Battery pack, thermal management system and thermal management method

Abstract

The present invention provides a battery pack, a thermal management system and a thermal management method, relating to the technical field of new energy vehicles, and solving the problem that the existing cooling medium distributor cannot synchronously adjust the flow rates of the cooling branches of each module. The battery pack includes battery modules, heat exchange plates and a medium distributor. The medium distributor divides the cooling main path into multiple parallel branches, and heat exchange plates are provided in each branch. The distributor has a main port and multiple branch ports, and the flow cross-section in each branch port is adjusted by a first piston and an elastic member. A second piston cavity is provided on the circumference of the control disk and is connected to the first piston cavity through a pipeline to achieve linkage. The regulator has adjusting rods distributed in a circular pattern corresponding to each second piston. The adjusting rods are connected to expansion blocks through locking mechanisms. After the telescopic power source of the regulator selects and adjusts the positions of each adjusting rod by rotation, the regulator moves towards the control disk, and each adjusting rod respectively pushes the second piston to move, thereby联动 the first piston to change the opening degree of the corresponding branch port, achieving the effect of synchronously adjusting the flow rates of each cooling branch.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle technology, specifically to battery packs, thermal management systems, and thermal management methods. Background Technology

[0002] New energy battery packs typically consist of multiple battery modules, and the overall performance of the pack is often constrained by the differences between the two modules with the greatest disparities. Capacity and voltage balance between modules is crucial for the system, and temperature is a key factor significantly affecting the charging and discharging differences between modules. Temperature differences between modules exacerbate performance inconsistencies, thus affecting the overall output capacity and lifespan of the battery pack, leading to decreased usable battery capacity, reduced driving range, and shortened battery life. Therefore, maintaining temperature balance between modules is an important way to improve battery pack performance and reliability.

[0003] To improve the balance between modules, existing technologies typically employ a strategy of independent cooling control for each module. By adjusting the cooling intensity of each module, the temperature difference is reduced, making the charge and discharge characteristics of each module more consistent, thereby delaying battery performance degradation and extending overall lifespan. However, this approach requires the placement of independent valves and corresponding controllers on each cooling branch, resulting in a complex system structure, large space occupation, and significantly impacting the energy density of the battery pack, which is detrimental to the lightweighting and range improvement of electric vehicles.

[0004] To further optimize thermal management, Chinese invention patent CN121054862B discloses a new energy heavy-duty truck battery pack, thermal management unit, and method. This method uses an active cooling medium distributor with a movable adjustment mechanism to regulate the cooling flow rate of each module branch. However, such distributors typically only adjust the flow rate of one branch at a time, requiring sequential movement to different positions to adjust each branch individually. They cannot simultaneously change the flow rate of all branches based on the real-time calculated required flow rate ratio. When some branches have been adjusted to the new flow rate while others maintain their original flow rate, the temperature distribution between modules changes again according to the current flow rate, causing distortion of previously calculated control parameters, necessitating recalculation and readjustment. This results in a long adjustment time and makes it difficult to achieve stable and rapid thermal equilibrium. The system is often in a dynamic process of continuous adjustment, limiting both control efficiency and accuracy. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention proposes a battery pack, a thermal management system, and a thermal management method to solve the technical problem that the cooling medium distributor of the battery pack thermal management system cannot simultaneously regulate the flow of cooling branches of each module within the pack.

[0006] The technical solution adopted in this invention is a battery pack, a thermal management system, and a thermal management method.

[0007] One type of battery pack includes a battery module, a heat exchange plate, and a medium distributor. The battery module and the heat exchange plate are correspondingly arranged. The medium distributor divides the main cooling medium circuit into multiple parallel branch circuits, and the heat exchange plate is connected in series to the branch circuits. The medium distributor includes:

[0008] A pipe housing with a main port and multiple branch ports is provided. A first cavity is provided inside the pipe housing for each branch port. A first piston is provided inside the first cavity. The position change of the first piston can adjust the flow cross section of the corresponding branch port. A first elastic element is provided inside the first cavity for controlling the initial flow cross section of the corresponding branch port.

[0009] The circular array has a control panel with multiple second cavities. Each second cavity is equipped with a second piston. The first and second cavities are arranged in pairs and are connected by pipes. The first and second pistons can be linked together. The center of the control panel is also equipped with a first telescopic power source.

[0010] And, an adjuster is provided on the telescopic shaft of the first telescopic power source. The adjuster includes an adjusting shell, an adjusting rod, a first locking block, an unlocking ramp, an expansion mechanism, a rotary power source, and a second telescopic power source. The multiple adjusting rods are circumferentially distributed. The adjusting rods slide through the adjusting shell and are positioned corresponding to the second piston. The adjusting shell is provided with a second elastic element for controlling the initial position of the adjusting rods. The expansion mechanism is located in the middle of the adjusting shell. The expansion mechanism has multiple circumferentially distributed expansion blocks that are synchronously extended and retracted. The unlocking ramp is located on one of the expansion blocks. The unlocking ramp has a first inclined surface on the side facing away from the control panel. The remaining expansion blocks are all abutted against the back end of the first locking block by a third elastic element. The head end of the first locking block abuts against the adjusting rod, and the abutment area has a cooperating conical engagement structure. The shell of the second telescopic power source is driven by the rotary power source and can rotate around the center of the adjusting shell. The second telescopic power source can correspond to the adjusting rod and the first inclined surface and push them toward the second piston.

[0011] Optionally, the expansion mechanism further includes a slide rod, slip rings, a fourth elastic element, and a connecting rod; the slide rod is fixedly disposed at the center of the adjusting shell; the two slip rings are slidably sleeved on both ends of the slide rod, and multiple hinge seats are arranged circumferentially on the two slip rings; the two fourth elastic elements abut against the two slip rings and the adjusting shell respectively; one end of the two connecting rods is hinged to the expansion block, and the other end is hinged to the hinge seats of the two slip rings respectively; the expansion block is slidably installed on the adjusting shell, and the sliding direction is along the radial direction of the slide rod.

[0012] Optionally, the control panel further includes a fifth elastic element, a sixth elastic element, and a second locking block; the control panel has a first annular groove facing the second cavity and a second annular groove facing the regulator, the first annular groove and the second annular groove have a communicating area, the regulator has a convex ring, and when the regulator moves toward the control panel, the convex ring can be inserted into the second annular groove; the fifth elastic element is disposed in the second cavity and can limit the initial position of the second piston; multiple second locking blocks are arranged in a circumferential array, the second locking blocks are slidably disposed in the first annular groove, the sixth elastic element abuts between the first annular groove and the tail of the second locking block, the head of the second locking block abuts the second piston and the abutting area is also provided with a cooperating conical engagement structure, and the second locking block has a second inclined surface corresponding to the area of ​​the second annular groove.

[0013] Optionally, the conical engagement structure includes a conical protrusion at one of the contact ends and a conical recess at the other contact end. The cross-sections of the conical protrusion and the conical recess are matched. Multiple cooperating conical protrusions and conical recesses are respectively provided at the two contact ends. Along the distribution direction of the multiple conical recesses, one side of the conical recess is an inclined surface and the other side is a plane.

[0014] Optionally, the first locking block is provided with a guide hole facing the adjusting rod, the expansion block is provided with a guide rod that slides into the guide hole, the third elastic element is sleeved on the guide rod and abuts between the first locking block and the expansion block, and the guide rod is provided with a limiting plate with a cross-section larger than the guide hole after passing through the guide hole.

[0015] Optionally, the heat exchange plate includes a branch inlet, a branch outlet, a first overflow valve, a second overflow valve, and a sealing layer; the sealing layer is a cylindrical shape that wraps around the battery module, with one end of the cylindrical sealing layer sealed to the upper end of the battery module, and the other end of the cylindrical sealing layer sealed to the heat exchange plate, forming a sealed medium space between the sealing layer and the battery module; the branch inlet and the branch outlet are connected in series in the branch circuit, the inlet end of the first overflow valve is located at the branch inlet, and the outlet end is connected to the medium space, the first overflow valve can open after the branch inlet pressure exceeds the preset opening pressure, the inlet end of the second overflow valve is located at the medium space, and the outlet end is connected to the branch outlet.

[0016] Optionally, the battery module is filled with thermally conductive adhesive, and the low-voltage connector and high-voltage terminal of the battery module are located in the upper region of the battery module and are higher than the connection area between the sealing layer and the battery module shell.

[0017] The thermal management system includes a battery pack as described above, and further includes:

[0018] A refrigeration circuit consisting of a condenser, a compressor, a heat exchanger, and an expansion valve connected in series.

[0019] In addition, a heat exchange circuit is formed by connecting a water pump, a heater and the heat exchanger in series, the main circuit of the battery pack is connected in series to the heat exchange circuit, and the refrigeration circuit and the heat exchange circuit exchange heat through the heat exchanger.

[0020] The thermal management method, applicable to the thermal management system described above, includes the following steps:

[0021] The real-time temperature of each battery module in the battery pack is obtained, and the target control temperature of the battery module is obtained.

[0022] The flow section control parameters of each battery module's corresponding branch circuit are calculated based on the real-time temperature and the target temperature.

[0023] The first piston of each of the branch circuits is moved simultaneously according to the flow section control parameters, specifically including:

[0024] The control panel and the regulator are in a separated state. The second telescopic power source presses against the first inclined surface. The expansion mechanism contracts and releases the first locking block from locking the adjusting rod. Each adjusting rod retracts to its initial position under the action of the second elastic element. The second telescopic power source retracts to release the pressure on the first inclined surface. The expansion mechanism expands and resets, and locks the adjusting rod in one direction through the conical interlocking structure.

[0025] The rotary power source drives the housing of the second telescopic power source to rotate and align with each of the adjusting rods respectively. The second telescopic power source pushes the position of each of the adjusting rods by telescopic movement.

[0026] After all the adjusting rods have been adjusted, the first telescopic power source pulls the regulator towards the control panel. The adjusting rod of the regulator corresponds to the second piston of the control panel. The adjusting rod pushes the second piston to move, which in turn pushes the first piston to move, thereby changing the flow cross section of each branch circuit.

[0027] Optionally, the method further includes the following steps: when the medium pressure in one of the branch circuits increases and exceeds the preset opening pressure of the first relief valve, the first relief valve is connected, the medium space begins to be filled with medium, the medium space begins to increase pressure after being filled with medium, and after the pressure in the medium space reaches the opening pressure of the second relief valve, the second relief valve is connected, and the medium flows out of the medium space.

[0028] As can be seen from the above technical solution, the beneficial technical effects of the present invention are as follows:

[0029] The medium distributor achieves the technical effect of synchronously and simultaneously adjusting the flow rate of each cooling branch based on the real-time temperature differences of each module within the battery pack. This distributor, through the coordinated rotation and extension of the regulator, drives multiple circumferentially distributed regulating rods to pre-positioned locations. The regulator then moves towards the control panel, synchronously triggering the adjustment action. Furthermore, through the linkage of the second and first pistons, the flow cross-section of all branch circuits is changed simultaneously, allowing the flow rate of each branch circuit to switch synchronously according to a preset ratio. This mechanism solves the time lag and parameter distortion problems caused by sequential adjustments in existing technologies, avoids repeated temperature fluctuations caused by some branches being adjusted while others remain unadjusted, significantly shortens the adjustment cycle required to reach thermal equilibrium, and improves the response speed and steady-state accuracy of temperature control. Simultaneously, this solution replaces multiple independent valves and controllers with a centralized mechanical drive and linkage mechanism, greatly simplifying the system structure, saving valuable internal layout space within the battery pack, and contributing to increased energy density. Attached Figure Description

[0030] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0031] Figure 1 This is a schematic diagram of the thermal management system.

[0032] Figure 2 This is a schematic diagram of the overall thermal management system.

[0033] Figure 3 This is a schematic diagram of the media distributor.

[0034] Figure 4 for Figure 3 Schematic diagram of the section cut along the AA direction.

[0035] Figure 5 for Figure 4 A magnified view of a portion of point C in the middle.

[0036] Figure 6 for Figure 3 Schematic diagram of the BB-direction section.

[0037] Figure 7 for Figure 6 A magnified view of a portion of point D in the middle.

[0038] Figure 8 A cross-sectional view of the control panel and regulator.

[0039] Figure 9 for Figure 8 A magnified view of a portion of point E in the middle.

[0040] Figure 10 for Figure 8 A magnified view of a portion of point F in the middle.

[0041] Figure 11 This is a schematic diagram of the control panel and regulator assembly.

[0042] Figure 12 This is a schematic diagram of the battery module.

[0043] Reference numerals: Medium distributor 1, pipe housing 11, first cavity 111, first piston 112, first elastic element 113, control panel 12, second cavity 121, second piston 122, first telescopic power source 123, fifth elastic element 124, sixth elastic element 125, second locking block 126, second inclined surface 1261, first annular groove 127, second annular groove 128, adjuster 13, adjusting shell 131, convex ring 1311, adjusting rod 132, first locking block 133, unlocking inclined block 134, first inclined surface 1341, expansion mechanism 135, expansion block 1351, guide rod 13511, limit Positioning plate 13512, slide rod 1352, slip ring 1353, fourth elastic element 1354, connecting rod 1355, second elastic element 136, third elastic element 137, conical interlocking structure 14, conical protrusion 141, conical recess 142, second telescopic power source 15, rotational power source 16, heat exchange plate 2, branch inlet 21, branch outlet 22, first overflow valve 23, sealing layer 24, battery module 3, low-pressure connector 31, high-pressure terminal 32, main circuit 4, refrigeration circuit 5, condenser 51, compressor 52, expansion valve 53, heat exchange circuit 6, water pump 61, heater 62, heat exchanger 7. Detailed Implementation

[0044] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the technical solution of the present invention and are therefore intended to limit the scope of protection of the present invention.

[0045] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application should have the ordinary meaning as understood by those skilled in the art to which this invention pertains.

[0046] One type of battery pack, see [link / reference] Figure 2 It includes a battery module 3, a heat exchange plate 2 and a medium distributor 1. The battery module 3 is set in relation to the heat exchange plate 2. The medium distributor 1 divides the main cooling medium circuit 4 into multiple parallel branch circuits. The heat exchange plate 2 is connected in series to the branch circuits and exchanges heat with the battery module 3.

[0047] Please refer to the appendix for the outline of media distributor 1. Figure 3 For internal structure, please refer to Figures 4-11 One possible implementation is as follows: the media distributor 1 includes:

[0048] The pipe casing 11 has a main port and multiple branch ports, see reference. Figure 6 The pipe shell 11 is provided with a first cavity 111 corresponding to each branch. The first cavity 111 is provided with a first piston 112. The position change of the first piston 112 can adjust the flow section of the corresponding branch. The first cavity 111 is provided with a first elastic element 113 for controlling the initial flow section of the corresponding branch.

[0049] The circular array has multiple control panels 12 of the second cavity 121, see reference. Figure 7 The second cavity 121 is provided with a second piston 122. The first cavity 111 and the second cavity 121 are arranged in pairs and are connected by pipelines (the pipelines are not shown in the attached figure). The first piston 112 and the second piston 122 can be linked by pressure. That is, when the second piston 122 slides in the second cavity 121, the first piston 112 will also slide in the first cavity 111. The control panel 12 is also provided with a first telescopic power source 123 in the middle.

[0050] And, please refer to the adjuster 13 located on the telescopic shaft of the first telescopic power source 123. Figure 8 and Figure 9 , combined Figure 11 The regulator 13 includes an adjusting shell 131, adjusting rods 132, a first locking block 133, an unlocking ramp 134, an expansion mechanism 135, a rotational power source 16, and a second telescopic power source 15. Multiple adjusting rods 132 are circumferentially distributed, sliding through the adjusting shell 131 and corresponding to the position of the second piston 122. A second elastic element 136 for controlling the initial position of the adjusting rods 132 is provided inside the adjusting shell 131. The second elastic element 136 abuts against the stepped plate of the adjusting rod 132 and the end face of the adjusting shell 131. The expansion mechanism 135 is located in the middle of the adjusting shell 131 and has multiple circumferentially distributed expansion blocks 1351 that are synchronously extended and retracted. The unlocking ramp 134 is located on one of the expansion blocks 1351. The unlocking ramp 134 has a first ramp 1341 on the side facing away from the control panel 12 (facing the second telescopic power source 15). The remaining expansion blocks 1351 are all abutted against the back end of the first locking block 133 by the third elastic member 137. The head end of the first locking block 133 abuts against the adjusting rod 132 and the abutting area is provided with a matching conical engagement structure 14. The housing of the second telescopic power source 15 is driven by the rotary power source 16 and can rotate around the center of the adjusting housing 131. During the rotation, the second telescopic power source 15 can correspond to the adjusting rod 132 and the first ramp 1341 and move towards the second piston 122 by extending and pushing it.

[0051] Furthermore, in one possible implementation, see Appendix Figure 11 The conical engagement structure 14 includes a conical protrusion 141 located at one contact end and a conical recess 142 located at the other contact end. The conical protrusion 141 and the conical recess 142 are cross-sectionally matched. Multiple mutually engaging conical protrusions 141 and conical recesses 142 are respectively provided at the two contact ends. Along the distribution direction of the multiple conical recesses 142, one side of the conical recess 142 is a slope, and the other side is a plane. Figure 9 The flat side of the tapered protrusion 141 of the adjusting rod 132 is located at one end of the adjuster 13, and the inclined side is located at one end of the tube housing 11. When the expansion mechanism 135 is in the expanded state, the tapered structure of the first locking block 133 is embedded in the tapered structure of the adjusting rod 132. When the adjusting rod 132 is pushed by the second telescopic power source 15, the adjusting rod 132 can overcome the elastic force of the third elastic element 137 to retract the current first locking block 133. The adjusting rod 132 can slide in one direction, that is, the position after being pushed can be maintained. Only when the expansion mechanism 135 is in the contracted state, the tapered structure of the first locking block 133 loses its locking effect on the adjusting rod 132, and the adjusting rod 132 can move backward and reset under the action of the second elastic element 136.

[0052] In the above embodiments, the cooling medium flow rate adjustment process is as follows:

[0053] The vehicle starts, the battery pack is powered on, and the battery pack self-test is completed. In the media distributor 1, the regulator 13 and the control panel 12 are in a disconnected state, that is, as shown... Figure 8In the state shown, the regulator 13 has no regulating function. The first piston 112 and the second piston 122 are in their initial positions under the action of the first elastic element 113. The initial position can be the position with the maximum flow cross-section. At this time, the positions of all the first pistons 112 in the medium distributor 1 are consistent, that is, each branch has the same cross-sectional area and cooling flow rate. Therefore, the flow rate of each branch can be controlled by controlling the total flow rate of the pump. For example, if the total flow rate is 10 units and there are 10 battery modules 3, then the flow rate of each battery module 3 is 1 unit. After the battery pack has been running for a period of time, a temperature difference appears between the battery modules 3. For example, the temperature of one battery module 3 is too high, and the temperature of another battery module 3 is too low, while the temperature of the other 8 battery modules 3 is still within the set range. Assuming that the required flow rate ratio is 1.2:0.8:1:1:1:1:1:1:1:1, that is, the first piston 112 of one battery module 3 needs to move forward to increase the flow area, the first piston 112 of another battery module 3 needs to move backward to reduce the flow area, and the first piston 112 of the remaining battery modules 3 needs to remain stationary to maintain the original flow area. If the total flow rate of the pump is adjusted to 20 units, the required flow area ratio of the first piston 112 of each battery module 3 becomes: 0.6:0.4:0.5:0.5:0.5:0.5:0.5:0.5:0.5:0.5, thus requiring all branches to be reduced, that is, the first piston 112 moves backward in all branches.

[0054] In the media distributor 1, the rotary power source 16 drives the second telescopic power source 15 to rotate to a position aligned with the unlocking ramp 134. The second telescopic power source 15 extends and presses against the first ramp 1341, causing the unlocking ramp 134 to retract towards the center. The expansion block 1351 also retracts synchronously, and the first locking block 133 moves backward and loses its locking effect on the adjusting rod 132. All the adjusting rods 132 move backward under the action of the corresponding second elastic element 136. Subsequently, the second telescopic power source 15 retracts and loses its pressing effect on the first ramp 1341. The expansion mechanism 135 returns to its expanded state, and the expansion block 1351 and the first locking block 133 move forward. The conical engagement structure 14 of the first locking block 133 and the adjusting rod 132 re-engages. At this time, each adjusting rod 132 can only move unidirectionally toward the control panel 12.

[0055] Based on the required cross-sectional area of ​​the first piston 112 corresponding to each battery module 3, the distance that each adjusting rod 132 needs to move is calculated, then converted into the distance that the second piston 122 needs to move, and thus the corresponding distance that the adjusting rod 132 needs to move. Then, the rotary power source 16 drives the second telescopic power source 15 to rotate to a position aligned with each adjusting rod 132 and pushes the adjusting rod 132 to move axially a corresponding distance before being fixed in position by the first locking block 133.

[0056] After all the adjusting rods 132 have been adjusted, the first telescopic power source 123 pulls the regulator 13 to move towards the control panel 12. Each adjusting rod 132 of the regulator 13 pushes the second piston 122 of the control panel 12 to move accordingly. The second piston 122 pushes the first piston 112 to move through air pressure linkage, thereby realizing the synchronous adjustment of the throttling area of ​​each branch.

[0057] The technical solution in the above embodiments achieves synchronous proportional adjustment of the flow rate of all cooling branches within the battery pack through the medium distributor 1. Its core advantages are: 1. The regulator 13, through the coordination of the rotary power source 16 and the second telescopic power source 15, can pre-set and independently set the extension length of each adjusting rod 132 and lock it using the conical engagement structure 14. Subsequently, the first telescopic power source 123 pushes all adjusting rods 132 at once, and then, through the hydraulic linkage between the second piston 122 and the first piston 112, synchronously changes the flow cross-section of all branches, achieving instantaneous switching of the flow rate ratio. This solves the time lag and intermediate state parameter distortion problems caused by existing sequential adjustment, enabling the system to quickly and accurately achieve temperature equilibrium. 2. This solution replaces multiple independent valves and controllers with a highly integrated mechanical mechanism, significantly simplifying the system, saving internal space in the battery pack, and contributing to improved energy density.

[0058] In one possible implementation, see Appendix Figure 9 The expansion mechanism 135 also includes a slide rod 1352, a slip ring 1353, a fourth elastic element 1354, and a connecting rod 1355; the slide rod 1352 is fixedly disposed at the center of the adjusting shell 131; two slip rings 1353 are slidably sleeved on both ends of the slide rod 1352, and multiple hinge seats are arranged circumferentially on the two slip rings 1353; two fourth elastic elements 1354 respectively abut against the two slip rings 1353 and the adjusting shell 131; one end of the two connecting rods 1355 is hinged to the expansion block 1351, and the other end is respectively hinged to the hinge seats of the two slip rings 1353; the expansion block 1351 is slidably installed on the adjusting shell 131, and the sliding direction is along the radial direction of the slide rod 1352.

[0059] In the above embodiment, when the unlocking ramp 134 is pushed and retracts towards the center, the connecting rod 1355 drives the two slip rings 1353 to move away from each other along the slide rod 1352 and compress the fourth elastic element 1354, thereby achieving synchronous radial contraction of all expansion blocks 1351. When the external force is removed, under the action of the fourth elastic element 1354, the slip rings 1353 reset and drive all expansion blocks 1351 to expand outward synchronously through the connecting rod 1355. This structure is a purely mechanical structure, ensuring the synchronicity and reliability of the opening and closing actions of multiple expansion blocks 1351.

[0060] In one possible implementation, see Appendix Figure 10The control panel 12 also includes a fifth elastic element 124, a sixth elastic element 125, and a second locking block 126. The control panel 12 is provided with a first annular groove 127 facing the second cavity 121 and a second annular groove 128 facing the adjuster 13. The first annular groove 127 and the second annular groove 128 have a communicating area. The adjuster 13 is provided with a protruding ring 1311. When the adjuster 13 moves toward the control panel 12, the protruding ring 1311 can be inserted into the second annular groove 128. The fifth elastic element 124 is provided in the second cavity 121 and can limit the initial movement of the second piston 122. Position: One end of the fifth elastic element 124 is fixedly connected to the bottom of the second cavity 121, and the other end is fixedly connected to the second piston 122; multiple second locking blocks 126 are arranged in a circumferential array, and the second locking blocks 126 are slidably disposed in the first annular groove 127; the sixth elastic element 125 abuts between the first annular groove 127 and the tail of the second locking block 126; the head of the second locking block 126 abuts against the second piston 122, and the abutting area is also provided with a cooperating conical engagement structure 14; the second locking block 126 is provided with a second inclined surface 1261 corresponding to the area of ​​the second annular groove 128.

[0061] When the regulator 13 separates from the control panel 12, the second piston 122 is locked by the second locking block 126. When the regulator 13 moves toward the control panel 12, the extended adjusting rod 132 presses against the second piston 122 for adjustment, reducing the flow cross-section of the corresponding branch. Simultaneously, the convex ring 1311 presses against the second inclined surface 1261 and pushes it to move, thus releasing the lock on the second piston 122. A shorter second piston 122 extends from the corresponding adjusting rod 132, and under the action of the fifth elastic element 124, the second piston 122 can move in the opposite direction to a position aligned with the adjusting rod 132, increasing the flow cross-section.

[0062] The above scheme, through the optimized design of the control panel 12, achieves bidirectional and synchronous adjustment of cooling flow rate, which can be adjusted without changing the total pumping flow rate. Its working process is as follows: When the regulator 13 separates from the control panel 12, the second piston 122 is locked by the second locking block 126 through the conical engagement structure 14. During adjustment, the first telescopic power source 123 pushes the regulator 13 towards the control panel 12, and the convex ring 1311 inserts into the second annular groove 128, compressing the second inclined surface 1261 of the second locking block 126 to cause it to contract radially, thereby releasing the lock on all second pistons 122. At this time, the extended longer adjusting rod 132 pushes the corresponding second piston 122 to move against the elastic force of the fifth elastic element 124, thereby reducing the flow cross-section of the corresponding port; while the second piston 122 corresponding to the extended shorter adjusting rod 132 moves in the opposite direction to the corresponding position of the adjusting rod 132 under the restoring force of the fifth elastic element 124, thereby increasing the flow cross-section. This mechanism enables all second pistons 122 to simultaneously adjust the flow rate of different branches by increasing or decreasing the flow rate in one action according to the preset stroke of the adjusting rod 132, thereby quickly and accurately redistributing the flow rate ratio of each branch.

[0063] In one possible implementation, see Appendix Figure 9 The first locking block 133 has a guide hole facing the adjusting rod 132, and the expansion block 1351 has a guide rod 13511 that slides into the guide hole. The third elastic element 137 is sleeved on the guide rod 13511 and abuts between the first locking block 133 and the expansion block 1351. After the guide rod 13511 passes through the guide hole, it is also provided with a limiting plate 13512 with a cross-section larger than the guide hole. When the expansion mechanism 135 contracts, the limiting plate 13512 can pull the first locking block 133 backward to release the lock; while in the locked state, when the adjusting rod 132 is pushed, it can squeeze the first locking block 133 backward and achieve sliding.

[0064] In one possible implementation, see Appendix Figure 2 and Figure 12 The heat exchange plate 2 includes a branch inlet 21, a branch outlet 22, a first overflow valve 23, a second overflow valve, and a sealing layer 24. The sealing layer 24 is a cylindrical shape that wraps around the battery module 3. One end of the cylindrical sealing layer 24 is sealed to the upper end of the battery module 3, and the other end of the cylindrical sealing layer 24 is sealed to the heat exchange plate 2. The sealing layer 24 and the battery module 3 form a closed medium space. The branch inlet 21 and the branch outlet 22 are connected in series in the branch circuit. The inlet end of the first overflow valve 23 is located at the branch inlet 21, and the outlet end is connected to the medium space. The first overflow valve 23 can connect after the pressure at the branch inlet 21 exceeds the preset opening pressure. The specific opening pressure is determined by the specification and model of the overflow valve. The inlet end of the second overflow valve is located in the medium space, and the outlet end is connected to the branch outlet 22.

[0065] Furthermore, the battery module 3 is filled with thermally conductive adhesive. The low-voltage connector 31 and high-voltage terminal 32 of the battery module 3 are located in the upper region of the battery module 3 and are higher than the connection area between the sealing layer 24 and the outer shell of the battery module 3. As a specific embodiment, the sealing layer 24 can be a rigid shell material or a flexible and elastic membrane material. When using a membrane material, the sealing layer 24 is initially in close contact with the surface of the battery module 3, and expands after being pressurized. This mode prevents air from entering the cooling medium circulation path.

[0066] The above embodiment, through the unique design of the heat exchange plate 2, provides active cooling and immersion safety protection for the battery module 3 in extreme situations. Under normal operating conditions, the cooling medium flows through the heat exchange plate 2 via the branch inlet 21 for heat exchange and flows out from the branch outlet 22, thereby cooling the battery module 3. When a battery module 3 experiences extreme overheating or enters the early stage of thermal runaway, and the system allocates an excessively large flow rate to it, the pressure at the branch inlet 21 rises sharply due to the flow resistance of the heat exchange plate 2, exceeding the preset opening pressure of the first overflow valve 23, and the valve is opened. The cooling medium directly enters the sealed medium space formed by the sealing layer 24 through the first overflow valve 23, quickly immersing and enveloping the battery module 3 body for direct and efficient heat absorption and cooling. The heat-absorbing medium is then discharged to the branch outlet 22 through the second overflow valve. This design, in addition to conventional thermal management, constructs an emergency cooling and physical isolation barrier, which can effectively slow down the spread of thermal runaway, buy valuable escape time for occupants, and significantly improve the active safety performance of the battery system.

[0067] One possible implementation of the thermal management system is as follows, see below. Figure 1 Including the battery pack mentioned above, it also includes:

[0068] The refrigeration circuit 5 is formed by the condenser 51, compressor 52, heat exchanger 7 and expansion valve 53 connected in series. The refrigeration circuit 5 is located in a separate box outside the battery pack.

[0069] Furthermore, a heat exchange circuit 6 is formed by connecting a water pump 61, a heater 62, and a heat exchanger 7 in series. The main circuit 4 of the battery pack is connected in series to the heat exchange circuit 6. The cooling circuit 5 and the heat exchange circuit 6 exchange heat through the heat exchanger 7. More specifically, the battery pack housing has a total inlet and a total outlet, which are connected in series to the heat exchange circuit 6.

[0070] One possible implementation of the thermal management method, applicable to the above-mentioned thermal management system, includes the following steps:

[0071] The system can acquire the real-time temperature of each battery module 3 in the battery pack (collected by temperature sensors), acquire the control target temperature of the battery module 3 (preset and stored by the battery management system), and share data through the CAN bus, enabling the controllers of the battery management system and the thermal management system to communicate.

[0072] The flow section control parameters of each battery module 3 corresponding to the branch circuit are calculated based on the real-time temperature and the target temperature. The final result is the pumping pressure and flow rate of the water pump 61 and the axial movement distance required by each regulating rod 132.

[0073] The first piston 112 of each branch circuit is moved simultaneously according to the flow section control parameters, specifically including:

[0074] Initially, the control panel 12 and the regulator 13 are in a separated state. The second telescopic power source 15 presses the first inclined surface 1341, the expansion mechanism 135 retracts and releases the first locking block 133 from locking the adjusting rod 132. Each adjusting rod 132 retracts to the initial position under the action of the second elastic element 136. The second telescopic power source 15 retracts and releases the pressure on the first inclined surface 1341. The expansion mechanism 135 expands and resets, and locks the adjusting rod 132 in one direction through the conical interlocking structure 14.

[0075] The rotary power source 16 drives the housing of the second telescopic power source 15 to rotate and align with each adjusting rod 132 respectively. The second telescopic power source 15 pushes the position of each adjusting rod 132 by telescopic movement.

[0076] After all the adjusting rods 132 have been adjusted, the first telescopic power source 123 pulls the regulator 13 to move toward the control panel 12. The adjusting rod 132 of the regulator 13 corresponds to the second piston 122 of the control panel 12. The adjusting rod 132 pushes the second piston 122 to move, which in turn pushes the first piston 112 to move, thereby changing the flow cross section of each branch circuit.

[0077] Furthermore, the process also includes the following steps: In the heat exchange circuit 6, the medium pressure in one of the branch circuits increases and exceeds the preset opening pressure of the first overflow valve 23, the first overflow valve 23 is connected, the medium space begins to be filled with medium, the medium space begins to increase pressure after it is full of medium, and after the medium space pressure reaches the opening pressure of the second overflow valve, the second overflow valve is connected, and the medium flows out of the medium space.

[0078] In summary, this solution achieves synchronous proportional regulation of the flow rate of each cooling branch through the medium distributor 1, solving the problems of lag and parameter distortion in sequential regulation. Its highly integrated mechanical structure significantly saves space and is conducive to improving energy density. Combined with the bidirectional adjustment mechanism of the control panel 12 and the emergency immersion cooling function of the heat exchange plate 2, the system achieves rapid thermal equalization and active safety protection. The overall solution effectively improves the thermal management efficiency and reliability of the battery pack, helping to optimize battery performance, delay degradation, and extend service life.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

Claims

1. A battery pack comprising a battery module (3), a heat exchange plate (2) and a medium distributor (1), the battery module (3) being arranged corresponding to the heat exchange plate (2), the medium distributor (1) dividing a main circuit (4) of a cooling medium into a plurality of parallel branch circuits, the heat exchange plate (2) being connected in series to the branch circuits, characterized in that The media distributor (1) includes: A pipe housing (11) is provided with a main port and multiple branch ports. A first cavity (111) is provided in the pipe housing (11) for each branch port. A first piston (112) is provided in the first cavity (111). The position change of the first piston (112) can adjust the flow section of the corresponding branch port. A first elastic element (113) is provided in the first cavity (111) for controlling the initial flow section of the corresponding branch port. The circular array has a control panel (12) with multiple second cavities (121). The second cavity (121) is equipped with a second piston (122). The first cavity (111) and the second cavity (121) are arranged in pairs and connected by pipelines. The first piston (112) and the second piston (122) can be linked together. The control panel (12) is also equipped with a first telescopic power source (123) in the middle. And, an adjuster (13) is provided on the telescopic shaft of the first telescopic power source (123). The adjuster (13) includes an adjusting shell (131), adjusting rods (132), a first locking block (133), an unlocking ramp (134), an expansion mechanism (135), a rotational power source (16), and a second telescopic power source (15). The multiple adjusting rods (132) are circumferentially distributed. The adjusting rods (132) slide through the adjusting shell (131) and their positions correspond to the second piston (122). The adjusting shell (131) is provided with a second elastic element (136) for controlling the initial position of the adjusting rods (132). The expansion mechanism (135) is located in the middle of the adjusting shell (131). The expansion mechanism (135) has multiple circumferentially distributed components and their expansion and contraction states are synchronized. The expansion block (1351) is provided with an unlocking ramp (134) on one of the expansion blocks (1351). The unlocking ramp (134) has a first ramp (1341) on the side facing away from the control panel (12). The remaining expansion blocks (1351) are all abutted against the back end of the first locking block (133) by a third elastic member (137). The head end of the first locking block (133) abuts against the adjusting rod (132) and the abutting area is provided with a matching conical engagement structure (14). The housing of the second telescopic power source (15) is driven by the rotary power source (16) and can rotate around the center of the adjusting housing (131). The second telescopic power source (15) can correspond to the adjusting rod (132) and the first ramp (1341) and push them to move toward the second piston (122). The adjustment process includes: The control panel (12) and the regulator (13) are in a separated state. The second telescopic power source (15) presses the first inclined surface (1341). The expansion mechanism (135) contracts and releases the first locking block (133) from locking the adjusting rod (132). Each of the adjusting rods (132) retracts to the initial position under the action of the second elastic element (136). The second telescopic power source (15) retracts and releases the pressure on the first inclined surface (1341). The expansion mechanism (135) expands and resets, and locks the adjusting rod (132) in one direction through the conical interlocking structure (14). At this time, each adjusting rod (132) can only move in one direction toward the control panel (12). The rotary power source (16) drives the housing of the second telescopic power source (15) to rotate and align with each of the adjusting rods (132). The second telescopic power source (15) pushes the position of each of the adjusting rods (132) by telescopic movement. After all the adjusting rods (132) have been adjusted, the first telescopic power source (123) pulls the regulator (13) toward the control panel (12). The adjusting rod (132) of the regulator (13) corresponds to the second piston (122) of the control panel (12). The adjusting rod (132) pushes the second piston (122) to move, which in turn pushes the first piston (112) to move, thereby changing the flow cross section of each branch circuit.

2. The battery pack as described in claim 1, characterized in that: The expansion mechanism (135) also includes a slide bar (1352), a slip ring (1353), a fourth elastic element (1354), and a connecting rod (1355); The slide bar (1352) is fixedly disposed at the center of the adjusting shell (131); The two slip rings (1353) are slidably sleeved on both ends of the slide rod (1352), and multiple hinge seats are arranged in a circular array on the two slip rings (1353); The two fourth elastic elements (1354) respectively abut against the two slip rings (1353) and the adjusting shell (131); One end of each of the two connecting rods (1355) is hinged to the expansion block (1351), and the other end is respectively hinged to the hinge seat of each of the two slip rings (1353); The expansion block (1351) is slidably mounted on the adjusting shell (131), and the sliding direction is along the radial direction of the slide rod (1352).

3. A battery pack as described in claim 1, characterized in that: The control panel (12) also includes a fifth elastic element (124), a sixth elastic element (125), and a second locking block (126); The control panel (12) has a first annular groove (127) facing the second cavity (121) and a second annular groove (128) facing the regulator (13). The first annular groove (127) and the second annular groove (128) have a communicating area. The regulator (13) has a convex ring (1311). When the regulator (13) moves toward the control panel (12), the convex ring (1311) can be inserted into the second annular groove (128). The fifth elastic element (124) is disposed in the second cavity (121) and can limit the initial position of the second piston (122); Multiple second locking blocks (126) are arranged in a circumferential array. The second locking blocks (126) are slidably disposed in the first annular groove (127). The sixth elastic member (125) abuts between the first annular groove (127) and the tail of the second locking block (126). The head of the second locking block (126) abuts against the second piston (122), and the abutting area is also provided with a cooperating conical engagement structure (14). The second locking block (126) is provided with a second inclined surface (1261) corresponding to the area of ​​the second annular groove (128).

4. The battery pack of claim 1 or 3, wherein: The conical engagement structure (14) includes a conical protrusion (141) at one of the contact ends and a conical recess (142) at the other contact end. The conical protrusion (141) and the conical recess (142) are matched in cross sections. Multiple matching conical protrusions (141) and conical recesses (142) are respectively provided at the two contact ends. Along the distribution direction of the multiple conical recesses (142), one side of the conical recess (142) is a slope and the other side is a plane.

5. The battery pack of claim 1, wherein: The first locking block (133) is provided with a guide hole facing the adjusting rod (132), the expansion block (1351) is provided with a guide rod (13511) that slides into the guide hole, the third elastic member (137) is sleeved on the guide rod (13511) and abuts between the first locking block (133) and the expansion block (1351), and the guide rod (13511) is also provided with a limiting plate (13512) with a cross section larger than the guide hole after passing through the guide hole.

6. A battery pack as described in claim 1, characterized in that: The heat exchange plate (2) includes a branch inlet (21), a branch outlet (22), a first overflow valve (23), a second overflow valve, and a sealing layer (24); The sealing layer (24) is a cylindrical shape that wraps around the battery module (3). One end of the cylindrical sealing layer (24) is sealed to the upper end of the battery module (3), and the other end of the sealing layer (24) is sealed to the heat exchange plate (2). The sealing layer (24) and the battery module (3) form a closed medium space. The branch inlet (21) and branch outlet (22) are connected in series in the branch circuit. The inlet end of the first overflow valve (23) is located at the branch inlet (21), and the outlet end is connected to the medium space. The first overflow valve (23) can be connected after the pressure at the branch inlet (21) exceeds the preset opening pressure. The inlet end of the second overflow valve is located at the medium space, and the outlet end is connected to the branch outlet (22).

7. The battery pack of claim 6, wherein: The battery module (3) is filled with thermally conductive adhesive. The low-voltage connector (31) and high-voltage terminal (32) of the battery module (3) are located in the upper region of the battery module (3) and are higher than the connection area between the sealing layer (24) and the outer shell of the battery module (3).

8. A thermal management system characterized by, The battery pack, as described in claim 7, further includes: A refrigeration circuit (5) is formed by connecting the condenser (51), compressor (52), heat exchanger (7) and expansion valve (53) in series. In addition, a heat exchange circuit (6) is formed by connecting a water pump (61), a heater (62) and the heat exchanger (7) in series, the main circuit (4) of the battery pack is connected in series to the heat exchange circuit (6), and the cooling circuit (5) and the heat exchange circuit (6) exchange heat through the heat exchanger (7).

9. A thermal management method, characterized in that, The thermal management system as described in claim 8 includes the following steps: Get the real-time temperature of each battery module (3) in the battery pack, and get the control target temperature of the battery module (3); The flow section control parameters of each battery module (3) corresponding to the branch circuit are calculated based on the real-time temperature and the target temperature. The first piston (112) of each of the branch circuits is moved simultaneously according to the flow section control parameters.

10. The thermal management method as described in claim 9, characterized in that, It also includes the following steps: When the medium pressure in one of the branch circuits increases and exceeds the preset opening pressure of the first relief valve (23), the first relief valve (23) is connected, the medium space begins to be filled with medium, the medium space begins to increase pressure after it is full of medium, and the medium space pressure reaches the opening pressure of the second relief valve, the second relief valve is connected, and the medium flows out of the medium space.

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