Immersed cooling channel structure with dry area and wet area

Abstract

The invention discloses a dry and wet partitioned immersed cooling channel structure. The structure comprises a battery box, a module mounting cavity is formed in the battery box, a rear dry cavity is formed in the rear end of the module mounting cavity, and an electric appliance mounting cavity is formed in the front end of the module mounting cavity; communication plates are arranged at the tops of the electric appliance mounting cavity and the rear dry cavity, a battery module is arranged in the module mounting cavity, the battery module is immersed in immersion liquid, and the height of the immersion liquid does not exceed the height of the communication plates; the cooling channel formed by combining and splicing the bolts and the sealing rings is simple to mount, the sealing performance is ensured, a battery area and an electrical area can be well separated, the battery can be independently immersed in oil, the risk of liquid leakage is avoided, the immersed oil can be fully filled and then integrally transported, the production and after-sales maintenance cost is reduced, and the production efficiency is improved. And a basic condition is laid for normal operation and large-scale application of the immersed battery box.

Description

Technical Field

[0001] This invention relates to the field of battery boxes, specifically a dry and wet zone immersion cooling channel structure. Background Technology

[0002] The application of submersible battery boxes is becoming increasingly widespread. However, how to reduce the cost of mobile equipment while ensuring reliability and safety has become a pain point in the industry. If submersible oil circulation cooling is used, excessive pressure in the cooling system may lead to leakage risks and low reliability. Maintenance requires disassembling the entire battery box for repair or replacement of electrical components, which is inconvenient and costly. Large-scale application significantly increases after-sales costs. Therefore, static submersible battery boxes have emerged and become a development trend. Among these, the design of the cooling channel is the most important. A good cooling channel must not only ensure that the battery operating temperature is within the set range and maintain reliability, but also facilitate the overall and intact transportation and installation of the equipment, and meet the requirements for quick daily inspection and maintenance, in order to directly and effectively save on equipment costs, transportation costs, and maintenance costs.

[0003] Therefore, it is necessary to improve such a structure to overcome the above-mentioned defects. Summary of the Invention

[0004] The purpose of this invention is to provide a dry and wet zone immersion cooling channel structure to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A wet-dry partitioned immersion cooling channel structure includes a battery box; the battery box has a module mounting cavity inside, a rear dry cavity at the rear end of the module mounting cavity, and an electrical mounting cavity at the front end of the module mounting cavity; a connecting plate is provided at the top of both the electrical mounting cavity and the rear dry cavity; the module mounting cavity is a wet zone, and the rear dry cavity and the electrical mounting cavity are dry zones; a battery module is installed inside the module mounting cavity, and the battery module is immersed in an immersion liquid, the height of which does not exceed the height of the connecting plate; it also includes a side liquid cooling device, which includes a liquid cooling channel; the side liquid cooling device also includes a rear main pipe, a front inlet main pipe, and a front return main pipe.

[0007] Furthermore, the liquid cooling channel includes three parallel hollow tubes and primary distribution tubes located at both ends of the hollow tubes. The primary distribution tubes are hollow, and the ends of the hollow tubes are connected to the primary distribution tubes. A bend is connected to the top of the primary distribution tubes. A first connector is welded onto the bend, with a first abutment ring at its top and a first external thread on its outer wall. The first connector passes through a through hole in the connecting plate and is fixedly connected to a first fixing nut via the first external thread. A first sealing ring is also provided between the first abutment ring and the connecting plate for sealing. An annular mounting groove for installing the first sealing ring is provided at the bottom of the first abutment ring. A second connector is welded to the end of the bend, and a third connector adapted to the second connector is provided on both the front inlet main pipe and the front return main pipe. The second and third connectors are fixedly connected by a second fixing nut.

[0008] Furthermore, the front-end inlet manifold and the front-end return manifold are respectively connected to an inlet and a return outlet.

[0009] Furthermore, the liquid cooling channel is made by extruding profiles into pipes and then welding them together.

[0010] Furthermore, the liquid cooling channel is formed by stamping and welding profiles.

[0011] Furthermore, the liquid cooling channel is formed by bending and welding other metal tubes such as aluminum tubes and copper tubes.

[0012] Furthermore, the liquid cooling channel is made of plastic injection molding or extrusion molding.

[0013] Furthermore, the liquid cooling channels are located on both sides of the battery module; the bend at the rear end of the liquid cooling channel is connected to the rear main pipe, wherein the rear main pipe is located in the rear dry cavity; the front liquid inlet main pipe and the front liquid return main pipe are located in the electrical installation cavity; the bend at the front end of the liquid cooling channel located on the inner side of the several sets of liquid cooling channels is connected to the front liquid inlet main pipe, and the bend at the front liquid return main pipe of the liquid cooling channel located on the outer side of the several sets of liquid cooling channels is connected to the front liquid return main pipe.

[0014] Furthermore, the top outer wall of the second connector is provided with a second external thread, which meshes with the second fixing nut, and the lower end of the second connector is inserted into the third connector; the top of the third connector is provided with a second limiting ring, and the lower end of the second fixing nut is provided with a third limiting ring; the top of the second limiting ring abuts against the lower end of the second external thread of the second connector; the bottom of the second limiting ring abuts against the top of the third limiting ring.

[0015] Furthermore, two second sealing rings are provided between the outer wall of the second connector and the inner wall of the third connector for sealing between them.

[0016] Furthermore, a third sealing ring is provided between the top of the second limiting ring and the lower end of the second external thread of the second connector to enhance the sealing effect between the two.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] Liquid cooling channel layout optimization: Multiple sets of liquid cooling channels are used to form a symmetrical arrangement of "entry in the middle and exit on both sides". The coolant enters from the middle group and flows back from the side groups, forming a U-shaped flow channel. This allows the coolant to preferentially contact the middle area with the highest temperature. The heat exchange path is reasonable and the heat dissipation efficiency is higher.

[0019] Modular connection structure: The liquid cooling channel is connected to the main pipe and the box body through a connector with a sealing ring and a limit ring. It adopts a multi-seal method of thread fastening + sealing ring, which not only ensures the reliability of sealing, but also enables quick disassembly and convenient maintenance, reducing maintenance costs.

[0020] Structural strength and vibration resistance design: The connector adopts a welding + threaded composite connection, combined with a limiting ring structure and structural adhesive for auxiliary fixation, forming a rigid-flexible structural system that can effectively resist vibration and impact loads, and is suitable for harsh working conditions such as vehicle-mounted applications.

[0021] In summary, the cooling channel assembled by bolts and sealing rings is simple to install, ensures airtightness, effectively separates the battery area from the electrical area, allows the battery to be independently immersed in the immersion liquid, eliminates the risk of leakage, and can be transported as a whole after being filled with immersion oil, reducing production and after-sales maintenance costs, thus laying the foundation for the normal operation and large-scale application of immersion battery boxes. Attached Figure Description

[0022] Figure 1 This is a front view of a dry and wet zone immersion cooling channel structure.

[0023] Figure 2 This is a side view of a dry and wet zone immersion cooling channel structure.

[0024] Figure 3 A top view of a dry and wet zone immersion cooling channel structure after removing the top cover.

[0025] Figure 4 This is a schematic diagram of a dry and wet partitioned immersion cooling channel structure after removing the top cover and the battery module.

[0026] Figure 5 A top view of a dry and wet partitioned immersion cooling channel structure after removing the top cover and battery module.

[0027] Figure 6 This is a schematic diagram of the side liquid cooling device in a dry and wet partitioned immersion cooling channel structure.

[0028] Figure 7 A partial structural diagram of the liquid cooling channel in some embodiments of this solution.

[0029] Figure 8 for Figure 1 Sectional view along the AA direction.

[0030] Figure 9 for Figure 8 A magnified view of a portion of point a.

[0031] Figure 10 for Figure 8 A magnified view of a section at point b. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] Please see Figure 1-10 A wet and dry partitioned immersion cooling channel structure includes a battery box 1; the battery box 1 has a module mounting cavity 101 inside, a rear dry cavity 102 at the rear end of the module mounting cavity 101, and an electrical mounting cavity 103 at the front end of the module mounting cavity 101; a connecting plate 104 is provided at the top of both the electrical mounting cavity 103 and the rear dry cavity 102; a battery module 2 is installed inside the module mounting cavity 101, and the battery module 2 is immersed in an immersion liquid, which is an insulating heat-conducting oil; the height of the immersion liquid does not exceed the height of the connecting plate 104; wherein, the module mounting cavity 101 is a wet zone, and the rear dry cavity 102 and the electrical mounting cavity 103 are dry zones.

[0034] It also includes a side liquid cooling device, which includes a liquid cooling channel 3; the liquid cooling channel 3 is located on both sides of the battery module 2; in this solution, the battery module 2 is provided with four sets, and the liquid cooling channel 3 is provided with five sets. Among the five sets of liquid cooling channels 3, the three sets located on the inner side are liquid cooling channels 3 for liquid inlet, and the two sets located on the outer side are liquid cooling channels 3 for liquid return.

[0035] The liquid cooling channel 3 includes three parallel hollow pipes 301 and primary distribution pipes 302 located at both ends of the hollow pipes 301. The primary distribution pipes 302 are hollow, and the ends of the hollow pipes 301 are connected to the primary distribution pipes 302. At the same time, the top of the primary distribution pipes 302 is connected to a bend 303.

[0036] The side liquid cooling device also includes a rear main pipe 4, a front liquid inlet main pipe 5, and a front liquid return main pipe 6. The bends 303 at the rear ends of the five sets of liquid cooling channels 3 are connected to the rear main pipe 4, wherein the rear main pipe 4 is located in the rear dry chamber 102; the front liquid inlet main pipe 5 and the front liquid return main pipe 6 are located in the electrical installation chamber 103.

[0037] The bends 303 at the front ends of the three inner liquid cooling channels 3 are connected to the front liquid inlet main pipe 5, and the bends 303 at the outer two liquid cooling channels 3 are connected to the front liquid return main pipe 6.

[0038] Liquid cooling channel layout optimization: Five sets of liquid cooling channels are arranged symmetrically with "three in and two out". The coolant enters from the three middle sets and flows back from the two sets on both sides, forming a U-shaped flow channel. This allows the coolant to preferentially contact the middle area with the highest temperature. The heat exchange path is reasonable and the heat dissipation efficiency is higher.

[0039] like Figure 9-10 As shown, in this solution, a first connector 304 is welded onto the bend 303. The top of the first connector 304 is provided with a first abutment ring 304, and the outer wall of the first connector 304 is provided with a first external thread 305. The first connector 304 passes through a through hole on the connecting plate 104 and is fixedly connected to a first fixing nut 306 through the first external thread 305. At the same time, a first sealing ring 307 is provided between the first abutment ring 304 and the connecting plate 104 for sealing between the two. The bottom of the first abutment ring 304 is provided with an annular mounting groove for installing the first sealing ring 307.

[0040] Meanwhile, a second connector 308 is welded to the end of the bend 303, and a third connector 309 adapted to the second connector 308 is provided on both the front inlet main pipe 5 and the front return main pipe 6; the second connector 308 and the third connector 309 are fixedly connected by a second fixing nut 310.

[0041] The second connector 308 has a second external thread 311 on its top outer wall, which meshes with the second fixing nut 310. The lower end of the second connector 308 is inserted into the third connector 309. The third connector 309 has a second limiting ring 312 on its top and a third limiting ring 313 on its lower end. The top of the second limiting ring 312 abuts against the lower end of the second external thread 311 of the second connector 308. The bottom of the second limiting ring 312 abuts against the top of the third limiting ring 313.

[0042] In this solution, two second sealing rings 314 are provided between the outer wall of the second connector 308 and the inner wall of the third connector 309 for sealing between the two.

[0043] Meanwhile, a third sealing ring 315 is provided between the top of the second limiting ring 312 and the lower end of the second external thread 311 of the second connector 308 to enhance the sealing effect between the two.

[0044] In this design, the 104 connecting plate and oil level control serve to isolate the cavity, protect electrical components, and prevent oil from flowing into the cavity. The first connector 304 (with mounting groove and sealing ring) ensures a reliable seal between the liquid cooling channel and the housing, and accurate assembly positioning.

[0045] The second connector 308 and the third connector (three sealing rings + a limiting ring) provide redundant sealing between the liquid cooling channel and the main pipe, offering good vibration resistance. The limiting ring's design prevents over-tightening or loosening, ensuring assembly quality.

[0046] In this scheme, the front-end liquid inlet manifold 5 and the front-end liquid return manifold 6 are respectively connected to a liquid inlet 501 and a liquid return outlet 601;

[0047] Coolant enters the front inlet manifold 5 from the inlet 501. The coolant in the front inlet manifold 5 enters the middle three sets of liquid cooling channels 3, then enters the rear manifold 4, and finally enters the front return manifold 6 through the liquid cooling channels 3 on both sides and is discharged from the return port 601.

[0048] The advantage of this scheme is that the coolant temperature in the three sets of liquid cooling channels 3 that enter the inner side first is lower, while the temperature in the middle of the battery box 1 is higher, resulting in higher heat exchange efficiency; the coolant that returns last goes back through the liquid cooling channels 3 on both sides.

[0049] The liquid cooling channel 3 is formed by extruding profiles into pipes and then welding them together, or by stamping sheet metal and then welding them together. It can also be replaced by bending and welding other metal pipes such as aluminum pipes and copper pipes, or non-metallic pipes.

[0050] If it is a non-metallic tube, it can be made of plastic injection molding or extrusion molding.

[0051] The liquid cooling channel 3 in this solution is installed and fixed as follows: First, install the battery module 2 inside the battery box 1, then install the liquid cooling channel 3 on the side of the battery module 2. Repeat this step. After fixing the battery module 2 and the liquid cooling channel, connect and splice the liquid cooling channel 3 and fix it with screws and sealing rings to prevent loosening and ensure the overall sealing of the battery box. Finally, structural adhesive can be used for further fixing to ensure the firmness of the liquid cooling device.

[0052] It is worth noting that the laying method in this solution is only for the purpose of describing the present invention and should not be construed as a limitation of the present invention. For example, the liquid cooling channel can also be installed first and then the battery module can be installed.

[0053] When this solution is used, the external coolant enters through the three inlet channels 3 between the four battery modules 2, then gathers at the rear of the battery box 1, and then returns through the inlet channels 3 near the sides of the box. The immersion liquid is cooled by the liquid cooling channels 3 set on the side of the solution, so that the heat generated by the battery cells is cooled by heat exchange with the cooling system.

[0054] This static cooling method not only solves the problem of oil leakage in dynamic circulating oil systems, but also ensures complete isolation between the battery area and the electrical area. Furthermore, the cooling pipe connections are located above the immersion liquid level (the immersion liquid height does not exceed 104mm from the connecting plate). Additionally, a sealing ring is added during tightening to enhance sealing and prevent oil leakage from long-term immersion of the connectors in the immersion liquid. This significantly improves the service life and economic efficiency of the submersible battery box.

[0055] In this solution, the side-mounted liquid cooling channels do not occupy the vertical space of the module. The liquid cooling channels are located on both sides of the module, which can keep the module compactly arranged, improve the energy density of the battery pack, and make the manufacturing process flexible.

[0056] Liquid cooling channels offer a variety of material options and controllable costs. They can be manufactured using various processes such as profile extrusion, aluminum tube bending, copper tube welding, or plastic injection molding to meet different cost requirements and provide ease of maintenance.

[0057] The modular design facilitates the replacement of liquid cooling channels, which are relatively independent of the modules and can be replaced individually when damaged, reducing maintenance costs.

[0058] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "left," and "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. These terms are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, terms such as "set" and "connect" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

Claims

1. A dry and wet zone immersion cooling channel structure, comprising a battery box; characterized in that, The battery box contains a module mounting cavity, a rear dry cavity at the rear end of the module mounting cavity, and an electrical mounting cavity at the front end of the module mounting cavity. A connecting plate is provided at the top of both the electrical mounting cavity and the rear dry cavity. The module mounting cavity is a wet zone, while the rear dry cavity and the electrical mounting cavity are dry zones. A battery module is installed inside the module mounting cavity and is immersed in an immersion liquid. The box also includes a side liquid cooling device, which includes a liquid cooling channel. The side liquid cooling device further includes a rear main pipe, a front inlet main pipe, and a front return main pipe.

2. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The liquid cooling channel includes several hollow tubes arranged in parallel and primary distribution tubes located at both ends of the hollow tubes. The primary distribution tubes are hollow, and the ends of the hollow tubes are connected to the primary distribution tubes. A bend is connected to the top of the primary distribution tubes. A first connector is welded onto the bend, with a first abutment ring at the top and a first external thread on its outer wall. The first connector passes through a through hole in a connecting plate and is fixedly connected to a first fixing nut via the first external thread. A first sealing ring is also provided between the first abutment ring and the connecting plate for sealing. An annular mounting groove for installing the first sealing ring is provided at the bottom of the first abutment ring. A second connector is welded to the end of the bend, and a third connector adapted to the second connector is provided on both the front inlet main pipe and the front return main pipe. The second and third connectors are fixedly connected by a second fixing nut.

3. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The front-end inlet manifold and the front-end return manifold are also respectively connected to an inlet and a return outlet.

4. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The liquid cooling channel is made by extruding profiles into pipes and then welding them together.

5. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The liquid cooling channel is formed by stamping and welding profiles.

6. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The liquid cooling channel is made of aluminum tubes, copper tubes, or other metal tubes that have been bent and welded.

7. The dry and wet zone immersion cooling channel structure according to claim 1, characterized in that, The liquid cooling channel is made of plastic injection molding or extrusion molding.

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