Anti-shock lithium ion battery pack for battery replacement

Abstract

The application belongs to the technical field of lithium ion batteries, and specifically discloses an anti-shock lithium ion battery pack for battery replacement, which comprises a battery pack cover plate, a battery pack shell, a plug-in mounting seat, a battery replacement module and a liquid cooling module. The battery pack cover plate is arranged above the battery pack shell. The battery pack shell is internally provided with a built-in shell. The liquid cooling module is provided with a liquid cooling plate above. The liquid cooling plate is fixedly connected with the bottom of the battery replacement module. The liquid cooling module is arranged at the bottom of the inner side of the built-in shell. The built-in shell is provided with a transparent cover plate above. The built-in shell is provided with U-shaped wiring shells outside the two sides. The application enhances the structural strength and shock resistance of the connecting lug, absorbs and dissipates the vibration energy in the battery replacement, avoids the abrasion and cracking of the connecting part, simultaneously realizes the active and accurate heat dissipation of the wire harness area, solves the local hot spot problem, improves the insulation life of the wire harness and the temperature field consistency of the battery pack, guarantees the stable connection and safe and reliable work of the battery pack, and is suitable for the use scene of frequent disassembly and assembly in the battery replacement.

Description

Technical Field

[0001] This invention belongs to the field of lithium-ion battery technology, and specifically discloses a shock-resistant lithium-ion battery pack for battery swapping. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the driving range and energy replenishment efficiency of electric vehicles have become key factors restricting their large-scale popularization. To solve problems such as long charging time and battery degradation, battery swapping technology has emerged. The existing battery swapping mode mainly involves building swapping stations and using hydraulic mechanical platforms to lift and disassemble depleted battery modules and replace them with fully charged battery modules.

[0003] In actual battery swapping operations, battery swapping equipment typically employs four independently configured motor bolt drivers. These drivers need to be precisely aligned with the connecting lugs on the battery pack housing, automatically tightening or loosening the bolts to achieve rapid assembly and disassembly of the battery pack. However, the existing technology has the following technical problems: During battery swapping operations, the four sets of motor bolt drivers generate continuous mechanical vibration as they rotate at high speed to drive in or remove bolts. This vibrational energy directly acts on the battery pack's connecting lugs and is transmitted to the entire housing through the lugs. Because the battery pack needs to be frequently disassembled and installed (potentially undergoing multiple swaps daily), this high-frequency, long-term vibration and impact can cause fretting wear at the connection interface between the connecting lug root and the housing, and in severe cases, even stress fatigue cracks. Over time, this may lead to partial separation of the connecting lugs from the battery swapping module housing or a decrease in structural strength, posing a risk of battery module detachment when the vehicle is traveling on bumpy roads, seriously threatening driving safety. Existing battery swapping modules typically integrate liquid cooling systems for cell thermal management, but water-cooling modules (such as water-cooling plates) are mostly concentrated at the bottom of the battery module. Meanwhile, to enable monitoring and high-voltage output by the battery management system (BMS), numerous high- and low-voltage wiring harnesses and data acquisition harnesses are usually arranged on both sides of the battery casing. This layout inevitably results in the wiring harnesses being close to or covering parts of the heat dissipation area, or situated in narrow spaces with poor natural convection. Since the wiring harnesses themselves generate heat during charging and discharging, and the water-cooling module primarily cools the bottom, the heat dissipation effect in the wiring harness areas on both sides is poor, easily forming localized hot spots. This not only affects the insulation life of the wiring harnesses but also hinders the uniformity of the overall temperature field of the battery pack. Summary of the Invention

[0004] The purpose of this invention is to solve the problems existing in the background art, and to propose a shock-resistant lithium-ion battery pack for battery swapping, including a battery pack cover, a battery pack housing, a plug-in mounting base, a battery swapping module, and a liquid cooling module. The battery pack cover is disposed above the battery pack housing, and an inner shell is disposed inside the battery pack housing. A liquid cooling plate is disposed above the liquid cooling module, and the liquid cooling plate is fixedly connected to the bottom of the battery swapping module. The liquid cooling module is disposed at the bottom inner side of the inner shell, and a transparent cover is disposed above the inner shell. U-shaped wiring shells are disposed on both outer sides of the inner shell, and wiring cooling components are disposed inside the U-shaped wiring shells. The plug-in mounting base is disposed on the outer side of one end of the battery pack housing, and connecting ears are symmetrically installed on both outer sides of the battery pack housing. Shock-resistant reinforcement members are disposed outside the connecting ears, and reinforcing blocks are disposed on both outer sides of the plug-in mounting base. The reinforcing blocks are fixedly connected to the outer wall of the battery pack housing.

[0005] In the above technical solution, the line cooling component further includes two sets of fans, which are respectively embedded in the two ends of the U-shaped wiring shell. A wire frame is provided inside the U-shaped wiring shell, and a temperature monitoring device is provided on the upper surface of the wire frame near the middle.

[0006] In the above technical solution, the temperature monitoring device further includes four temperature sensors, which are divided into two groups and symmetrically installed on the upper surface of the frame near the middle.

[0007] In the above technical solution, the wire frame is further provided with a cooling airflow cavity, the fan outlet is connected to a connecting pipe, and an air inlet is provided inside the end of the connecting pipe away from the fan, and the air inlet is connected to the inside of the wire frame.

[0008] In the above technical solution, the air intake component further includes connecting pipes that are respectively installed on both sides inside the connecting pipe, and the ends of the two connecting pipes away from the connecting pipe are connected to the inside of the wire frame.

[0009] In the above technical solution, the seismic reinforcement component further includes a reinforcing beam, one side of which is connected to the outer wall of the battery pack housing. The reinforcing beam has a wrapping groove inside and at the corresponding connecting lug. The reinforcing beam and the two connecting lugs on the same side are integrally formed.

[0010] In the above technical solution, hydraulic dampers are further embedded on both sides inside the connecting ear, and gaskets are fixedly installed on the telescopic ends of the two sets of hydraulic dampers.

[0011] In the above technical solution, the upper surface of the wire frame is provided with multiple ventilation openings, all of which are inclined and have an inclined air outlet housing installed inside.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention significantly enhances the structural strength between the connecting ear and the battery pack housing by incorporating a reinforced crossbeam and a hydraulic damper embedded within the connecting ear. During battery swapping, the high-frequency vibration generated by the motor bolt driver is transmitted to the hydraulic damper through a gasket. The damping characteristics of the damper effectively absorb and dissipate vibration energy, reducing impact on the root of the connecting ear and the battery pack housing. This prevents fretting wear and stress fatigue cracks, thereby improving the overall shock resistance of the battery swapping module. It ensures a stable connection between the connecting ear and the battery pack housing during vehicle operation, effectively preventing battery module detachment and ensuring driving safety.

[0013] 2. This invention constructs an active cooling zone for the wiring harness area by installing a wire frame, a fan, and a temperature sensor inside the U-shaped wiring housing. This cooling zone is based on the conventional wiring area within the battery pack. The fan guides the cooling airflow from the bottom liquid-cooled module into the internal cavity of the wire frame through connecting and connecting pipes, and then directs it to the inclined ventilation openings. The air is then evenly blown onto the wiring harness surface through the inclined exhaust housing, achieving targeted heat dissipation for the wiring harness area. This avoids localized hotspots caused by dense wiring harness arrangement or confined spaces, improves the insulation life of the wiring harness and the consistency of the overall temperature field of the battery swapping module, further enhancing the safety and reliability of the battery swapping module. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is another schematic diagram of the overall structure of the present invention; Figure 3 This is a schematic diagram showing the connection structure between the battery pack shell, battery pack cover, and transparent cover of the present invention. Figure 4 This is a schematic diagram of the connection structure between the U-shaped wiring shell and the inner shell of the present invention; Figure 5 This is a schematic diagram showing the connection structure between the battery swapping module, the liquid cooling plate, and the liquid cooling module of the present invention. Figure 6 This is a schematic diagram of the connection structure between the reinforcing beam and the connecting lug of the present invention; Figure 7 This is a schematic diagram of the connection structure between the U-shaped wiring shell and the wire frame of the present invention; Figure 8 This is a schematic diagram of a partial structural connection between the fan and the cable frame of the present invention; Figure 9 This is a schematic diagram of the partial structural connection between the wire frame and the inclined air outlet housing of the present invention.

[0015] In the diagram: 1. Battery pack cover; 2. Battery pack housing; 3. Reinforcing beam; 4. Plug-in mounting base; 5. Connecting ear; 6. Reinforcing block; 7. Internal shell; 8. Transparent cover; 9. Battery swapping module; 10. U-shaped wiring housing; 11. Fan; 12. Liquid cooling plate; 13. Liquid cooling module; 14. Hydraulic damper; 15. Gasket; 16. Temperature sensor; 17. Wire frame; 18. Connecting pipe; 19. Connecting pipe; 20. Slanted exhaust housing. Detailed Implementation

[0016] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0017] Numerous specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the invention is not limited to the specific embodiments disclosed below.

[0018] like Figures 1-9 The diagram shows a shock-resistant lithium-ion battery pack for battery swapping, comprising a battery pack cover 1, a battery pack housing 2, a plug-in mounting base 4, a battery swapping module 9, and a liquid cooling module 13. The battery pack cover 1 is positioned above the battery pack housing 2. An inner shell 7 is provided inside the battery pack housing 2. A liquid cooling plate 12 is positioned above the liquid cooling module 13 and is fixedly connected to the bottom of the battery swapping module 9. The liquid cooling module 13 is positioned at the bottom inside the inner shell 7. A transparent cover 8 is positioned above the inner shell 7. U-shaped wiring shells 10 are provided on both sides of the inner shell 7, and wiring cooling components are provided inside the U-shaped wiring shells 10. The plug-in mounting base 4 is positioned outside one end of the battery pack housing 2. Connecting ears 5 are symmetrically installed on both sides of the outer surface of the battery pack housing 2. Shock-resistant reinforcement components are provided outside the connecting ears 5. Reinforcing blocks 6 are provided on both sides of the outer surface of the plug-in mounting base 4 and are fixedly connected to the outer wall of the battery pack housing 2. In this embodiment, when the liquid cooling module 13 is working, it continuously outputs cooling energy to the liquid cooling plate 12. The liquid cooling plate 12 is fully attached to the bottom of the battery swapping module 9, which can quickly absorb the heat generated by the battery swapping module 9 during charging and discharging, realize basic liquid cooling heat dissipation of the battery swapping module 9, effectively control the core working temperature of the battery swapping module 9, avoid the battery cell from degrading due to high temperature, and improve the service life of the battery swapping module 9. The transparent cover 8 can not only protect the internal components of the inner shell 7, but also allow staff to directly observe the working status of the battery swapping module 9. Initial inspections can be completed without removing the cover, improving the maintenance convenience of the battery swapping module 9. The U-shaped wiring housing 10 provides a dedicated arrangement channel for the high and low voltage wiring harnesses and data acquisition wiring harnesses of the battery swapping module 9, avoiding messy accumulation of wiring harnesses. At the same time, its internal line cooling components can specifically dissipate heat in the line area, solving the problem of poor heat dissipation in the wiring harness area and improving the stability of the wiring harness operation. The plug-in mounting base 4 enables the battery swapping module 9 to be quickly plugged in and connected with external power supply and electrical equipment. Reinforcing blocks 6 are set on both sides of the plug-in mounting base 4 to enhance the connection strength between the plug-in mounting base 4 and the battery pack housing 2, prevent loosening of the connection during plugging and unplugging, and improve the stability of the plug-in structure.

[0019] The line cooling component includes two sets of fans 11, which are respectively embedded in the two ends of the U-shaped wiring shell 10. A wire frame 17 is provided inside the U-shaped wiring shell 10, and a temperature monitoring device is provided on the upper surface of the wire frame 17 near the middle. In this embodiment, during operation, the two sets of fans 11 start simultaneously, drawing in cold air from the outside of the U-shaped wiring housing 10 and conveying it to the inside of the housing, forming a cooling airflow that penetrates the U-shaped wiring housing 10. The airflow can directly blow on the surface of the wire harness on the wire frame 17, quickly removing the heat generated by the wire harness during operation, realizing active air cooling of the line area, effectively reducing the ambient temperature of the wire harness area, preventing insulation aging of the wire harness due to long-term high-temperature operation, and improving the insulation life of the wire harness. The arrangement of the two sets of fans 11 at opposite ends can form a bidirectional convection airflow channel, allowing the cooling airflow to flow fully through the wire harness area inside the U-shaped wiring housing 10, avoiding heat dissipation dead zones and improving the uniformity of heat dissipation in the wiring area.

[0020] The temperature monitoring device includes four temperature sensors 16, which are divided into two groups and symmetrically installed on the upper surface of the frame 17 near the middle. In this embodiment, during operation, four temperature sensors 16 continuously collect the real-time temperature of the position harness and convert the temperature signal into an electrical signal to be transmitted to the external battery management system. By monitoring the temperature, it can be ensured that the fan 11 operates in a timely manner.

[0021] The wire frame 17 has a cooling airflow cavity inside, and the air outlet of the fan 11 is connected to a connecting pipe 19. The end of the connecting pipe 19 away from the fan 11 has an air inlet, which is connected to the inside of the wire frame 17. In this embodiment, the cooling airflow cavity provides a dedicated flow channel for cooling airflow, changing the traditional air cooling method that only blows from the outside, realizing air cooling heat dissipation of the wire harness from the inside out, and greatly improving heat dissipation efficiency; The connecting pipe 19 can directionally deliver the cooling airflow of the fan 11, and then guide it into the wire frame 17 through the air inlet. The cooling airflow inside the cavity can not only blow on the wire harness, but also become a cooling structure itself through contact, preventing the wire frame 17 from absorbing heat and rising in temperature, thereby preventing the wire frame 17 from transferring heat to the wire harness in the opposite direction, and ensuring the continuity and effectiveness of heat dissipation.

[0022] The air intake component includes connecting pipes 18 that are respectively installed on both sides inside the connecting pipe 19, and the ends of the two connecting pipes 18 away from the connecting pipe 19 are connected to the inside of the wire frame 17. In this embodiment, the connecting pipe 18 is located on both sides of the connecting pipe 19, which can realize bidirectional diversion and delivery of cooling airflow, so that the cooling air can quickly and evenly fill the entire wire frame 17, reducing the airflow pressure of a single air inlet channel.

[0023] The seismic reinforcement includes a reinforcing beam 3. One side of the reinforcing beam 3 is connected to the outer wall of the battery pack housing 2. The reinforcing beam 3 has a wrapping groove inside and at the corresponding connecting lug 5. The reinforcing beam 3 and the two connecting lugs 5 on the same side are integrally formed. In this embodiment, the reinforcing crossbeam 3 set outside the connecting ear 5 eliminates gaps and stress concentration points at the connection interface compared to the traditional single fixed-point connection method. This significantly improves the structural integrity and connection strength between the connecting ear 5 and the battery pack housing 2, effectively withstanding vibration and impact loads during battery swapping and vehicle operation. This reduces the force concentrated at the root of the connecting ear 5 during battery swapping and disassembly, ensuring the connection strength between the connecting ear 5 and the battery pack housing 2. This effectively solves the problem that the connecting ear 5 is easily damaged by vibration in the prior art, and improves the seismic stability of the battery swapping module 9.

[0024] Hydraulic dampers 14 are embedded on both sides of the inside of the connecting ear 5, and gaskets 15 are fixedly installed on the telescopic ends of the two sets of hydraulic dampers 14. In this embodiment, during operation, the high-frequency vibration generated by the motor bolt driver is transmitted to the gasket 15 through the bolt during the battery swapping process. The gasket 15 first provides initial elastic buffering for the vibration, and then the remaining vibration energy is transmitted to the hydraulic damper 14. The hydraulic oil inside the hydraulic damper 14 flows through the damping hole under the action of vibration. The viscous resistance generated during the flow can quickly absorb and dissipate the vibration energy, converting the mechanical energy of the vibration into the heat energy of the hydraulic oil and releasing it slowly. This significantly reduces the transmission of vibration to the root of the connecting ear 5 and the battery pack housing 2, avoiding fretting wear and stress fatigue cracks at the root of the connecting ear 5 caused by vibration impact.

[0025] The upper surface of the wire frame 17 has multiple ventilation openings, all of which are inclined and connected to the inclined air outlet housing 20. In this embodiment, during operation, the cooling airflow inside the wire frame 17, under pressure, enters the inclined exhaust housing 20 through multiple inclined vents. Guided by the inclined exhaust housing 20, the airflow is directed towards the wire harness at an inclined angle. This airflow method allows the cooling airflow to flow along the wire harness's laying direction, forming a directional cooling airflow along the wire harness. This allows the airflow to fully envelop the wire harness surface, quickly removing the heat generated by the wire harness and improving heat dissipation. Multiple vents are evenly distributed on the upper surface of the wire frame 17, allowing the cooling airflow to be blown out simultaneously from multiple locations, achieving multi-point uniform cooling of the wire harness and avoiding uneven local heat dissipation, thus improving the consistency of the temperature field in the wiring area. The inclined exhaust housing 20 prevents the cooling airflow from rapidly diffusing after exiting the vents, converging the airflow and increasing the exhaust pressure, allowing the airflow to reach all parts of the wire harness. Even in areas with densely packed wire harnesses, the cooling airflow can penetrate smoothly, avoiding heat dissipation dead zones. Meanwhile, the inclined air outlet reduces backflow caused by airflow directly blowing onto the inner wall of the U-shaped wiring housing 10, improving airflow efficiency and allowing the cooling airflow to form an orderly flow channel inside the U-shaped wiring housing 10, further enhancing the convective heat dissipation effect in the wiring area. This structure allows for full utilization of the cooling airflow inside the wire frame 17, achieving precise and efficient cooling of the wiring harness, effectively solving the problem of localized hot spots in the wiring harness area, and improving the insulation life of the wiring harness and the overall thermal management level of the battery pack.

[0026] Working Principle: During battery swapping, the four sets of motor bolt drivers on the external battery swapping equipment need to be aligned with the connecting ears 5 on both sides of the battery pack housing 2. The battery pack can be quickly installed or removed by automatically tightening or loosening the bolts. During disassembly or installation, the high-speed rotation of the motor bolt drivers generates continuous mechanical vibration. This vibration energy first acts on the gasket 15 inside the connecting ear 5. The gasket 15 is fixedly connected to the telescopic ends of two sets of hydraulic dampers 14 embedded inside the connecting ear 5, and the vibration energy is then transmitted to the hydraulic dampers 14 through the gasket 15. The hydraulic dampers 14 utilize the damping characteristics of their internal hydraulic medium to convert the mechanical energy of the high-frequency vibration into heat energy for dissipation and absorption, thereby significantly reducing the residual vibration transmitted to the root of the connecting ear 5 and the battery pack housing 2. Meanwhile, since the connecting ear 5 and the reinforcing beam 3 are integrally formed, and the reinforcing beam 3 reinforces the root of the connecting ear 5 and attaches it to the outer wall of the battery pack shell 2 through the wrapping groove, the overall structural strength and fatigue resistance of the connection area are further enhanced, effectively avoiding fretting wear and stress cracks caused by long-term vibration, and ensuring the connection stability of the battery pack under frequent battery swapping and vehicle driving bumpy conditions. During the charging and discharging process of the battery pack, the battery swapping module 9 inside the battery pack housing 2 generates heat, which is cooled by the liquid cooling module 13 through the liquid cooling plate 12. Simultaneously, the high and low voltage wiring harnesses arranged inside the U-shaped wiring housings 10 on both sides of the inner housing 7 also generate heat. Four temperature sensors 16 installed at the middle of the upper surface of the wire frame 17 monitor the temperature of the wiring harness area in real time. When the temperature of a certain area exceeds a set threshold, the corresponding fan 11 is activated. The fan 11 generates cooling airflow, which enters the connecting pipe 19 through the air outlet, and then is split through the connecting pipes 18 on both sides inside the connecting pipe 19 before entering the internal cavity of the wire frame 17. After the internal cavity of the wire frame 17 is filled with cooling airflow, the airflow enters the inclined exhaust housing 20 through multiple ventilation holes on the upper surface of the wire frame 17. Because the inclined exhaust housing 20 adopts an inclined guiding structure, the cooling airflow is able to change its vertical outflow direction and diffuse evenly to the surface of the wiring harness and its surrounding space at a preset inclination angle. Compared to traditional vertical vents or ducts, this inclined air outlet method can effectively expand the airflow coverage area, avoid local overcooling or heat dissipation blind spots caused by concentrated direct airflow, and make the cooling airflow form a more uniform convection environment in the wire harness area, thereby further improving the heat dissipation efficiency of the wire harness, eliminating local hot spots, ensuring that the wire harness works stably at a suitable temperature, and improving the consistency and safety of the overall temperature field of the battery swapping module 9.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A shock-resistant lithium-ion battery pack for battery swapping, comprising a battery pack cover (1), a battery pack housing (2), a plug-in mounting base (4), a battery swapping module (9), and a liquid cooling module (13), characterized in that: The battery pack cover (1) is located above the battery pack housing (2). The battery pack housing (2) has an inner shell (7) inside. The liquid cooling module (13) has a liquid cooling plate (12) above it. The liquid cooling plate (12) is fixedly connected to the bottom of the battery swapping module (9). The liquid cooling module (13) is located at the bottom inside the inner shell (7). The inner shell (7) has a transparent cover (8) above it. The inner shell (7) has U-shaped wiring shells (10) on both sides outside. The U-shaped wiring shells (10) have line cooling components inside. The plug-in mounting base (4) is located outside one end of the battery pack housing (2). The battery pack housing (2) has connecting ears (5) symmetrically installed on both sides outside. The connecting ears (5) have anti-vibration reinforcement components outside. The plug-in mounting base (4) has reinforcing blocks (6) on both sides outside. The reinforcing blocks (6) are fixedly connected to the outer wall of the battery pack housing (2).

2. The shock-resistant lithium-ion battery pack for battery swapping according to claim 1, characterized in that: The line cooling component includes two sets of fans (11), which are respectively embedded in the two ends of the U-shaped wiring shell (10). A wire frame (17) is provided on the inner side of the U-shaped wiring shell (10), and a temperature monitoring device is provided on the upper surface of the wire frame (17) near the middle.

3. The shock-resistant lithium-ion battery pack for battery swapping according to claim 2, characterized in that: The temperature monitoring device includes four temperature sensors (16), which are divided into two groups and symmetrically installed on the upper surface of the frame (17) near the middle.

4. A shock-resistant lithium-ion battery pack for battery swapping according to claim 2, characterized in that: The wire frame (17) has a cavity for cooling airflow inside. The air outlet of the fan (11) is connected to a connecting pipe (19). An air inlet is provided inside the end of the connecting pipe (19) away from the fan (11). The air inlet is connected to the inside of the wire frame (17).

5. A shock-resistant lithium-ion battery pack for battery swapping according to claim 4, characterized in that: The air intake component includes connecting pipes (18) that are respectively connected to both sides of the connecting pipe (19) inside the connecting pipe (19), and the ends of the two connecting pipes (18) away from the connecting pipe (19) are connected to the inside of the wire frame (17).

6. A shock-resistant lithium-ion battery pack for battery swapping according to claim 1, characterized in that: The seismic reinforcement includes a reinforcing beam (3), one side of which is connected to the outer wall of the battery pack housing (2). The reinforcing beam (3) has a wrapping groove inside and at the corresponding connecting ear (5). The reinforcing beam (3) and the two connecting ears (5) on the same side are integrally formed.

7. A shock-resistant lithium-ion battery pack for battery swapping according to claim 1, characterized in that: Hydraulic dampers (14) are embedded in both sides of the connecting ear (5), and gaskets (15) are fixedly installed on the telescopic ends of the two sets of hydraulic dampers (14).

8. A shock-resistant lithium-ion battery pack for battery swapping according to claim 5, characterized in that: The upper surface of the wire frame (17) is provided with multiple ventilation openings, all of which are inclined and are connected to an inclined air outlet housing (20).

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