Double-structure protection and double-sealing battery pack with heat management function

Abstract

The invention belongs to the technical field of batteries, and provides a double-structure protection and double-sealing battery pack with heat management. The battery pack comprises at least two battery cells provided with tabs on the top surfaces and a metal plate shell wrapping the battery pack, a heat insulation elastic structure is arranged above the battery cells, a pressure-sensitive elastic structure is arranged on the side of the battery cells, a heating film is arranged on one surface of the heat insulation elastic structure, a BMS is embedded in the other surface of the heat insulation elastic structure, and the heating film is located between the heat insulation elastic structure and the tabs. The BMS is located between the heat insulation elastic structure and the metal plate shell, and the BMS is electrically connected with the heating film and the pressure sensing elastic structure. By adopting the arrangement, long-time thermal management of the electric motorcycle battery pack is realized, and the temperature consistency of battery cells is kept and the temperature is in a normal interval; the mechanical damage resistance of the battery pack is improved; the sealing performance and the anti-aging performance of the battery pack are realized; and the inner-layer structure protection provides pre-tightening force for the battery cell, so that the cycle life of the battery is prolonged.

Description

Technical Field

[0001] This invention belongs to the field of battery technology, specifically relating to a battery pack with thermal management, featuring dual-structure protection and dual sealing. Background Technology

[0002] With the rapid development of new energy battery technology, electric motorcycles are increasingly becoming an important mode of transportation for people. Compared to electric bicycles, the high-speed characteristics of electric motorcycles place greater demands on the vehicle and its battery pack. Firstly, the battery pack needs to have adequate thermal management capabilities. The high speed of electric motorcycles requires the battery pack to withstand high-current charging and discharging, necessitating internal heat dissipation. In low-temperature environments, the battery pack needs to be heated before discharging, making efficient heating solutions crucial. Secondly, the high speed of electric motorcycles places high demands on safety. Under potential impacts, compression, and other complex conditions, the battery pack itself needs a robust structure to ensure the user's safety. Furthermore, the airtightness of the battery pack is critical to its overall performance. Given the long lifespan of electric motorcycles, the aging resistance of some battery pack sealing solutions needs improvement, potentially reducing the battery pack's normal service life. Prior art CN115241592B discloses a solid-state battery module, including a lower housing, an end plate, an upper cover, a battery pack, and an elastic limiting mechanism; the lower housing and the end plate form a receiving cavity; the upper cover is connected to the top end face of the end plate; the battery pack is disposed in the receiving cavity, the battery pack includes multiple cells, the elastic limiting mechanism is connected to or abuts against the upper surface of the battery pack, and the elastic limiting mechanism is connected to or abuts against the lower surface of the upper cover; the elastic limiting mechanism limits the battery pack between the elastic limiting mechanism and the lower housing through elastic force. The inventor believes there is considerable room for improvement. Summary of the Invention

[0003] The purpose of this invention is to achieve long-term thermal management of the electric motorcycle battery pack using a pressure-sensitive elastic structure, heater, and BMS (Battery Management System), maintaining the temperature consistency of the battery cells and keeping them within the normal temperature range. Secondly, multiple structural protections are employed to improve the battery pack's resistance to mechanical damage; different types of sealants are used for potting and applying, respectively, to achieve the battery pack's sealing and anti-aging properties; the inner layer structure provides pre-tightening force to the battery cells, extending the battery's cycle life.

[0004] A dual-structure, dual-sealed battery pack with thermal management includes at least two battery cells with tabs on their top surfaces and a sheet metal casing covering the battery pack. A thermally insulating elastic structure is provided above the battery cells, and a pressure-sensitive elastic structure is provided on the side of the battery cells. A heating film is provided on one side of the thermally insulating elastic structure, and a battery management system (BMS) is embedded on the other side of the thermally insulating elastic structure. The heating film is located between the thermally insulating elastic structure and the tabs, and the BMS is located between the thermally insulating elastic structure and the sheet metal casing. The BMS is electrically connected to the heating film and the pressure-sensitive elastic structure. The heating film is located above the battery cell tabs, directly heating the tabs to conduct heat into the battery cell rather than heating the cell through separators such as aluminum-plastic films. This improves the heating efficiency of the battery cell. One side of the heating film has a heat-insulating elastic structure that provides soft support and insulation for the heating film and tabs, preventing the heating film from heating the BMS and avoiding heat waste caused by conduction from both sides. The soft support effectively supports the heating film and tabs, preventing gaps between them that would affect heat transfer efficiency. At the same time, it ensures that there is a certain buffer space for the direction of the battery cell tabs, improving the impact resistance of the battery pack, especially the tabs and BMS. The heat-insulating elastic structure embedded in the BMS helps to organize the wiring direction of the BMS.

[0005] Preferably, the battery pack also includes a module structure located between the sheet metal casing and the battery cells. The module structure encloses the battery cells, and its surface has through holes. After the battery cells are stacked, the module structure is used to fix and protect them, covering each surface of the battery cells to form the first layer of structural protection. After the above structure is inserted into the sheet metal casing, the sheet metal casing provides the second layer of structural protection. These two layers of structural protection improve the battery pack's resistance to mechanical damage. The through holes on the surface of the module structure facilitate glue pouring during installation, allowing the glue to flow horizontally and fill the gaps between the module structure, battery cells, and sheet metal casing, and also helps improve the heat dissipation efficiency of the battery cells during use.

[0006] Preferably, the module structure includes a top plate and side plates. The top plate is positioned between the heating film and the heat-insulating elastic structure, while the side plates are positioned between the battery cell and the pressure-sensitive elastic structure. The side plates are connected by fasteners, and the side plates compress the pressure-sensitive elastic structure and the battery cell. The stacked battery cells are compressed between the side plates to their designed length and width values, and then fixed together by fasteners. At this designed position, the battery cell is compressed, generating internal pressure, which promotes the contact between the internal materials of the battery cell and ensures the cycle life of the battery.

[0007] Preferably, the battery pack also includes a soft adhesive layer, and the module structure includes a module base plate. The soft adhesive layer fills the gaps between the battery cells, the module structure, and the sheet metal casing, and bonds the bottom of the battery cells to the module base plate. After the battery cells, encased in the module structure, are placed into the sheet metal casing, the bottom of the sheet metal casing is potted with thermally conductive adhesive. This facilitates fixing the designed position of the battery cells within the sheet metal casing and fills the gaps between the battery cells, thermally conductive insulating sheets, the module structure, and the sheet metal casing. This ensures that heat transfer between these four structures occurs entirely through thermal conduction via the thermally conductive adhesive, improving the heat dissipation efficiency of the battery cells and effectively increasing their cycle life. Simultaneously, the adhesive on the bottom surface of the battery cells cures into a soft adhesive layer. This soft adhesive layer bonds the bottom of the battery cells to the module base plate, and also bonds the module base plate to the sheet metal casing, forming a buffer layer for the entire battery pack and improving the impact resistance of the battery cells.

[0008] Preferably, a thermally conductive insulating sheet is provided between the side of the battery cell and the pressure-sensitive elastic structure. One side of the thermally conductive insulating sheet is in contact with the side of the battery cell, and the other side is in close contact with the pressure-sensitive elastic structure. Using a thermally conductive insulating sheet to isolate the battery cell and the pressure-sensitive elastic structure improves the heat conduction of both, enhances the heat dissipation performance of the battery cell, and provides insulation, allowing the pressure-sensitive elastic structure to detect only the breathing effect of the battery cell and generate an electrical signal.

[0009] Preferably, a thermally conductive silicone pad is provided on the side of the heating film near the tab. One side of the thermally conductive silicone pad is in contact with the tabs of each cell, and the other side is in close contact with the heating film. The thermally insulating elastic material and the cell compress the thermally conductive silicone pad and the heating film. The thermally conductive silicone pad serves as insulation between the heating film and the tab. Under the elasticity of the thermally insulating elastic material, the thermally conductive silicone pad adheres to the cell tab together with the heating film, preventing gaps between the heating film, tabs, and thermally conductive silicone pad that could affect heat conduction efficiency. The thermally conductive silicone pad connects the tabs of each cell, creating a heat conduction channel between the tabs and achieving uniform temperature between the cells. When there is a large temperature difference between the cells, the thermally conductive silicone pad at the tab conducts heat from the hotter cell to the colder cell, effectively reducing the temperature difference and achieving temperature uniformity among the internal cells.

[0010] Preferably, the sheet metal casing includes a sheet metal base and a sheet metal top cover. The lower part of the sheet metal top cover is embedded in the sheet metal base, and there is a gap between the sheet metal top cover and the sheet metal base. The sheet metal top cover and the sheet metal base form a potting groove, which is an inverted L-shape, and the gap is the horizontal part of the inverted L-shape. After the sheet metal top cover and the sheet metal base are assembled, they form a potting groove, which is used to seal the battery pack, maintain battery sealing, and extend battery cycle life.

[0011] Preferably, a sealing ring is provided at the connection between the sheet metal top cover and the sheet metal bottom shell. After the glue-filling groove is filled with glue, the vertical part of the groove forms the glue-filling layer of the top cover, and the horizontal part forms the glue-applying strip of the top cover. The viscosity of the glue forming the glue-filling layer of the top cover is lower than that of the glue forming the glue-applying strip of the top cover. The presence of the sealing ring fills the assembly gap between the sheet metal top cover and the sheet metal bottom shell. Direct glue filling would cause the glue to flow out from the installation gap. Therefore, a sealing ring is set in the installation gap. The elasticity of the sealing ring allows the sheet metal top cover and the sheet metal bottom shell to be assembled and fill the installation gap, forming an inverted L-shaped glue-filling groove, preventing the glue from flowing out from the bottom of the glue-filling groove. After the sheet metal top cover and sheet metal bottom shell are assembled, a low-viscosity self-leveling adhesive is first poured in. Bolts are then used to seal the large surface of the adhesive filling groove, filling the vertical portion of the groove. This vertical portion, located on the inner side of the groove, has low exposure and inherent good anti-aging properties, forming the first layer of seal for the battery pack and improving the sealing performance of the filling groove. The horizontal portion of the filling groove uses a high-viscosity sealant, with the adhesive exposed. A UV-resistant sealing adhesive can be selected to form the second layer of seal, providing good anti-aging properties. These two seals focus on different performance characteristics, thereby improving the overall sealing and anti-aging performance of the battery pack.

[0012] Preferably, the pressure-sensitive elastic structure contains at least two layers of metal mesh, which are wrapped with an insulating elastic material. Detection gaps are provided between the metal meshes, and the metal meshes are electrically connected to the BMS and the heater. During the cell's breathing process, the pressure-sensitive elastic structure deforms. When the cell temperature causes the deformation due to the breathing effect to reach a preset value, the pressure-sensitive elastic structure is compressed, and the metal meshes come into contact with each other. Depending on the tightness of the contact, the BMS receives different electrical signals to control whether the heater operates and for how long. This prevents the heater from overheating due to excessive heating time or from underheating due to insufficient heating time. Because the cell's breathing effect lags behind the cell temperature and the heater's heating process, the BMS initially adjusts the heater temperature below the preset value of the cell temperature upon receiving the first electrical signal. Then, based on the BMS's algorithm prediction and subsequent electrical signal evaluation of the lag, the BMS calibrates and adjusts the heater temperature accordingly. The metal mesh provides a framework and restricts deformation for the insulating elastic material, ensuring uniform deformation under impact and thermal expansion, maintaining good cushioning performance. During battery assembly, the metal mesh maintains the shape of the pressure-sensitive elastic structure, preventing bending and folding, and facilitates insertion into the sheet metal casing.

[0013] Preferably, the battery cells are arranged in a vertical parallel array, and the contact surface of the battery cells is provided with an insulating elastic material. The insulating elastic material is foam. Through the above arrangement and the use of foam material, the foam provides a pre-tightening force when the battery cells are inside the shell. That is, during the manufacturing process, the assembly of foam and battery cells is compressed. Since the battery cells themselves are incompressible, the foam deforms under pressure. After being inserted into the shell, the foam provides a pre-tightening force for the battery cells to return to their original shape when they are inside the shell. Secondly, in the later stages of the battery cell's use, during cyclic charging and discharging, especially during charging, the expansion is intensified. Compared with other insulating elastic materials, foam has a smaller elastic modulus, which can provide a larger expansion space for the battery cells under the same expansion force, ensuring that the overall deformation of the module is small.

[0014] This invention has the following advantages: it employs a pressure-sensitive elastic structure, a heater, and a BMS to achieve long-term thermal management of the electric motorcycle battery pack, maintaining the temperature consistency of the battery cells and keeping them within the normal temperature range; it adopts multiple structural protections to improve the battery pack's resistance to mechanical damage; it uses potting and applying different types of sealant to achieve the battery pack's sealing and anti-aging properties; and the inner layer structure provides pre-tightening force to the battery cells, extending the battery's cycle life. Attached Figure Description

[0015] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of a battery pack with dual-structure protection and dual sealing, featuring thermal management. Figure 2 An exploded view of a dual-structure, dual-sealed battery pack with thermal management; Figure 3 A schematic diagram of the battery cell and foam; Figure 4 for Figure 3 A structural diagram showing the addition of a module structure; Figure 5 for Figure 4 A schematic diagram of the structure with an added thermally conductive silicone pad; Figure 6 for Figure 5 Schematic diagram of the structure with added heating film; Figure 7 This is a structural diagram of the module top plate, BMS, and thermal insulation elastic structure. Figure 8This is a structural diagram of the module structure, BMS, and thermal insulation elastic structure. Figure 9 A schematic diagram of the module structure being installed in a sheet metal housing; Figure 10 A cross-sectional view of a dual-structure, dual-sealed battery pack with thermal management; Figure 11 for Figure 10 Enlarged view of the upper and middle cover area after glue application and gluing; Figure 12 This is a cross-sectional view of a pressure-sensitive elastic structure.

[0017] Legend: 1 Sheet metal bottom shell; 2 Module bottom plate; 3 Pressure-sensitive elastic structure; 3a Metal mesh; 3b Detection gap; 4 Module end plate; 5 Battery cell; 6 Adapter plate; 7 Thermal conductive silicone pad; 8 Heating film; 9 Power harness; 10 BMS; 11 Socket adapter piece; 12 Socket; 13 Sheet metal top cover; 14 Top cover sealing ring; 15 Top cover adhesive strip; 16 Top cover potting layer; 17 Thermal insulation elastic structure; 18 Module top plate; 19 Thermally conductive insulating sheet; 20 Module side plate; 21 Insulating elastic material. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0019] Example 1 Combination Figure 1 , Figure 2 , Figure 7 and Figure 8As shown, a dual-structure, dual-sealed battery pack with thermal management includes at least two battery cells 5 with tabs on their top surfaces and a sheet metal shell covering the battery pack. A thermally insulating elastic structure 17 is located above the battery cells 5, and a pressure-sensitive elastic structure 3 is located on the side of the battery cells 5. A heating film 8 is located on one side of the thermally insulating elastic structure 17, and a BMS10 is embedded on the other side of the thermally insulating elastic structure 17. The heating film 8 is located between the thermally insulating elastic structure 17 and the tabs, and the BMS10 is located between the thermally insulating elastic structure 17 and the sheet metal shell. The BMS10 is electrically connected to the heating film 8 and the pressure-sensitive elastic structure 3. After the sheet metal cover 13 is installed, a socket 12 is pulled out. The opening of the socket 12 on the sheet metal cover 13 is larger than the size of the socket 12. Two identical socket adapter pieces 11 are first fixed to the sheet metal cover 13, and then the socket 12 is installed on the socket 12 adapter plate 6 to achieve structural installation. Finally, glue is injected into the groove of the socket 12 to achieve a seal. BMS10 is short for Battery Management System. The heating film 8 is located above the tabs of the battery cell 5. It directly heats the tabs to conduct heat into the battery cell 5, rather than heating the battery cell 5 through a separator such as an aluminum-plastic film. One side of the heating film 8 has a heat-insulating elastic structure 17, which provides soft support and heat insulation for the heating film 8 and the tabs, preventing the heating film 8 from heating the BMS10 and avoiding heat waste caused by conduction from both the top and bottom. The soft support can effectively support the heating film 8 and the tabs, preventing gaps between the heating film 8 and the tabs from affecting heat transfer efficiency. At the same time, it ensures that there is a certain buffer space for the direction of the battery cell 5 tabs, improving the impact resistance of the battery pack, especially the tabs and BMS10. The heat-insulating elastic structure 17 is embedded in the BMS10, which helps to organize the routing direction of the power harness 9 of the BMS10.

[0020] The excessive use of connectors can easily lead to increased costs and failure rates. Electric motorcycles generally draw high current, and the internal power harness 9 should ideally have fewer or no connectors to reduce the risk of connector burnout due to increased internal resistance caused by loose connectors. However, due to the generally external mounting requirements of the socket 12 and the constraints of the internal assembly sequence, the power harness 9 often needs to be connected before the top cover is installed. The use of connectors not only increases costs but also introduces problems such as low current-carrying capacity and a large installation space required for anti-loosening measures. An externally mounted socket 12 is adopted. The top cover is installed first, then the socket 12 is pulled out, followed by the socket adapter 11, then the socket 12 is fixed, and finally, the groove is sealed with glue. The pull-out sheet metal top cover 13 of the socket 12 avoids the use of connectors for the power harness 9 on the socket 12, directly reducing costs without considering issues such as anti-loosening and current-carrying problems. The socket adapter 11 serves two purposes: it is fixed to the sheet metal top cover 13 and provides mounting holes for the socket 12. After installation, the groove of the socket 12 is sealed with glue to meet the sealing requirements.

[0021] like Figure 3As shown, the battery cells 5 are arranged in a vertical parallel array. The surfaces of the battery cells 5 are first glued and stacked into modules. An insulating elastic material 21, which is foam, is placed between every four battery cells 5. This foam is used to accommodate the breathing effect of the battery cells 5, releasing and compressing space during expansion and contraction. During charging and discharging, the battery cells 5 expand and contract, which is the aforementioned breathing effect. The battery pack also includes a module structure located between the sheet metal shell and the battery cells 5. The module structure covers the battery cells 5, and its surface has through holes. After the battery cells 5 are stacked, the module structure is used to fix and protect them. The module structure covers each surface of the battery cells 5, forming the first layer of structural protection. After the above structure is inserted into the sheet metal shell, the shell provides the second layer of structural protection. These two layers of structural protection improve the battery pack's resistance to mechanical damage. The through-holes on the module structure facilitate glue application during installation, allowing the glue to flow horizontally and fill the gaps between the module structure, battery cell 5, and the sheet metal casing. This also improves the heat dissipation efficiency of battery cell 5 during use. Through these features, and by using foam material, the foam provides pre-tightening force when the battery cell is inside the casing. During manufacturing, the assembly of the foam and battery cell is compressed. Since the battery cell itself is incompressible, the foam deforms under pressure. After being inserted into the casing, the foam provides pre-tightening force to restore the battery cell's shape when it is inside the casing. Secondly, during later stages of use, the battery cell expands significantly during cyclic charging and discharging, especially during charging. Compared to other insulating elastic materials, foam has a lower elastic modulus, providing greater expansion space for the battery cell under the same expansion force, ensuring minimal overall module deformation.

[0022] like Figure 2 , Figure 4 and Figure 7 As shown, the module structure includes a module end plate 4, a module top plate 18, and a module side plate 20. The module top plate 18 is located between the heating film 8 and the heat-insulating elastic structure 17. The module side plate 20 and the module end plate 4 are located between the battery cell 5 and the pressure-sensitive elastic structure 3. The module side plate 20 and the module end plate 4 are connected by fasteners. The module end plate 4 compresses the pressure-sensitive elastic structure 3 and the battery cell 5. The battery cells 5 stacked between the module side plate 20 and the module end plate 4 are compressed to the designed length and width values, and then fixed together by fasteners. At this designed position, the battery cell 5 will be compressed, generating internal pressure, which promotes the mutual contact of the internal materials of the battery cell 5 and ensures the cycle life of the battery.

[0023] like Figure 5 , Figure 6As shown, a thermally conductive silicone pad 7 and an adapter plate 6 are provided on the side of the heating film 8 near the tab. One side of the thermally conductive silicone pad 7 is in contact with the tabs of each battery cell 5, and the other side of the thermally conductive silicone pad 7 is in close contact with the heating film 8. The thermally insulating elastic material and the battery cell 5 compress the thermally conductive silicone pad 7 and the heating film 8. The thermally conductive silicone pad 7 serves as insulation between the heating film 8 and the tab. Under the elastic action of the thermally insulating elastic material, the thermally conductive silicone pad 7 and the heating film 8 are in close contact with the tabs of the battery cell 5, avoiding gaps between the heating film 8, the tabs, and the thermally conductive silicone pad 7 that would affect the heat conduction efficiency. The adapter plate 6 connects the tabs of each battery cell 5. The thermally conductive silicone pad 7 covers the adapter plate 6, creating a heat conduction channel between the tabs, achieving uniform temperature between the battery cells 5. When there is a large temperature difference between the battery cells 5, the thermally conductive silicone pad 7 at the tab conducts heat from the battery cell 5 with a higher temperature to the battery cell 5 with a lower temperature, effectively reducing the temperature difference and achieving temperature uniformity among the internal battery cells 5.

[0024] like Figure 2 , Figure 10 and Figure 11 As shown, the sheet metal casing includes a sheet metal base shell 1 and a sheet metal top cover 13. The lower part of the sheet metal top cover 13 is embedded in the sheet metal base shell 1, and there is a gap between the sheet metal top cover 13 and the sheet metal base shell 1. The sheet metal top cover 13 and the sheet metal base shell 1 form a potting groove, which is an inverted L-shape, and the gap is the horizontal part of the inverted L-shape. The presence of the top cover sealing ring 14 fills the assembly gap between the sheet metal top cover 13 and the sheet metal base shell 1. Direct potting would cause the potting glue to flow out from the installation gap. Therefore, the top cover sealing ring is set in the installation gap. The elasticity of the top cover sealing ring allows the sheet metal top cover 13 and the sheet metal base shell 1 to be assembled and fill the installation gap, forming an inverted L-shaped potting groove, preventing the potting glue from flowing out from the bottom of the potting groove. After assembly, the sheet metal top cover 13, the sheet metal base shell 1, and the top cover sealing ring 14 constitute the potting groove, which is used to seal the battery pack, maintain battery sealing, and extend battery cycle life.

[0025] like Figure 2 and Figure 11As shown, a top cover sealing ring 14 is provided at the connection between the sheet metal top cover 13 and the sheet metal bottom shell 1. After the glue filling tank is completed, the vertical part of the glue filling tank forms the top cover glue filling layer 16, and the horizontal part of the glue filling tank forms the top cover glue strip 15. The viscosity of the glue forming the top cover glue filling layer 16 is lower than that of the glue forming the top cover glue strip 15. After the sheet metal top cover 13 and the sheet metal bottom shell 1 are assembled, a low-viscosity self-leveling adhesive is first poured in. The large surface of the adhesive filling groove is then sealed with bolts, filling the vertical part of the groove. The vertical part of the groove is located on the inner side of the groove, with low exposure. The structure itself has good anti-aging properties, forming the first layer of seal for the battery pack and improving the sealing performance of the groove. The horizontal part of the groove uses a high-viscosity sealant, with the adhesive exposed. A UV-resistant sealing adhesive can be selected to form the second layer of seal, which has good anti-aging properties. The two seals focus on different performances, thereby improving the overall sealing performance and anti-aging performance of the battery pack.

[0026] like Figure 8 , Figure 9 and Figure 10 As shown, the battery pack also includes a soft adhesive layer, and the module structure includes a module base plate 2. The soft adhesive layer fills the gaps between the battery cell 5, the module structure, and the sheet metal shell, and bonds the bottom of the battery cell 5 to the module base plate 2. After the battery cell 5, encased in the module structure, is placed into the sheet metal shell, the bottom of the sheet metal shell is filled with thermally conductive adhesive to facilitate fixing the designed position of the battery cell 5 in the sheet metal shell and to fill the gaps between the battery cell 5, the thermally conductive insulating sheet 19, the module structure, and the sheet metal shell. This ensures that the heat transfer between the above four structures is all through thermal conduction via the thermally conductive adhesive, improving the heat dissipation efficiency of the battery cell 5 and effectively increasing its cycle life. Simultaneously, the adhesive on the bottom surface of the battery cell 5 cures into a soft adhesive layer, which bonds the bottom of the battery cell 5 to the module base plate 2, and also bonds the module base plate 2 to the sheet metal shell, forming a buffer layer for the entire battery pack and improving the impact resistance of the battery cell 5.

[0027] A thermally conductive insulating sheet 19 is provided between the side of the battery cell 5 and the pressure-sensitive elastic structure 3. One side of the thermally conductive insulating sheet 19 is in contact with the side of the battery cell 5, and the other side of the thermally conductive insulating sheet 19 is in close contact with the pressure-sensitive elastic structure 3. The use of the thermally conductive insulating sheet 19 to isolate the battery cell 5 and the pressure-sensitive elastic structure 3 improves the heat conduction effect of the battery cell 5 and the heat dissipation performance of the pressure-sensitive elastic structure 3, and the insulation between the battery cell 5 and the pressure-sensitive elastic structure 3 allows the pressure-sensitive elastic structure 3 to detect the breathing effect of the battery cell 5 and generate an electrical signal only.

[0028] like Figure 12As shown, the pressure-sensitive elastic structure 3 has two layers of metal mesh 3a inside, and the outside of the metal mesh 3a is wrapped with insulating elastic material 21. A detection gap 3b is provided between the metal meshes 3a. The metal meshes 3a are electrically connected to the BMS10 and the heater. The pressure-sensitive elastic structure 3 deforms during the breathing process of the battery cell 5. When the temperature of the battery cell 5 reaches a preset value, the deformation of the battery cell 5 due to the breathing effect also reaches a preset value. The pressure-sensitive elastic structure 3 is compressed, and the metal meshes 3a come into contact with each other. Depending on the tightness of the contact, the BMS10 receives different electrical signals to control whether the heater works and the working time. This avoids the battery cell 5 from overheating due to a long heating time and the battery cell 5 from being too cold due to a short heating time. Because the thermally conductive insulating sheet 19 is used to insulate the battery cell 5 and the pressure-sensitive elastic structure 3, the discharge process of the battery cell 5 will not affect the metal mesh 3a inside the pressure-sensitive elastic structure 3. Because the breathing effect of cell 5 lags behind the temperature of cell 5 and the heating process of the heater, the BMS10 needs to adjust the corresponding temperature of the heater to be lower than the preset value of the temperature of cell 5 when it first receives the electrical signal. Then, based on the algorithm prediction of BMS10 and the evaluation of the lag by subsequent electrical signals, BMS10 is calibrated to adjust the temperature of the heater.

[0029] The present invention has the following beneficial effects: by employing a pressure-sensitive elastic structure 3, a heater, and a BMS10, long-term thermal management of the electric motorcycle battery pack is achieved, maintaining the temperature consistency of the battery cells 5 and keeping the temperature within the normal range; multiple structural protections are adopted to improve the battery pack's resistance to mechanical damage; different types of sealants are filled by potting and applying glue to achieve the battery pack's sealing and anti-aging properties; the inner layer structure provides pre-tightening force to the battery cells 5, extending the battery's cycle life.

[0030] The above embodiments and / or implementation methods are merely illustrative of preferred embodiments and / or implementation methods for realizing the technology of the present invention, and are not intended to limit the implementation methods of the technology of the present invention in any way. Any person skilled in the art may make some modifications to other equivalent embodiments without departing from the scope of the technical means disclosed in the content of the present invention, but these should still be regarded as the technology or embodiments that are substantially the same as the present invention.

Claims

1. A dual-structure, protected, and double-sealed battery pack with thermal management, comprising at least two battery cells (5) with tabs on their top surfaces and a sheet metal casing covering the battery pack, characterized in that, A heat-insulating elastic structure (17) is provided above the battery cell (5), and a pressure-sensitive elastic structure (3) is provided on the side of the battery cell (5). A heating film (8) is provided on one side of the heat-insulating elastic structure (17), and a BMS (10) is embedded on the other side of the heat-insulating elastic structure (17). The heating film (8) is located between the heat-insulating elastic structure (17) and the tab, and the BMS (10) is located between the heat-insulating elastic structure (17) and the sheet metal shell. The BMS (10) is electrically connected to the heating film (8) and the pressure-sensitive elastic structure (3).

2. The battery pack with thermal management, dual-structure protection, and dual sealing as described in claim 1, characterized in that, The battery pack also includes a module structure located between the sheet metal shell and the battery cell (5), the module structure covering the battery cell (5), and the surface of the module structure having through holes.

3. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 2, characterized in that... The module structure includes a module top plate (18) and a module side plate (20). The module top plate (18) is provided between the heating film (8) and the heat insulation elastic structure (17). The module side plate (20) is provided between the battery cell (5) and the pressure-sensitive elastic structure (3). The module side plates (20) are connected by fasteners. The module side plate (20) squeezes the pressure-sensitive elastic structure (3) and the battery cell (5).

4. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 2, characterized in that... The battery pack also includes a soft adhesive layer, and the module structure also includes a module base plate (2). The soft adhesive layer fills the gaps between the battery cell (5), the module structure and the sheet metal shell, and the soft adhesive layer bonds the bottom of the battery cell (5) and the module base plate (2).

5. A battery pack with thermal management, dual-structure protection, and dual sealing as described in claim 1, characterized in that, A thermally conductive insulating sheet (19) is provided between the side of the battery cell (5) and the pressure-sensitive elastic structure (3). One side of the thermally conductive insulating sheet (19) is in contact with the side of the battery cell (5), and the other side of the thermally conductive insulating sheet (19) is in close contact with the pressure-sensitive elastic structure (3).

6. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 1, characterized in that... The heating film (8) has a thermally conductive silicone pad (7) on the side near the electrode tab. One side of the thermally conductive silicone pad (7) is in contact with the electrode tab of each battery cell (5), and the other side of the thermally conductive silicone pad (7) is in close contact with the heating film (8). The thermally insulating elastic material and the battery cell (5) squeeze the thermally conductive silicone pad (7) and the heating film (8).

7. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 1, characterized in that... The sheet metal housing includes a sheet metal bottom shell (1) and a sheet metal top cover (13). The lower part of the sheet metal top cover (13) is embedded in the sheet metal bottom shell (1). There is a gap between the sheet metal top cover (13) and the sheet metal bottom shell (1). The sheet metal top cover (13) and the sheet metal bottom shell (1) form a glue-filling groove. The glue-filling groove is an inverted L-shape. The gap is the horizontal part of the inverted L-shape.

8. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 7, characterized in that... The connection between the sheet metal top cover (13) and the sheet metal bottom shell (1) is provided with a top cover sealing ring (14). After the glue filling groove is filled, the vertical part of the glue filling groove forms the top cover glue filling layer (16), and the horizontal part of the glue filling groove forms the top cover glue strip (15). The viscosity of the glue forming the top cover glue filling layer (16) is lower than that of the glue forming the top cover glue strip (15).

9. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 1, characterized in that... The pressure-sensitive elastic structure (3) has at least two layers of metal mesh (3a) inside, and the outside of the metal mesh (3a) is wrapped with insulating elastic material (21). There is a detection gap (3b) between the metal mesh (3a), and the metal mesh (3a) is electrically connected to the BMS (10) and the heater.

10. A battery pack with thermal management, featuring dual-structure protection and dual sealing, as described in claim 1, characterized in that... The battery cells (5) are arranged in a vertical parallel array.

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