompanying drawings and accompanying drawings.

[0033] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments of the present application and the features therein may be combined with each other.

[0034] The terms "first", "second", "third", etc. are only used for distinction and description and should not be understood as indicating or implying relative importance.

[0035] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0036] The following describes the specific embodiments of the present invention in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present invention and are not intended to limit the present invention.

[0037] Example 1:

[0038] like Figure 1-3 As shown, a modular power battery pack includes: an upper guard plate 1, a battery cell group and a BMS high-voltage box 5;

[0039] The top of the battery cell group is connected to an upper guard plate 1, and the battery cell group includes a plurality of battery cell layers stacked longitudinally, and the battery cell layer includes a battery box 2 and a battery cell module 6 located in the middle of the battery box 2;

[0040] A cross reinforcement plate 201 is provided inside the battery box 2, and a mounting notch is provided between the cross reinforcement plate 201 and the battery box 2 (not marked in the figure, the mounting notch is used for wiring, that is, it is convenient for welding the copper bus 605 to pass through), the battery box 2 is also provided with an explosion-proof valve mounting hole 206, a water cooling plate 202 is provided at the bottom of the battery box 2, a bolt mounting hole 203 is provided at the lower part of the battery box 2, and a sealing gasket mounting groove 204 for mounting the sealing gasket 7 is provided at the upper part of the battery box 2; the sealing gasket 7 is provided in the sealing gasket mounting groove 204, and a threaded hole 205 is provided in the sealing gasket mounting groove 204, and the threaded hole 205 is arranged in a one-to-one correspondence with the bolt mounting port.

[0041] The battery cases 2 are connected by bolts. The bolt mounting holes 203 of the upper battery case 2 are aligned with the threaded holes 205 of the lower battery case 2, and then the battery cases 2 are connected by bolts. The sealing gasket 7 is also provided with holes for passing the bolts. The sealing gasket 7 is provided between the two battery cases 2 to provide a sealing effect. In order to facilitate the passage of the bolts through the sealing gasket 7, corresponding holes are also provided on the sealing gasket 7.

[0042] The explosion-proof valve mounting hole 206 is used to connect the explosion-proof valve 3 .

[0043] The battery module 6 includes multiple electric chips 601. The positive and negative electrodes of the multiple electric chips 601 are connected in series by welding copper busbars 605. The positive and negative electrodes of the battery module 6 are both connected to the BMS high-voltage box 5. The positive electrode of the first electric chip 601 is connected to the negative electrode of the second electric chip 601, the positive electrode of the second electric chip 601 is connected to the negative electrode of the third electric chip 601, and so on.

[0044] Example 2:

[0045] On the basis of Example 1, Figure 4 and 5 As shown, multiple electric chips 601 are welded to obtain a battery layer, and then the multiple battery layers are stacked to form a battery group, which changes the original flat structure and makes full use of the longitudinal space. By controlling the number of battery layers, battery groups with different capacitances can be combined, making the battery more applicable and the layout more reasonable.

[0046] The battery box 2 is made of lightweight magnesium-aluminum alloy and is cast in one piece. A cross-reinforcement plate 201 is set inside the battery box 2 to increase the overall strength; a water cooling plate 202 is set at the bottom of the battery box 2, and an S-shaped water channel is cast inside the water cooling plate 202 ( Figure 5For ease of understanding, the S-shaped water channel is shown schematically; the actual S-shaped channel is internal and invisible from the outside. It features low water resistance, a large cooling and heat dissipation area, and rapid heat dissipation. The S-shaped water channel is connected to the cooling inlet / outlet 404. Bolt mounting holes 203 are located at the bottom of the box, while a sealing gasket mounting groove 204 and threaded holes 205 are located at the top for connecting the upper battery modules. The front panel features explosion-proof valve mounting holes 206 for installing explosion-proof valve 3, cooling water inlet 207 and cooling water outlet 208 for installing cooling manifold 4, and wiring holes 209 for routing high-voltage busbars and signal acquisition cables 603. The rear panel features explosion-proof valve mounting holes 206 for installing explosion-proof valve 3, and lifting holes 211 are located on both sides for lifting the battery modules. The battery cell modules 6 are installed in partitions to enhance safety.

[0047] A cross reinforcement plate 201 is provided inside the battery box 2 to partition the battery module 6 and increase the overall strength; a water cooling plate 202 is provided at the bottom of the battery box 2; bolt mounting holes 203 are provided at the lower part of the box, and a sealing gasket mounting groove 204 and a threaded hole 205 are provided at the upper part for connecting the upper battery module; an explosion-proof valve mounting hole 206 is provided at the rear end plate for installing the explosion-proof valve 3; and lifting holes 211 are provided on both sides for lifting the battery module.

[0048] Example 3:

[0049] On the basis of Example 2, Figure 6-8 As shown, since the battery cell group is composed of multiple stacked battery cell layers, a cross-reinforcement plate 201 is provided to provide good support for the upper battery cell layer. At the same time, in order not to affect the welding of the electric chip 601, a notch is provided in the cross-reinforcement plate 201. The notch is used for welding the copper busbar 605. Since the copper busbars on the left and right sides are only welded at the ends, only notches need to be provided at the ends. The copper busbars on the front and back sides have electric chips 601 that need to be welded at the ends and the middle, so notches need to be provided at both the ends and the center.

[0050] The battery cell module 6 is composed of multiple battery cell layers, and the battery cell layer is composed of multiple electric chips 601 connected by welding copper busbars 605 without traditional connecting plates at both ends, further improving the energy density; four battery cell modules 6 are installed in the four partitions of the battery box 2, and then the positive bus copper busbar 602, signal acquisition line 603, negative bus copper busbar 604 and other components are welded.

[0051] Apply glue to the bottom of the cell module 6 and install it in the internal partition of the battery case 2. Connect the busbars and signal acquisition cables 603 on the same level, and pass them through the reserved wiring holes 209 in the battery case 2 to form the battery module. Install the sealing gasket 7 in the upper mounting groove of the lower battery module, stack the middle battery module on top of the lower battery module, and connect the middle and lower battery modules with bolts. Install the sealing gasket 7 in the upper mounting groove of the middle battery module, stack the upper battery module on top of the middle battery module, and connect the upper and middle battery modules with bolts. Install the upper guard plate 1 on the upper battery module. Connect the cooling water pipe 4 to the water inlet 403 and outlet 404 of the upper, middle, and lower battery modules. Install the BMS high-voltage box 5. This completes the modular battery pack installation.

[0052] The water-cooling plate 202 is internally provided with an S-shaped water channel, with a cooling water inlet 207 and a cooling water outlet 208 at either end. The S-shaped water channel, cast within the water-cooling plate 202, features low water resistance, a large cooling and heat dissipation area, and rapid heat dissipation. The S-shaped water channel is connected to the cooling water inlet 207 and the cooling water outlet 208.

[0053] The water-cooling plate 202 is mainly used to cool the electric chip 601. Providing an S-shaped water channel inside the water-cooling plate 202 can maximize the water channel contact area and improve the cooling efficiency.

[0054] Example 4:

[0055] On the basis of Example 3, Figure 9 As shown, it also includes a cooling converging water pipe 4, which includes a converging water inlet pipe 401 and a converging water outlet pipe 402. The converging water inlet pipe 401 is connected to the cooling water inlet 207 through the water inlet 403, and the converging water inlet pipe 401 is connected to the vehicle cooling system through the vehicle water inlet 405. The converging water outlet pipe 402 is connected to the cooling water outlet 208 through the water outlet 404, and the converging water outlet pipe 402 is connected to the vehicle cooling system through the vehicle water outlet 406.

[0056] Since each battery cell group is equipped with a corresponding water-cooling plate 202, in order to facilitate unified control of multiple water-cooling plates 202, a cooling confluence water pipe 4 is provided to uniformly manage multiple water-cooling plates 202. The water-cooling plate 202 participates in the cooling cycle of the entire vehicle through the cooling confluence water pipe 4. The confluence water inlet pipe 401 is provided with a vehicle water inlet 405, and multiple water inlets 403 are provided according to the number of water-cooling plates 202. Each water inlet 403 is connected to a cooling water inlet 207; similarly, the confluence water outlet pipe 402 is provided with a vehicle water outlet 406, and multiple water outlets 404 are provided according to the number of water-cooling plates 202. Each water outlet 404 is connected to a cooling water outlet 208.

[0057] Cooling converging water pipe 4: The converging water inlet pipe 401 and the converging water outlet pipe 402 are connected to the water inlet 403 and the water outlet 404 for cooling the battery module. A single water inlet 403 and a water outlet 404 for connecting the entire vehicle are set on the converging water pipe. The beneficial effect is that a water inlet 403 and a water outlet 404 are set to facilitate the connection of the entire vehicle, reduce the cooling water pipes of the entire vehicle, reduce the difficulty and reduce the failure rate.

[0058] Example 5:

[0059] Based on Example 4, a modular power battery pack adopts a highly integrated, lightweight and modular design. The battery pack integrates battery box, battery cell module, fuse, pre-charge resistor, pre-charge relay, high-voltage connector, slave control module, BMS control module, high connector, low-voltage connector and other components. The battery box and battery cell module are stacked in multiple layers, and the battery box is cast in one piece using high-strength American aluminum alloy material, which effectively improves the energy density of the battery pack. The shell has an integrated frame function and can be directly installed on the frame, which is convenient and efficient. The modular battery pack can make full use of the space layout of the whole vehicle and is flexible in layout, thereby improving the convenience of expanding the power of the whole vehicle. The two sides of the battery pack are reserved with lifting holes to realize overall lifting, improve assembly timeliness and ease of maintenance. The battery system realizes multiple packs in parallel. When a battery pack fails during the operation of the whole vehicle, the BMS control cuts off the branch battery pack for "discarding" processing, which does not affect the normal operation of other battery packs and the vehicle can continue to drive. BMS high-voltage box 5: The high-voltage box integrates a positive high-voltage busbar, fuse, pre-charge resistor, pre-charge relay, main positive relay, main negative relay, negative high-voltage busbar, positive and negative high-voltage connectors, slave control module, low-voltage interface, control line, diagnostic interface, BMS control module, high-voltage box housing, and end caps. BMS high-voltage box 5 is prior art and is directly adopted here.

[0060] The present invention is not limited to the above-mentioned optional implementation modes. Anyone can derive other forms of products under the inspiration of the present invention. However, no matter what changes are made in the shape or structure, any technical solution that falls within the scope defined by the claims of the present invention falls within the scope of protection of the present invention.

Claims

1. A modular power battery pack, characterized by: include: Upper guard plate (1), battery cell group and BMS high voltage box (5); The top of the battery cell group is connected to an upper guard plate (1), and the battery cell group includes a plurality of battery cell layers stacked longitudinally, and the battery cell layers include a battery box (2) and a battery cell module (6) located in the middle of the battery box (2); A cross reinforcing plate (201) is provided inside the battery box (2), a mounting notch is provided between the cross reinforcing plate (201) and the battery box (2), the battery box (2) is further provided with an explosion-proof valve mounting hole (206), a water cooling plate (202) is provided at the bottom of the battery box (2), a bolt mounting hole (203) is provided at the lower portion of the battery box (2), and a sealing gasket mounting groove (204) for mounting a sealing gasket (7) is provided at the upper portion of the battery box (2); the sealing gasket (7) is provided in the sealing gasket mounting groove (204), a threaded hole (205) is provided in the sealing gasket mounting groove (204), and the threaded hole (205) is provided in a one-to-one correspondence with the bolt mounting opening.

2. The modular power battery pack according to claim 1, characterized in that: The battery module (6) comprises a plurality of electric chips (601), the positive and negative electrodes of the plurality of electric chips (601) are sequentially connected in series via welding copper bars (605), and the positive and negative electrodes of the battery module (6) are both connected to the BMS high-voltage box (5).

3. The modular power battery pack according to claim 1, characterized in that: An S-shaped water channel is provided inside the water-cooling plate (202), and a cooling water inlet (207) and a cooling water outlet (208) are respectively provided at both ends of the S-shaped water channel.

4. The modular power battery pack according to claim 1, characterized in that: The cooling water confluence pipe (4) is also included. The cooling water confluence pipe (4) includes a confluence water inlet pipe (401) and a confluence water outlet pipe (402). The confluence water inlet pipe (401) is connected to the cooling water inlet (207) via a water inlet (403). The confluence water inlet pipe (401) is connected to the vehicle cooling system via a vehicle water inlet (405). The confluence water outlet pipe (402) is connected to the cooling water outlet (208) via a water outlet (404). The confluence water outlet pipe (402) is connected to the vehicle cooling system via a vehicle water outlet (406).

5. The modular power battery pack according to claim 1, characterized in that: The explosion-proof valve mounting hole (206) is used for connecting the explosion-proof valve (3).

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