A new energy automobile battery pack explosion-proof aluminum alloy conductor flat cable and a manufacturing method thereof

Abstract

The application discloses a new energy automobile battery pack explosion-proof aluminum alloy conductor flat cable and a manufacturing method, relates to the technical field of cables, and is characterized in that an arc-shaped pipe is welded on the outer side of a side guard plate, a plurality of ventilation frames are connected to the top and the bottom of an insulation layer, a plurality of elliptical pipes are welded at equal intervals in the ventilation frames, a ventilation pipe is welded between two adjacent elliptical pipes, a T-shaped groove is slidably connected to the outer side of a T-shaped strip, a plurality of spring sheets are welded at equal intervals between the top portions of two T-shaped grooves located on the same horizontal plane, the arc-shaped pipe and the ventilation frame in the heat dissipation and pressure resistance assembly are distributed around the cable, the insulation layer is wrapped, the uniform distribution of the elliptical pipes and the ventilation pipes in the ventilation frame enables the cable to have a good heat dissipation effect, in the reinforced connection assembly, part of the air in the ventilation pipe enters the inside of the strip-shaped box and is sprayed out of the strip-shaped opening, the cooling of a wiring terminal is realized, the two assemblies are matched, and the overall heat dissipation effect of the cable is better.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to an explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs and its manufacturing method. Background Technology

[0002] The automotive battery pack is the core energy storage device for new energy vehicles. It consists of components such as cells, modules, battery management system, and thermal management system, and directly affects the vehicle's range, safety, and performance. New energy vehicle battery packs often use flat aluminum alloy conductor cables to connect the battery modules.

[0003] In the Chinese patent with publication number CN221040602U, entitled "A Conductive Transmission Aluminum Busbar for Battery Pack", the patent uses a first insulating layer to wrap the conductor, and then a second insulating layer to cross-wrap the first insulating layer, which makes the manufactured conductive transmission aluminum busbar resistant to high temperature and high voltage, and has better performance.

[0004] In existing technologies, aluminum alloy conductor flat cables are often subjected to compression during battery pack assembly and transportation. The cables have poor compressive strength. If the insulation layer on the outside of the flat conductor breaks, the flat cable must be replaced. In hot weather, existing automotive battery packs often use water-cooled and air-cooled machines to cool the outside of the battery pack. However, the flat cables inside the battery pack are limited by their position and cannot be effectively cooled. If the cables are energized for a long time, the cable temperature will rise, which will accelerate the aging of the insulation layer and may lead to short circuit risk. In addition, the increased cable temperature will increase the resistance, resulting in increased energy loss. Summary of the Invention

[0005] This invention provides an explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs and its manufacturing method. It can effectively solve the problems in the prior art mentioned above, such as the aluminum alloy conductor flat cable being subjected to compression during battery pack assembly and transportation, poor cable compressive strength, the flat cable inside the battery pack being restricted by its position and unable to be effectively cooled, the cable insulation layer aging rapidly, and the increased resistance and energy loss caused by the increase in cable temperature.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs, comprising a flat conductor, wherein a heat dissipation and pressure-resistant component is provided on the outside of the flat conductor, and the heat dissipation and pressure-resistant component includes an insulation layer;

[0007] Side guards are connected to both sides of the insulation layer. Arc-shaped tubes are welded to the outer side of the side guards. Multiple ventilation frames are connected to the top and bottom of the insulation layer. Multiple elliptical tubes are welded at equal intervals inside the ventilation frames. A ventilation tube is welded between two adjacent elliptical tubes. Multiple ventilation holes are opened at equal intervals at the top and bottom of the ventilation tube. Diffuser holes are opened at equal intervals on both sides of the elliptical tube. The elliptical tube and the ventilation tube are connected through the diffuser holes. Multiple air dissipation holes are opened at the top of the ventilation frame.

[0008] The top and bottom of the outer side of the arc-shaped tube are welded with T-shaped strips, and T-shaped grooves are slidably connected to the outer side of the T-shaped strips. Multiple spring plates are welded at equal intervals between the tops of two T-shaped grooves located on the same horizontal plane. A pressure-resistant plate is connected between the tops of the spring plates located on the same horizontal plane, and a rubber block is connected to the middle of the bottom of the spring plates.

[0009] According to the above technical solution, the top and bottom of the side guard plate are provided with connecting openings, which are connected to the inside of the arc-shaped tube. The top of both sides of the ventilation frame are connected with multiple fixing ears, which are connected to the adjacent side guard plates by screws.

[0010] According to the above technical solution, the two ends of the ventilation frame are connected to the two ends of the ventilation pipe, and a ventilation box is connected between two adjacent ventilation frames. The two ends of the ventilation box are connected to the adjacent ventilation head.

[0011] According to the above technical solution, the top of the ventilation box located on the same horizontal plane is connected to one side of the external air supply main pipe through the air distribution pipe, and a cooling pipe is connected to one side of the side guard plate in the middle of the arc-shaped pipe.

[0012] According to the above technical solution, multiple fins are welded to the outside of the cooling pipe, one end of the cooling pipe is connected to one end of the infusion pipe, one end of the other cooling pipe is connected to one end of the drain pipe, and a return pipe is connected between the other ends of the two cooling pipes.

[0013] According to the above technical solution, the other end of the infusion pipe is connected to the water outlet of the battery pack water chiller, and the other end of the drain pipe is connected to the water inlet of the battery pack water chiller.

[0014] According to the above technical solution, the flat conductor is provided with reinforced connection components at both ends, and the reinforced connection components include male connectors;

[0015] The flat conductor is connected to male connectors at both ends, and a female connector is connected to one side of the male connector. Multiple connecting plates are welded to the opposite sides of the male and female connectors. The connecting plates at one end of the male connector and the connecting plates at one end of the female connector are stacked and connected. Adjacent connecting plates are connected by crimping bolts. A crimping plate is connected to the top of the top connecting plate and a crimping plate is also connected to the bottom of the bottom connecting plate. Multiple release grooves are opened on the opposite sides of two adjacent connecting plates.

[0016] Fastening lugs are connected at the four corners of the pressing plate, and fastening screws are connected between two opposite fastening lugs. A fastening circular plate is welded to the top of the fastening screw, and a memory spring is connected between the fastening circular plate and the adjacent fastening lug. Circular hole plates are welded to both ends of the memory spring, and the memory spring and the circular hole plates are sleeved on the outside of the fastening screw.

[0017] According to the above technical solution, reinforcing boxes are installed at the top and bottom ends of the insulation layer. One side of the reinforcing box is connected to an adjacent gas supply head. One side of the connecting sheet is connected to a strip box between two adjacent pressing plates. One side of the strip box is connected to one end of a three-way pipe. The other two ends of the three-way pipe are respectively connected to one end of an adjacent reinforcing box. A strip-shaped opening is provided on one side of the strip box.

[0018] According to the above technical solution, the insulating layer is made of ceramicized silicone rubber, and its temperature resistance rating meets the requirements of -60℃ to 180℃.

[0019] According to the above technical solution, the present invention also provides a method for manufacturing an explosion-proof aluminum alloy conductor flat cable for a new energy vehicle battery pack, comprising the following steps:

[0020] S1. After being straightened left and right, up and down and treated with high frequency electromagnetic heating, the solid flat aluminum alloy conductor enters the extruder head. The insulating material is fed, melted and plasticized by the extruder and then extruded onto the flat conductor through an extrusion die to form an insulating layer.

[0021] S2. Place the side guard plate on both sides of the insulation layer, and use screws and fixing ears to splice and install the ventilation frame, and then connect the ventilation box to the air supply head.

[0022] S3. Assemble the spring sheet and the pressure plate by using the T-strip and T-slot.

[0023] S4. Use crimping bolts to connect and fix the male and female connectors to each other, and use fastening screws and memory springs to connect and fix the crimping plate.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] 1. Equipped with heat dissipation and pressure resistance components, with arc-shaped tubes distributed on both sides of the cable and vent frames distributed on the top and bottom of the cable, wrapping around the insulation layer. Under the action of heat conduction, the heat generated by the flat conductor can be conducted to the outside of the cable. The arc-shaped tubes and spring sheets are elastic. When the cable is subjected to external pressure, it absorbs the external force through deformation and returns to its original shape after the external force is removed, protecting the cable insulation layer. The cable has strong pressure resistance. During the car's operation, the sub-control valve connected to the air intake end is opened. The airflow generated by the car's operation enters the vent pipe through the transfer pipe, main air supply pipe, distribution pipe and vent box. The air entering the vent pipe then enters the elliptical tube and arc-shaped tube through the diffuser hole, vent hole and connecting port, carrying away the heat around the cable, thereby cooling the cable, extending the cable's service life and reducing current energy loss.

[0026] The airflow generated by the car's movement can also diffuse through the vents to the surrounding area of ​​the cable, cooling the electrical components such as the battery cells around the cable. Combined with the existing water-cooled and air-cooled cooling systems for the outside of the battery pack, the internal and external cooling work together to improve the heat dissipation effect of the battery pack. When air cooling is insufficient to cool the cable, the coolant output from the water-cooled system can enter the cooling pipe and return pipe through the inlet pipe, and then flow back to the water-cooled system through the outlet pipe. By using water cooling and air cooling in combination, the cable can be further cooled, resulting in better heat dissipation of the cable.

[0027] In cold weather, opening the control valve connected to the hot air outlet of the car's air conditioner allows the hot air generated by the air conditioner to enter the vent pipe. Through heat conduction, this prevents the aluminum alloy flat conductor and insulation layer from becoming brittle and cracking due to low temperatures, thus improving the cable's cold resistance. Furthermore, the hot air can diffuse through the vent holes to the surrounding area of ​​the cable, warming the battery cells around the cable and preventing them from becoming too cold, thereby extending the battery's battery life.

[0028] When the battery pack catches fire, the control valve connected to the gas cylinder opens, and carbon dioxide gas is released from the vent and connection port. The released carbon dioxide gas can dilute the oxygen when the fire first occurs, slow down the spread of the flames, and provide more escape space for people to escape. The heat dissipation and pressure resistance components are multi-functional, and the cables have good explosion-proof capabilities.

[0029] 2. Equipped with reinforced connection components, the male and female connectors are connected by multiple connecting plates. Compared to the existing crimping connection method, this connection uses crimping bolts to crimp the connecting plates layer by layer, resulting in a larger cable connection contact area and better connection effect. The memory spring is made of shape memory alloy. When the cable joint temperature rises, the memory spring contracts, reducing the pressure applied by the crimping plate to the connecting plates. The release groove provides space for the expansion of the connecting plates. When the cable joint temperature drops, the memory spring extends, increasing the pressure applied by the crimping plate to the connecting plates, making the contact between the connecting plates tighter and improving the cable connection tightness. It can ensure the connection stability of the cable in both high and low temperature environments, and the cable has high current transmission stability.

[0030] When cooling or heating the cable, the air inside the vent pipe can enter the reinforced box, then enter the strip box through the tee pipe, and finally be ejected from the strip nozzle. The air ejected from the strip nozzle can blow on the connecting sheet, thereby cooling or heating the connecting sheet and preventing the temperature between the cable terminals from being too high or too low, thus further improving the connection stability of the cable.

[0031] In summary, the arc-shaped tubes and venting frames in the heat dissipation and pressure resistance components are distributed around the cable to wrap the insulation layer. The even distribution of elliptical tubes and venting tubes in the venting frames enables the cable to have good heat dissipation effect in a small volume. In the reinforced connection component, part of the air inside the venting tube enters the strip box and is ejected from the strip opening to cool the terminals. The two components work together to achieve better overall heat dissipation effect of the cable. Attached Figure Description

[0032] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0033] In the attached diagram:

[0034] Figure 1 This is a three-dimensional structural schematic diagram of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of the heat dissipation and pressure resistance component of the present invention;

[0036] Figure 3 This is a schematic diagram of the installation structure of the ventilation frame of the present invention;

[0037] Figure 4 This is a schematic diagram of the installation structure of the side guard plate of the present invention;

[0038] Figure 5 This is a schematic diagram of the installation structure of the spring sheet of the present invention;

[0039] Figure 6This is a schematic diagram of the installation structure of the cooling pipe of the present invention;

[0040] Figure 7 This is a schematic diagram of the installation structure of the gas delivery head of the present invention;

[0041] Figure 8 This invention comes from Figure 7 Enlarged view of region A;

[0042] Figure 9 This is a schematic diagram of the structure of the reinforced connection component of the present invention;

[0043] Figure 10 This is a schematic diagram of the installation structure of the reinforcing box of the present invention;

[0044] Figure 11 This is a schematic diagram of the installation structure of the pressure plate of the present invention;

[0045] Figure 12 This is a schematic diagram of the installation structure of the connecting sheet of the present invention;

[0046] Figure 13 This is a schematic diagram of the cable manufacturing process of the present invention;

[0047] Labels in the diagram: 1. Flat conductor;

[0048] 2. Heat dissipation and pressure resistance components; 201. Insulation layer; 202. Side guard plate; 203. Arc-shaped tube; 204. Connecting port; 205. Fixing lug; 206. Vent frame; 207. Elliptical tube; 208. Vent pipe; 209. Vent hole; 210. Diffuser hole; 211. Ventilation hole; 212. Air supply head; 213. Vent box; 214. Air distribution pipe; 220. Cooling pipe; 221. Fin; 222. Return pipe; 223. Infusion pipe; 224. Drain pipe; 225. T-shaped strip; 226. T-slot; 227. Spring sheet; 228. Rubber block; 229. Pressure-resistant plate;

[0049] 3. Reinforced connection components; 301. Male connector; 302. Female connector; 303. Connecting sheet; 304. Crimping bolt; 305. Crimping plate; 306. Release groove; 307. Fastening ear; 308. Fastening screw; 309. Fastening round plate; 310. Memory spring; 311. Round hole plate; 312. Reinforced box; 313. T-pipe; 314. Strip box; 315. Strip opening. Detailed Implementation

[0050] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0051] Example: Figure 1-12As shown, the present invention provides a technical solution for an explosion-proof aluminum alloy conductor flat cable for a new energy vehicle battery pack, including a flat conductor 1, and a heat dissipation and pressure-resistant component 2 disposed on the outside of the flat conductor 1. The heat dissipation and pressure-resistant component 2 includes an insulation layer 201, a side guard plate 202, an arc-shaped tube 203, a connecting port 204, a fixing ear 205, a vent frame 206, an elliptical tube 207, a vent pipe 208, a vent hole 209, a diffuser hole 210, a ventilation hole 211, a gas supply head 212, a vent box 213, a gas distribution pipe 214, a cooling pipe 220, fins 221, a return pipe 222, a liquid supply pipe 223, a drain pipe 224, a T-shaped strip 225, a T-shaped groove 226, a spring sheet 227, a rubber block 228, and a pressure-resistant plate 229.

[0052] The insulation layer 201 is made of ceramicized silicone rubber, with a temperature resistance rating of -60℃ to 180℃. It also has fire-resistant properties, meeting the requirements of high-temperature flames of 950℃ and above. It can maintain normal power supply without short circuit for more than 10 minutes, making it particularly suitable for the connection of battery pack components in new energy vehicles.

[0053] Side guard plates 202 are connected to both sides of the insulation layer 201. An arc-shaped tube 203 is welded to the outer side of the side guard plate 202. Multiple ventilation frames 206 are connected to the top and bottom of the insulation layer 201. Multiple elliptical tubes 207 are welded at equal intervals inside the ventilation frames 206. A ventilation pipe 208 is welded between adjacent elliptical tubes 207. Multiple ventilation holes 209 are opened at equal intervals at the top and bottom of the ventilation pipe 208. Diffuser holes 210 are opened at equal intervals on both sides of the elliptical tubes 207. The elliptical tubes 207 and the ventilation pipes 208 are connected through the diffuser holes 210. Multiple air diffusers 211 are opened at the top of the ventilation frames 206, allowing external air to flow through the air diffusers 211 and ventilation holes 209 into the ventilation pipes 208. The top and bottom of the side guard plate 202... A connecting port 204 is provided, which is connected to the inside of the arc-shaped tube 203. Air can flow through the connecting port 204 and the diffuser hole 210 into the inside of the arc-shaped tube 203. Multiple fixing ears 205 are connected to the top of both sides of the vent frame 206. The fixing ears 205 are connected to the adjacent side guard plate 202 by screws. After the vent frame 206 is connected and fixed to the side guard plate 202, it can wrap around the insulation layer 201 and provide all-round protection for the cable. The side guard plate 202, arc-shaped tube 203, vent frame 206, elliptical tube 207, vent pipe 208, cooling pipe 220 and fins 221 are made of uniform copper-aluminum alloy, which has good thermal conductivity and compressive strength. The heat generated by the flat conductor 1 can be conducted to the outside of the cable.

[0054] Ventilation frames 206 are connected to air supply heads 212 at both ends corresponding to the ends of ventilation pipes 208. Ventilation boxes 213 are connected between adjacent ventilation frames 206, with each end of the ventilation box 213 connected to an adjacent air supply head 212. The top of the ventilation box 213, located on the same horizontal plane, is connected to one side of an external main air supply pipe via a distribution pipe 214. One end of the main air supply pipe is connected to a transfer pipe, and one side of the transfer pipe is connected to three sub-control pipes. A sub-control valve is connected in the middle of each sub-control pipe, and a gas tank is connected to the top of one sub-control pipe. The gas tank stores compressed carbon dioxide gas. When the corresponding sub-control valve is opened, the carbon dioxide gas flows sequentially through the transfer pipe, the main air supply pipe, the distribution pipe 214, and the ventilation box 213. Inside the vent pipe 208, the input end of the sub-control valve is electrically connected to the output end of the external power supply through the controller. The sub-control valve can control the connectivity between the three sub-control pipes and the adapter pipe. The other two sub-control pipes are connected to the hot air outlet and the air inlet of the car's air conditioning system, respectively. When the cable temperature is high, the sub-control valve connected to the air inlet is opened, and the outside air, after being filtered by the air conditioning filter, can flow through the adapter pipe, the main air supply pipe, the air distribution pipe 214, and the vent box 213 into the vent pipe 208. When the outside temperature is low, the sub-control valve connected to the hot air outlet of the car's air conditioning system is opened, and the hot air can flow through the adapter pipe, the main air supply pipe, the air distribution pipe 214, and the vent box 213 into the vent pipe 208.

[0055] A cooling pipe 220 is connected to one side of the side guard plate 202 in the middle of the arc-shaped pipe 203. Multiple fins 221 are welded to the outside of the cooling pipe 220. One end of the cooling pipe 220 is connected to one end of the infusion pipe 223, and one end of the other cooling pipe 220 is connected to one end of the drain pipe 224. A return pipe 222 is connected between the other ends of the two cooling pipes 220. The other end of the infusion pipe 223 is connected to the water outlet of the battery pack water chiller, and the other end of the drain pipe 224 is connected to the water inlet of the battery pack water chiller. When air cooling is insufficient to cool the cable, the coolant output by the water chiller can enter the cooling pipe 220 and the return pipe 222 through the infusion pipe 223, and then return to the water chiller through the drain pipe 224. By combining water cooling and air cooling, the cable can be further cooled.

[0056] T-shaped strips 225 are welded to the top and bottom of the outer side of the arc-shaped tube 203. T-shaped grooves 226 are slidably connected to the outer side of the T-shaped strips 225. Multiple spring plates 227 are welded at equal intervals between the tops of two T-shaped grooves 226 located on the same horizontal plane. An anti-pressure plate 229 is connected between the tops of the spring plates 227 located on the same horizontal plane. A rubber block 228 is connected to the middle of the bottom of the spring plate 227.

[0057] The flat conductor 1 is provided with a reinforced connection component 3 at both ends. The reinforced connection component 3 includes a male connector 301, a female connector 302, a connecting sheet 303, a crimping bolt 304, a crimping plate 305, a release groove 306, a fastening ear 307, a fastening screw 308, a fastening round plate 309, a memory spring 310, a round hole plate 311, a reinforced box 312, a tee pipe 313, a strip box 314, and a strip opening 315.

[0058] The flat conductor 1 is connected to male connectors 301 at both ends, and a female connector 302 is connected to one side of the male connector 301. Multiple connecting plates 303 are welded to the opposite sides of the male connector 301 and the female connector 302. The connecting plates 303 at one end of the male connector 301 and the connecting plates 303 at one end of the female connector 302 are stacked and connected. The female connector 302 is welded to the wiring terminals inside the battery pack. Adjacent connecting plates 303 are connected by crimping bolts 304. A crimping plate 305 is connected to the top of the top connecting plate 303 and a crimping plate 305 is also connected to the bottom of the bottom connecting plate 303. Multiple release grooves 306 are opened on the opposite sides of two adjacent connecting plates 303.

[0059] Fastening lugs 307 are connected at the four corners of the pressing plate 305. Fastening screws 308 are connected between two opposite fastening lugs 307. Fastening round plates 309 are welded to the top of the fastening screws 308. Memory springs 310 are connected between the fastening round plates 309 and the adjacent fastening lugs 307. Circular hole plates 311 are welded to both ends of the memory springs 310. The memory springs 310 and the circular hole plates 311 are sleeved on the outside of the fastening screws 308.

[0060] Reinforcing boxes 312 are installed at the top and bottom ends of the insulation layer 201. One side of the reinforcing box 312 is connected to the adjacent air supply head 212. One side of the connecting sheet 303 is connected to a strip box 314 between two adjacent pressing plates 305. One side of the strip box 314 is connected to one end of the three-way pipe 313. The other two ends of the three-way pipe 313 are respectively connected to one end of the adjacent reinforcing box 312. A strip opening 315 is opened on one side of the strip box 314. Air inside the vent pipe 208 can enter the interior of the reinforcing box 312, then enter the interior of the strip box 314 through the three-way pipe 313, and finally be ejected from the strip opening 315. The air ejected from the strip opening 315 can blow the connecting sheet 303, thereby cooling or heating the connecting sheet 303.

[0061] like Figure 13 The present invention also provides a method for manufacturing an explosion-proof aluminum alloy conductor flat cable for a new energy vehicle battery pack, comprising the following steps:

[0062] S1. After being straightened left and right, up and down and treated with high frequency electromagnetic heating, the aluminum alloy solid flat conductor 1 enters the extruder head. The insulating material is fed, melted and plasticized by the extruder and then extruded onto the flat conductor 1 through the extrusion die to form the insulating layer 201.

[0063] S2. Place the side guard plate 202 on both sides of the insulation layer 201, and use screws and fixing ears 205 to splice and install the ventilation frame 206. Then connect the ventilation box 213 to the air supply head 212.

[0064] S3. Using the T-shaped strip 225 and the T-shaped groove 226, assemble the spring sheet 227 and the pressure plate 229;

[0065] S4. Use crimping bolts 304 to connect and fix the connecting plates 303 of the male connector 301 and the female connector 302, and use fastening screws 308 and memory springs 310 to connect and fix the crimping plate 305.

[0066] Among them, the nominal cross-sectional area of ​​the aluminum alloy solid flat conductor 1 is 30mm². 2 ~500mm 2 Its cross-sectional shape is rectangular or elliptical, with a width-to-thickness ratio of 4.5 to 8.5. The aluminum alloy solid flat conductor 1 has a tensile strength ≥140MPa, a yield strength ≥90MPa, an HV Vickers hardness ≥45, an elongation at break ≥16.5%, and a conductivity ≥59.5%IACS; the conductor's transverse bending radius meets the requirements of 1.5D to 3D.

[0067] When the cross-sectional shape of the aluminum alloy solid flat conductor 1 is rectangular, the four corners of the rectangular conductor are rounded and chamfered, with a chamfer radius of 0.8 to 3.0 mm.

[0068] When the cross-sectional shape of the aluminum alloy solid flat conductor 1 is elliptical, the two narrow sides of the elliptical conductor are semi-circular transitions, and its radius is 1 / 2 of the thickness value;

[0069] Among them, the insulating material series includes, but is not limited to, nylon materials, silicone rubber, PVC, XLPE, XLPO or TPE-like polymers;

[0070] The composition and percentage of each component of the aluminum alloy solid flat conductor 1 are as follows: Si: 0.35-0.55, Mg: 0.40-0.60, Fe: 0.05-0.15, Cu: content not greater than 0.01, Mn: content not greater than 0.03, Cr: content not greater than 0.01, B: content not greater than 0.01, Zn: content not greater than 0.01, with the balance being Al and unavoidable impurities. The content of each unavoidable impurity is not greater than 0.03, and the total impurity content is not greater than 0.10.

[0071] The working principle and usage process of this invention: The fixing ear 205 is connected to the adjacent side guard plate 202 by screws. The arc tube 203 is distributed on both sides of the cable, and the vent frame 206 is distributed on the top and bottom of the cable, wrapping the insulation layer 201. The side guard plate 202, arc tube 203, vent frame 206, elliptical tube 207, vent pipe 208, cooling pipe 220, and fins 221 are made of uniform copper-aluminum alloy, which has good thermal conductivity and compressive strength. Under the action of heat conduction, the heat generated by the flat conductor 1 can be conducted to the outside of the cable. During the operation of the car, if the cable temperature is high, the control valve connected to the air conditioning intake is opened. After being filtered by the air conditioning filter, the outside air can flow through the adapter pipe, the main air supply pipe, the air distribution pipe 214, and the vent box 213 into the vent pipe 208. Part of the air entering the vent pipe 208 passes through the diffuser hole 210 and the vent hole 209 towards the elliptical tube 208. The air flows inside the tube 207, carrying away the heat from the vent tube 208, the elliptical tube 207, and the vent frame 206. Some air passes through the diffuser hole 210 and the connecting port 204 into the arc-shaped tube 203. The flowing air carries away the heat from the arc-shaped tube 203, the cooling tube 220, and the fins 221, thereby cooling the cable. The elliptical tube 207 and the vent tube 208 are evenly distributed, resulting in a large heat dissipation area and good heat dissipation effect in a small volume. The airflow generated by the car's movement is used to cool the cable, preventing the cable temperature from becoming too high, extending the cable's service life, and reducing current energy loss. The cold air can also diffuse to the surrounding area of ​​the cable through the vent hole 211 to cool the electrical components such as the battery cells around the cable. Combined with the existing water-cooled and air-cooled cooling machines for cooling the outside of the battery pack, the battery pack is cooled from both inside and outside, improving the heat dissipation effect and the operational stability of the battery pack.

[0072] When air cooling is insufficient to cool the cable, the coolant output from the water chiller can enter the cooling pipe 220 and the return pipe 222 through the liquid delivery pipe 223, and then return to the water chiller through the liquid discharge pipe 224. By combining water cooling and air cooling, the cable can be further cooled, and the heat dissipation effect of the cable is better.

[0073] Arc-shaped tubes 203 are distributed on both sides of the cable, and pressure-resistant plates 229 are distributed on the top and bottom of the cable, wrapping the insulation layer 201 around. The arc-shaped tubes 203 and spring plates 227 are elastic. When the cable is subjected to external pressure, the arc-shaped tubes 203 and spring plates 227 undergo elastic deformation, absorbing the external force through deformation and returning to their original shape after the external force is removed. This prevents the external force from acting directly on the surface of the insulation layer 201, protecting the cable insulation layer 201 and giving the cable strong pressure resistance.

[0074] In cold weather, open the control valve connected to the hot air outlet of the car air conditioner and turn on the heating function of the air conditioner. The hot air generated by the air conditioner flows through the transfer pipe, the main air supply pipe, the distribution pipe 214 and the vent box 213 into the vent pipe 208. The hot air then flows through the diffuser hole 210, the vent hole 209 and the connecting port 204 to diffuse around the cable. Under the action of heat conduction, the aluminum alloy flat conductor 1 and the insulation layer 201 are prevented from brittle cracking due to low temperature, which improves the cold resistance of the cable. The hot air can also diffuse around the cable through the vent hole 211 to heat up the battery cells around the cable, prevent the battery cells from getting too cold and extend the battery cells' endurance.

[0075] A gas cylinder is connected to the top of a sub-control pipe. The gas cylinder stores compressed carbon dioxide gas. When the battery pack of a new energy vehicle catches fire, the sub-control valve connected to the gas cylinder opens. The carbon dioxide gas will flow through the transfer pipe, the main gas supply pipe, the gas distribution pipe 214 and the vent box 213 in sequence into the vent pipe 208. Finally, it will be emitted from the vent hole 211 and the connecting port 204. The emitted carbon dioxide gas can dilute the oxygen when the fire first occurs, slow down the spread of the flames, and provide more escape space for people to escape. The heat dissipation and pressure resistance component 2 is multi-functional and the cable has good explosion-proof capability.

[0076] The female connector 302 is welded to the wiring terminals inside the battery pack, and the male connector 301 is connected to the flat conductor 1. The male connector 301 and the female connector 302 are connected by multiple connecting plates 303. Compared with the crimping connection method of the prior art, this connection uses crimping bolts 304 to crimp the connecting plates 303 layer by layer, resulting in a larger connection contact area and a better connection effect for the cable.

[0077] The cable crimping connections inside the automotive battery pack are affected by thermal expansion and contraction under varying temperature conditions. The expansion and contraction of the metal can affect the tightness of the connection. The memory spring 310 is made of shape memory alloy. When the temperature rises, the memory spring 310 contracts and when the temperature drops, the memory spring 310 expands. When the cable joint temperature rises, the memory spring 310 contracts, and the pressure applied by the crimping plate 305 to the connecting sheet 303 decreases. The release groove 306 provides space for the expansion of the connecting sheet 303. When the cable joint temperature drops, the memory spring 310 expands, and the pressure applied by the crimping plate 305 to the connecting sheet 303 increases, making the contact between the connecting sheets 303 tighter and improving the cable connection tightness. The connection stability of the cable can be guaranteed in both high and low temperature environments, and the current transmission stability of the cable is high.

[0078] When cooling or heating the cable, the air inside the vent pipe 208 can enter the reinforcing box 312, then enter the strip box 314 through the three-way pipe 313, and finally be ejected from the strip opening 315. The air ejected from the strip opening 315 can blow the connecting sheet 303, thereby cooling or heating the connecting sheet 303, preventing the temperature between the cable terminals from being too high or too low, and further improving the connection stability of the cable.

[0079] In the heat dissipation and pressure resistance component 2, the arc-shaped tube 203 and the vent frame 206 are distributed around the cable to wrap the insulation layer 201. The uniform distribution of the elliptical tube 207 and the vent frame 208 in the vent frame 206 enables the cable to have a good heat dissipation effect in a small volume. In the reinforced connection component 3, part of the air inside the vent 208 enters the strip box 314 and is ejected from the strip opening 315 to cool the terminal. The two components work together to improve the overall heat dissipation effect of the cable.

[0080] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs, comprising a flat conductor (1), characterized in that, A heat dissipation and pressure-resistant component (2) is provided on the outside of the flat conductor (1), and the heat dissipation and pressure-resistant component (2) includes an insulating layer (201). The insulating layer (201) is connected to side guard plates (202) on both sides. An arc-shaped tube (203) is welded to the outside of the side guard plate (202). The top and bottom of the insulating layer (201) are connected to multiple ventilation frames (206). Multiple elliptical tubes (207) are welded at equal intervals inside the ventilation frame (206). A ventilation tube (208) is welded between two adjacent elliptical tubes (207). Multiple ventilation holes (209) are opened at equal intervals at the top and bottom of the ventilation tube (208). Diffuser holes (210) are opened at equal intervals on both sides of the elliptical tube (207). The elliptical tube (207) and the ventilation tube (208) are connected through the diffuser holes (210). Multiple air dissipation holes (211) are opened at the top of the ventilation frame (206). The top and bottom of the outer side of the arc-shaped tube (203) are welded with T-shaped strips (225), and T-shaped grooves (226) are slidably connected to the outer side of the T-shaped strips (225). Multiple spring plates (227) are welded at equal intervals between the tops of the two T-shaped grooves (226) located on the same horizontal plane. A pressure-resistant plate (229) is connected between the tops of the spring plates (227) located on the same horizontal plane. A rubber block (228) is connected to the middle of the bottom of the spring plate (227).

2. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 1, characterized in that, The side guard plate (202) has a communication port (204) at the top and bottom. The communication port (204) is connected to the inside of the arc-shaped tube (203). The top of both sides of the ventilation frame (206) is connected to a plurality of fixing ears (205). The fixing ears (205) are connected to the adjacent side guard plate (202) by screws.

3. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 2, characterized in that, The ventilation frame (206) has air supply heads (212) connected to both ends of the ventilation pipe (208) at both ends. A ventilation box (213) is connected between two adjacent ventilation frames (206), and the two ends of the ventilation box (213) are connected to the adjacent air supply heads (212).

4. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 3, characterized in that, The top of the ventilation box (213) located on the same horizontal plane is connected to one side of the external air supply main pipe through the air distribution pipe (214), and the side guard plate (202) is connected to the cooling pipe (220) in the middle of the arc-shaped pipe (203).

5. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 4, characterized in that, The cooling pipe (220) has multiple fins (221) welded to its outer side. One end of the cooling pipe (220) is connected to one end of the infusion pipe (223), and one end of the cooling pipe (220) is connected to one end of the drain pipe (224). A return pipe (222) is connected between the other ends of the two cooling pipes (220).

6. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 5, characterized in that, The other end of the infusion pipe (223) is connected to the water outlet of the battery pack water chiller, and the other end of the drain pipe (224) is connected to the water inlet of the battery pack water chiller.

7. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 2, characterized in that, The flat conductor (1) is provided with reinforced connection components (3) at both ends, and the reinforced connection components (3) include male connectors (301). The flat conductor (1) is connected to male connectors (301) at both ends, and a female connector (302) is connected to one side of the male connector (301). Multiple connecting plates (303) are welded to the opposite sides of the male connector (301) and the female connector (302). The connecting plates (303) at one end of the male connector (301) and the connecting plates (303) at one end of the female connector (302) are stacked and connected. Adjacent connecting plates (303) are connected by crimping bolts (304). A crimping plate (305) is connected to the top of the top connecting plate (303), and a crimping plate (305) is also connected to the bottom of the bottom connecting plate (303). Multiple release grooves (306) are opened on the opposite sides of two adjacent connecting plates (303). Fastening lugs (307) are connected at the four corners of the pressing plate (305). Fastening screws (308) are connected between two opposite fastening lugs (307). A fastening round plate (309) is welded to the top of the fastening screw (308). A memory spring (310) is connected between the fastening round plate (309) and the adjacent fastening lug (307). A round hole plate (311) is welded to both ends of the memory spring (310). The memory spring (310) and the round hole plate (311) are sleeved on the outside of the fastening screw (308).

8. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 7, characterized in that, The top and bottom ends of the insulation layer (201) are equipped with reinforcing boxes (312). One side of the reinforcing box (312) is connected to the adjacent gas supply head (212). One side of the connecting sheet (303) is located between two adjacent pressing plates (305) and is connected to a strip box (314). One side of the strip box (314) is connected to one end of a three-way pipe (313). The other two ends of the three-way pipe (313) are respectively connected to one end of the adjacent reinforcing box (312). A strip opening (315) is opened on one side of the strip box (314).

9. The explosion-proof aluminum alloy conductor flat cable for new energy vehicle battery packs according to claim 7, characterized in that, The insulation layer (201) is made of ceramicized silicone rubber, and its temperature resistance rating meets the requirements of -60℃ to 180℃.

10. A method for manufacturing an explosion-proof aluminum alloy conductor flat cable for a new energy vehicle battery pack, used in accordance with the method for manufacturing an explosion-proof aluminum alloy conductor flat cable for a new energy vehicle battery pack according to claim 8, characterized in that, Includes the following steps: S1. After being straightened left and right, up and down and treated with high frequency electromagnetic heating, the aluminum alloy solid flat conductor (1) enters the extruder head. The insulating material is fed, melted and plasticized by the extruder and then extruded onto the flat conductor (1) through the extrusion mold to form an insulating layer (201). S2. Place the side guard plate (202) on both sides of the insulation layer (201), and use screws and fixing ears (205) to splice and install the ventilation frame (206), and then connect the ventilation box (213) to the air supply head (212). S3. Using the T-strip (225) and T-slot (226) to assemble the spring sheet (227) and the pressure plate (229); S4. Use crimping bolts (304) to connect and fix the connecting plates (303) of the male connector (301) and female connector (302) to each other, and use fastening screws (308) and memory springs (310) to connect and fix the crimping plate (305).

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