A heat exchanger

Abstract

This invention belongs to the field of batteries, specifically a heat exchange component. It overcomes the problem of excessive localized heat at the terminals of individual cells in existing battery packs, leading to thermal runaway. The heat exchange component includes a water-cooled pipe and multiple conductive components. The inner cavity of the water-cooled pipe serves as a cooling water flow channel. Multiple conductive components are spaced apart along the length of the water-cooled pipe on its outer wall. Each conductive component connects the polarity terminals of two adjacent individual cells, achieving series connection of the individual cells. The water-cooled pipe and each conductive component are insulated. The heat generated at the battery polarity terminals is dissipated through the heat exchange component. Simultaneously, the conductive components of this invention enable series connection between individual cells. Furthermore, this invention can achieve heat exchange based on water cooling. Compared to insulating oil cooling, water cooling better meets the efficient, economical, and environmentally friendly cooling requirements of battery systems.

Description

Technical Field

[0001] This invention belongs to the field of batteries, specifically a heat exchange component. Background Technology

[0002] Currently, most common battery packs are composed of multiple battery modules connected together electrically.

[0003] Battery pack temperature control has always been a hot topic in this field. Most existing battery packs use air cooling or liquid cooling to control the overall temperature of the battery pack. However, since the terminals of individual cells in the battery pack are the areas where heat is most concentrated, if the local heat of the terminals becomes too high, it is very likely to cause thermal runaway of individual cells in the battery pack, which will seriously affect the safety and performance of the battery pack. Summary of the Invention

[0004] The purpose of this invention is to provide a heat exchange component that overcomes the problem of excessive local heat at the terminal posts of individual cells in existing battery packs, which leads to thermal runaway.

[0005] A first aspect of the present invention provides a heat exchanger. The heat exchanger includes a water-cooled pipe and a plurality of conductive elements;

[0006] The inner cavity of the aforementioned water-cooled pipe serves as a cooling water flow channel;

[0007] The aforementioned conductive components are spaced apart along the length of the water-cooling pipe on the outer wall of the water-cooling pipe; each conductive component is used to connect the polarity terminals of two adjacent individual cells with different polarities, thereby realizing the series connection of the individual cells.

[0008] The aforementioned water-cooled pipes are insulated from all conductive components.

[0009] This invention achieves efficient heat dissipation by fixing a heat exchange component on the polar terminal (the polar terminal can be a terminal post or an integral structure after connecting a terminal post extension to the terminal post). The heat generated by the battery polar terminal is conducted to the heat exchange component in close contact with it and dissipated through heat exchange.

[0010] Furthermore, the conductive component of this invention is connected to the polarity terminals of adjacent individual cells of different polarities, enabling series connection between individual cells. Therefore, in this invention, the heat exchange component not only serves as a heat exchange member but also as a current collector to realize the series connection of multiple individual cells, offering at least the following advantages:

[0011] Firstly, there is no need to set up a special busbar, which simplifies the overall structure of the battery component; secondly, since the heat exchanger performs both heat exchange and conductivity functions, the number of parts in the battery component is reduced, thus reducing assembly difficulty and cost.

[0012] Furthermore, the water-cooled pipes of this invention are insulated from all conductive components, achieving insulation between the conductive components and the cooling water, thus enabling heat exchange based on water cooling. Compared to insulating oil cooling, water cooling can better meet the efficient, economical, and environmentally friendly cooling requirements of battery systems.

[0013] Furthermore, an installation channel is provided on the aforementioned conductive component, and the water-cooling pipe is nested into the installation channel.

[0014] Furthermore, the aforementioned water-cooled pipe includes a metal pipe, and the outer wall of the aforementioned metal pipe is provided with an insulating layer.

[0015] From an insulation and safety perspective, the insulation layer of the outer wall of the metal pipe uses professional insulation materials such as polytetrafluoroethylene and epoxy resin, which can precisely isolate cooling water from conductive components, prevent short circuits, and ensure electrical safety. Its excellent corrosion resistance can resist the chemical erosion of cooling water, maintain long-term stable insulation, and extend battery pack life.

[0016] In terms of thermal conductivity, metal pipes have excellent thermal conductivity, which can quickly absorb and transfer heat to the cooling water inside the pipe, promptly remove heat from the battery polarity terminals, avoid local heat accumulation, and achieve efficient heat dissipation.

[0017] Furthermore, the aforementioned insulating layer can be an enamel insulating layer or an insulating and thermally conductive adhesive layer.

[0018] The enamel insulation layer is made of special enamel and fired at high temperature. It has extremely high insulation resistance and can effectively block the current path between cooling water and metal pipes and conductive parts, thus avoiding the risk of short circuit from the source.

[0019] The insulating and thermally conductive adhesive layer has excellent bonding properties, allowing it to firmly adhere to the outer wall of metal pipes and bond tightly with conductive components. During installation, it acts as an adhesive, securely fixing the pipes within the heat exchanger installation channel, enhancing the overall structural stability and reducing the risk of pipe loosening or displacement due to vibration, impact, or other factors.

[0020] Furthermore, the aforementioned water-cooled pipes can also be ceramic pipes. Ceramic materials possess excellent insulation properties, eliminating the need for additional complex insulation processes to isolate cooling water from conductive components. Simultaneously, ceramic materials have a low coefficient of thermal expansion, ensuring dimensional stability of the cooling water flow channel under temperature changes and maintaining smooth water flow; ceramic materials also have good thermal conductivity, enabling rapid heat dissipation and ensuring the battery operates at a suitable temperature.

[0021] Furthermore, the inner wall of the aforementioned ceramic pipe is provided with a metal reinforcement layer.

[0022] The addition of a metal reinforcement layer significantly enhances the mechanical strength of ceramic pipes. While ceramic materials are hard, they are relatively brittle and prone to cracking under external impact or vibration. The metal reinforcement layer, however, possesses excellent toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing ceramic pipe breakage, and extending their service life.

[0023] Furthermore, the aforementioned metal reinforcement layer is an aluminum layer. Compared to other metals, aluminum has better thermal conductivity, and is also highly malleable and easy to process.

[0024] Furthermore, the aforementioned water-cooling pipes consist of two parallel pipes; one of them is the inlet water channel, and the other is the outlet water channel.

[0025] Two parallel mounting channels are provided on each conductive component;

[0026] Two water-cooled pipes are nested into the two mounting channels of each conductive component.

[0027] Furthermore, the conductive component is provided with a welding part, which is used to weld and connect to the polarity terminal of the individual battery.

[0028] Welding the polarity terminal to the conductive component enables a tight connection between them. Compared to other connection methods, such as simple mechanical fixing, welding eliminates the tiny gaps between the connection points, greatly reducing thermal resistance, improving the heat conduction efficiency between the two, and ensuring effective heat transfer. Welding also enhances the stability of the connection, preventing the conductive component from separating from the polarity terminal due to vibration or other factors during battery operation, thus affecting the heat dissipation effect.

[0029] A second aspect of the present invention provides a battery component, including the heat exchanger described above and a plurality of individual battery cells;

[0030] In the heat exchange components described above, each conductive element connects to the polarity terminals of two adjacent individual cells with different polarities, thereby realizing the series connection of each individual cell and heat exchange between the cooling water in the cooling water channel and the polarity terminals.

[0031] Furthermore, the polar terminal is provided with a second through groove, the conductive element is fixed in the second through groove, and the welding part is welded to the side wall of the second through groove.

[0032] A second through slot is made on the polarity terminal to hold the heat exchanger in place, ensuring good thermal contact between the heat exchanger and the polarity terminal. After welding, the polarity terminal and the heat exchanger can be tightly bonded together.

[0033] Furthermore, the aforementioned battery component also includes a housing; the housing has an explosion vent; multiple individual cells are arranged inside the housing; the top plate of the housing has clearance holes corresponding to the polarity terminals of each individual cell; the polarity terminals of each individual cell extend out of the corresponding clearance holes, and the area corresponding to each clearance hole on the top plate of the housing is sealed and connected to the top cover plate of the corresponding individual cell; the aforementioned conductive component is connected to the portion of each individual cell's polarity terminal that extends out of the corresponding terminal clearance hole.

[0034] Furthermore, the aforementioned casing is provided with an explosion vent channel that communicates with the explosion vent. The explosion vent channel is sealed and covers the explosion vent of each individual battery cell. Thermal runaway fumes are discharged in an orderly manner through the explosion vent channel, thereby improving the safety performance of the battery components.

[0035] A third aspect of the present invention provides a battery pack comprising a plurality of the above-described battery components; water-cooled pipes on the heat exchange components of each battery component are interconnected to form a battery pack liquid circuit system to realize heat exchange of the battery pack.

[0036] Furthermore, each battery component includes two heat exchangers, which extend along a first direction and are arranged along a second direction; one heat exchanger is connected to the polar terminal on one side of each individual battery cell, and the other heat exchanger is connected to the polar terminal on the other side of each individual battery cell; wherein the first direction is the arrangement direction of the individual batteries in each battery component, and the second direction is the arrangement direction of multiple battery components.

[0037] Each heat exchanger includes one inlet channel and one outlet channel;

[0038] The inlet channels of multiple heat exchangers are connected in series to form the total inlet path; the outlet channels of multiple heat exchangers are connected in series to form the total outlet path; the end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section.

[0039] After entering the main inlet, the coolant flows through the inlet channels of each heat exchanger in sequence, and then through the outer pipe section, flows through the outlet channels of each heat exchanger in sequence, and flows out from the main outlet.

[0040] Within a single heat exchanger, the coolant forms an efficient heat exchange through adjacent inlet and outlet channels, ensuring that each polarity terminal receives a balanced heat dissipation effect. For all heat exchangers, the temperature difference between the inlet and outlet channels remains essentially constant, effectively avoiding localized overheating or undercooling phenomena present in traditional series cooling (traditional series cooling: the coolant gradually heats up as it flows from the main inlet to the main outlet, resulting in a lower battery temperature near the main inlet and a higher battery temperature at the main outlet).

[0041] The beneficial effects of this invention are:

[0042] The present invention fixes a heat exchange component on the polarity terminal to directly dissipate heat from the battery polarity terminal, which has a better heat dissipation effect.

[0043] Furthermore, the conductive component of this invention is connected to the polarity terminals of adjacent individual cells of different polarities, enabling series connection between individual cells. Therefore, in this invention, the heat exchange component not only serves as a heat exchange member but also as a current collector to realize the series connection of multiple individual cells, offering at least the following advantages:

[0044] Firstly, there is no need to set up a special busbar, which simplifies the overall structure of the battery component; secondly, since the heat exchanger performs both heat exchange and conductivity functions, the number of parts in the battery component is reduced, thus reducing assembly difficulty and cost.

[0045] Furthermore, the water-cooled pipes of this invention are insulated from all conductive components, achieving insulation between the conductive components and the cooling water, thus enabling heat exchange based on water cooling. Compared to insulating oil cooling, water cooling can better meet the efficient, economical, and environmentally friendly cooling requirements of battery systems. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the structure of a heat exchanger in Example 1;

[0047] Figure 2 This is an exploded structural diagram of a heat exchanger according to Example 1;

[0048] Figure 3 This is a cross-sectional view of a heat exchanger according to Example 1;

[0049] Figure 4 This is a schematic diagram of the structure of the first type of battery component in Example 1;

[0050] Figure 5 This is an exploded structural diagram of the first type of battery component in Example 1;

[0051] Figure 6 This is a cross-sectional view of the first type of battery component in Example 1;

[0052] Figure 7 This is a schematic diagram of the structure of the second type of battery component in Example 1;

[0053] Figure 8 This is an exploded structural diagram of the second type of battery component in Example 1;

[0054] Figure 9 This is a cross-sectional view of the second type of battery component in Example 1;

[0055] Figure 10 This is a first-view structural diagram of a battery pack according to Embodiment 1;

[0056] Figure 11This is a second-view structural diagram of a battery pack according to Embodiment 1;

[0057] Figure 12 This is a cross-sectional view of the heat exchanger in Example 2;

[0058] Figure 13 This is a schematic diagram of the heat exchanger structure in Example 3;

[0059] Figure 14 This is a cross-sectional view of the first type of heat exchanger in Example 3;

[0060] Figure 15 This is a cross-sectional view of the second type of heat exchanger in Example 3;

[0061] Figure 16 This is a first-view structural diagram of the battery pack in Example 3;

[0062] Figure 17 This is a second-view structural schematic diagram of the battery pack in Example 3.

[0063] The attached figures are labeled as follows:

[0064] 1. Heat exchanger; 11. Conductive component; 111. Stepped structure; 12. Water-cooled pipe; 13. Mounting channel; 131. Through hole; 14. Metal pipe; 15. Insulation layer; 16. Cooling water channel; 163. Inlet channel; 164. Outlet channel; 17. Ceramic pipe; 18. Metal reinforcement layer; 19. First heat exchanger; 10. Second heat exchanger; 2. Battery module; 21. Single cell; 22. Polar terminal; 221. Terminal post; 222. Terminal post extension; 23. Second through slot; 3. Outer shell; 5. Explosion venting channel; 6. Insulating seal. Detailed Implementation

[0065] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0066] Many 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 those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0067] In the description of this invention, it should be noted that the terms "top," "bottom," etc., indicating orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the invention and 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, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0068] This invention relates to a heat exchanger with electrical connection function, which is connected to the polarity terminal of a single battery cell. While cooling the polarity terminal by liquid cooling, it can also realize the series connection between single batteries.

[0069] In the field of battery thermal management, common liquid cooling methods mainly use liquids such as water and insulating oil as cooling media, relying on a circulation system to achieve heat exchange. Among these, water has significant advantages over liquid cooling media such as insulating oil.

[0070] Regarding cooling efficiency: the specific heat capacity of water is 4.2 × 10⁻⁶. 3 The thermal conductivity is approximately 0.6 W / (m·K), while the specific heat capacity of insulating oil is 1.6 × 10⁻⁶ W / (kg·℃). 3 J / (kg·℃)-2.5×10 3 Its thermal conductivity is between 0.1 and 0.15 W / (m·K), with a J / (kg·℃) value. Therefore, compared to insulating oil, water can more efficiently remove heat from the battery's polarity terminals.

[0071] In terms of cost: insulating oil is relatively expensive; water is widely available and inexpensive.

[0072] In terms of environmental protection: Insulating oil leaks are difficult to degrade and pollute the environment; water leaks are harmless and produce no waste.

[0073] In summary, water cooling offers significant advantages over insulating oil cooling in the selection of heat exchanger cooling methods, better meeting the high-efficiency, economical, and environmentally friendly cooling requirements of battery systems. Therefore, this invention adopts water cooling and designs a specific heat exchanger structure based on this, as follows:

[0074] To achieve the series connection function of the heat exchanger, it includes multiple conductive elements. Each conductive element is used to connect the polarity terminals of two adjacent individual cells with different polarities, thereby realizing the series connection of the individual cells.

[0075] To achieve the function of cooling polarized terminals using water cooling, a water cooling pipe is included, and multiple conductive components are spaced apart along the length of the water cooling pipe on the outer wall of the water cooling pipe.

[0076] To prevent short circuits caused by contact between conductive components and cooling water, and to prevent safety issues caused by electrified cooling water, the water-cooled pipes are insulated from each conductive component, thus achieving insulation isolation between the cooling water and the conductive components.

[0077] The present invention also discloses a battery component, including a battery module and the aforementioned heat exchanger. The battery module is mainly composed of multiple individual cells. Each conductive element in the heat exchanger is connected to the polarity terminals of two adjacent individual cells, thereby realizing the series connection of the individual cells and heat exchange between the polarity terminals.

[0078] The present invention also discloses a battery pack, comprising multiple battery components as described above, wherein water-cooled pipes in the heat exchange components of each battery component are interconnected to form a battery pack liquid circuit system to realize heat exchange of the battery pack.

[0079] It should be noted that:

[0080] 1. The polar terminal described in this invention can be a single battery terminal post, or it can be an integral structure of a single battery terminal post and a terminal post extension member connected thereto.

[0081] 2. The insulation methods between water-cooled pipes and various conductive parts can include at least the following four categories:

[0082] Category 1: Install insulation structures at the points on the water-cooled pipes that come into contact with various conductive bodies;

[0083] The second type: Insulation structure is installed between the water-cooled pipes and each conductive body;

[0084] The third type: Insulation structures are installed at the points on each conductor that come into contact with the water-cooled pipes;

[0085] Category 4: Insulation structure is installed on the entire outer wall of the water-cooled pipe.

[0086] 3. The above-mentioned water cooling pipes can be two, forming two cooling water flow channels; one cooling water flow channel is the inlet flow channel, and the other cooling water flow channel is the outlet flow channel; in the battery pack, multiple inlet flow channels are connected in series to form a total inlet path; multiple outlet flow channels are connected in series to form a total outlet path; the end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section.

[0087] After entering the main inlet, the coolant flows through one inlet channel of each heat exchanger in sequence, and then through the external pipe section, flows through the outlet channel of each heat exchanger in sequence, and flows out from the main outlet.

[0088] 4. The above-mentioned battery modules may include at least the following two types:

[0089] Type 1 battery module:

[0090] The first type of battery module includes multiple individual battery cells arranged along a first direction;

[0091] For ease of description, the arrangement direction of individual cells is defined as the x-direction in this invention; the height direction of individual cells is defined as the z-direction; and the direction perpendicular to both the x and z directions is defined as the y-direction.

[0092] Second type of battery module:

[0093] The second type of battery module, based on the first type of battery module, adds a shell, with multiple individual batteries arranged along the x-direction and placed inside the shell cavity.

[0094] The outer casing is equipped with an explosion vent, through which thermal runaway fumes are discharged. An explosion vent channel connecting the explosion vents can also be provided inside the casing. This channel seals over the explosion vents of each individual battery cell, allowing thermal runaway fumes to be discharged in an orderly manner through the channel, effectively preventing them from spreading into the casing and affecting other individual batteries, thus avoiding exacerbating thermal runaway.

[0095] This invention does not specifically limit the above-mentioned shell structure, but at least the following two structures can be adopted:

[0096] The first structure includes a first cylinder with open ends (i.e., the port parallel to the yz plane is an open end) and end plates fixed to the two open ends of the first cylinder (i.e., the end plates are parallel to the yz plane).

[0097] The second structure includes a second cylinder with open ends at the top and bottom (i.e., the port parallel to the xy plane is the open end) and a top plate and a bottom plate respectively fixed to the open ends at the top and bottom of the second cylinder (i.e., the top plate and the bottom plate are both parallel to the xy plane, and the bottom plate or the top plate can be an integral structure with the second cylinder).

[0098] The top plate of the outer casing (here, the top plate of the first cylindrical body in the first structure, and the top plate in the second structure) has clearance holes corresponding to the polarity terminals of each individual battery cell; the polarity terminals of each individual battery cell extend out of the corresponding clearance holes, and the area corresponding to each clearance hole on the top plate of the outer casing is sealed to the top cover plate of the corresponding individual battery cell. The area corresponding to the clearance hole can be the wall of the clearance hole, or it can be the area surrounding the clearance hole on the top plate of the outer casing.

[0099] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0100] Example 1

[0101] like Figure 1 , Figure 2 and Figure 3As shown, the heat exchanger 1 in this embodiment includes multiple conductive elements 11. Each conductive element 11 is a long columnar structure, and its cross-section is usually designed to be rectangular or circular. The size can be customized according to actual needs.

[0102] In this embodiment, each conductive element 11 serves as a busbar to connect the polarity terminals 22 of two adjacent individual cells 21 with different polarities, thereby realizing the series connection of each individual cell 21.

[0103] The conductive component 11 can be made of a metal material with good electrical and thermal conductivity, such as silver, copper, or aluminum. However, considering both cost and electrical and thermal conductivity, aluminum is generally chosen as the material for the conductive component 11.

[0104] In order to improve the connection stability between the conductive component 11 and the polar terminal 22, this embodiment provides a stepped structure 111 on the outer wall of each conductive component 11 along its length direction (x direction), and uses the horizontal surface of the stepped structure 111 as a welding part to weld to the polar terminal 22.

[0105] It should be noted that the horizontal plane of the aforementioned stepped structure 111 refers to the connection surface between the large-diameter section and the small-diameter section of the conductive component 11 in the z-direction.

[0106] By welding, a tight connection can be achieved between the conductive component 11 and the polarity terminal 22. Compared to other connection methods, such as simple mechanical fixing, welding eliminates the tiny gaps at the connection point, greatly reducing thermal resistance and significantly improving the heat conduction efficiency between the two, ensuring effective heat transfer. Simultaneously, welding enhances the connection stability, preventing the conductive component 11 from separating from the polarity terminal 22 due to vibration, impact, or other factors during battery operation, thus avoiding impact on heat dissipation and ensuring the continuous and stable operation of the battery component. Furthermore, the tight contact significantly reduces contact resistance, allowing current to be evenly distributed between the conductive component 11 and the polarity terminal 22, avoiding localized current concentration or hot spots caused by poor contact.

[0107] from Figures 1 to 3 As can be seen from the figure, in this embodiment, an installation channel 13 is provided on each conductive element 11. The installation channel 13 extends along the length of the conductive element 11 and passes through both ends of the conductive element 11.

[0108] The installation channel 13 can adopt the following two structures:

[0109] First structure: Through hole 131;

[0110] like Figure 2 As shown, the mounting channel 13 is a through hole 131 that passes through both ends of the conductive component 11 in the length direction.

[0111] The second structure: the first through groove;

[0112] The mounting channel 13 is the first through groove that runs through both ends of the conductive component 11 in the length direction.

[0113] In this embodiment, a water-cooled pipe 12 is nested inside the installation channel 13. The water-cooled pipe 12 is a metal pipe 14 with an integral insulation layer 15 on its outer wall. The insulation layer 15 is tightly fitted to the inner wall of the installation channel 13 to achieve insulation isolation between the cooling water and the conductive component 11.

[0114] from Figure 1 As can be seen from the figure, in this embodiment, multiple conductive elements 11 are spaced out and sleeved on the outer wall of the water-cooling pipe 12 along the length of the water-cooling pipe 12.

[0115] The aforementioned insulating layer 15 can take at least the following two structures:

[0116] Structure 1: Enamel insulation layer 15;

[0117] A mature enamel process can be used. By controlling the thickness of the enamel insulation layer 15, excellent insulation performance can be ensured, blocking the current path between the cooling water and the conductive component 11, without significantly affecting the thermal conductivity of the metal pipe 14. This ensures that heat can be quickly and efficiently transferred from the conductive component 11 to the metal pipe 14 and the cooling water inside the pipe, achieving a good heat dissipation effect.

[0118] The enamel insulation layer 15 is made of porcelain enamel fired at high temperature. It has extremely high insulation resistance and can effectively block the current path between the cooling water and the conductive part 11, thus avoiding short circuits and safety problems caused by the cooling water being electrified.

[0119] Furthermore, the enamel insulation layer 15, when tightly bonded to the metal conduit 14, does not significantly affect thermal conductivity. Compared to some organic insulating materials, the enamel insulation layer 15 maintains stable thermal conductivity even at high temperatures, and its heat dissipation efficiency is not reduced due to softening or decomposition caused by heat. This ensures that the heat generated by the battery polarity terminal 22 can be dissipated in a timely manner, maintaining the battery at a suitable operating temperature and improving its charge / discharge performance and lifespan.

[0120] Meanwhile, because the enamel insulation layer 15 has a stable structure and good wear resistance, it will not deform or fall off due to slight external impact or squeezing, thus ensuring structural stability.

[0121] Corresponding to the structure of the insulating layer 15, the mounting channel 13 can be a through hole 131 or a first through groove.

[0122] If the installation channel 13 is a through hole 131, the conductive component 11 can be cast to cover the metal pipe 14 with an enamel insulation layer 15 on its outer wall, and the casting temperature is lower than the heat deformation temperature of the metal pipe 14 and the enamel insulation layer 15. During the casting process, the material of the conductive component 11 fills the mold in a liquid state, tightly wrapping the metal pipe 14 with the enamel insulation layer 15. After cooling and solidification, a stable integral structure is formed, which greatly reduces the contact thermal resistance between the two.

[0123] If the installation channel 13 is the first through groove, the conductive part 11 can be processed first, and then the metal pipe 14 with an enamel insulation layer 15 on the outer wall can be inserted into the first through groove from the opening end of the first through groove.

[0124] Structure 2: Insulating and thermally conductive adhesive layer;

[0125] First, the metal pipe 14 can be placed in a predetermined position within the installation channel 13, ensuring accurate positioning. Then, insulating thermally conductive adhesive is poured between the metal pipe 14 and the installation channel 13. The cured adhesive layer firmly adheres to the outer wall of the metal pipe 14 and the inner wall of the installation channel 13, not only achieving insulation between the cooling water and the conductive component 11, but also promoting heat transfer from the conductive component 11 to the cooling water due to its excellent thermal conductivity. Simultaneously, the adhesive properties of the insulating thermally conductive adhesive make the connection between the metal pipe 14 and the installation channel 13 more stable, enhancing the overall stability of the heat exchanger 1 structure.

[0126] Corresponding to the structure of the insulation layer 15, the installation channel 13 is preferably a first through groove; the open end of the first through groove can serve as a dispensing port. During dispensing, due to the openness of the first through groove, the adhesive can evenly fill the gap between the metal pipe 14 and the inner wall of the installation channel 13 under the action of gravity and fluidity. When the size of the first through groove is larger than the size of the metal pipe 14 in the z-direction, an insulating and thermally conductive adhesive layer can be wrapped around the entire outer wall of the metal pipe 14. During the dispensing process, the thickness of the insulating and thermally conductive adhesive layer can be ensured to be uniform by controlling parameters such as dispensing speed and pressure, avoiding defects such as bubbles and voids.

[0127] The aforementioned insulating and thermally conductive adhesives can be silicone-based, epoxy resin-based, etc. Their thickness typically needs to comprehensively consider insulation, thermal conductivity, and adhesion requirements. Generally, while meeting insulation performance requirements, a thinner adhesive layer helps reduce thermal resistance and improve thermal conductivity; however, an excessively thin layer may affect bond strength and insulation reliability. A thicker adhesive layer, while enhancing adhesion and insulation, increases thermal resistance and hinders heat dissipation. In practical applications, the thickness of the insulating and thermally conductive adhesive layer must be controlled within a reasonable range based on the specific operating conditions and performance requirements of the battery components to achieve a balance among various performance aspects.

[0128] like Figures 4 to 6As shown, this is the first type of battery component in this embodiment, including a battery module 2 and the aforementioned heat exchanger 1. The battery module 2 in this embodiment is the aforementioned first type of battery module.

[0129] As shown in the figure, the battery module 2 in this embodiment includes 12 individual battery cells 21 arranged along the x-direction. In this embodiment, the individual battery cells 21 are prismatic cells, and the internal cavity of each individual battery cell 21 includes an electrolyte region and a gas region. In other embodiments, the number of individual battery cells 21 can be adjusted according to actual needs, and the shape of the individual battery cells 21 can also be adjusted according to actual needs.

[0130] Each individual cell 21 has a terminal extension 222 connected to its terminal post 221 as a polarity terminal 22.

[0131] A second through groove 23 for mounting the heat exchanger 1 is provided on the pole extension 222. The second through groove 23 extends along the x-direction, that is, the length direction of the second through groove 23 is parallel to the x-axis. The inner cavity shape of the second through groove 23 is adapted to the cross-sectional shape of the conductive element 11, and it is necessary to ensure that the conductive element 11 is tightly clamped in it to ensure installation stability while also ensuring heat transfer and electrical conductivity between the conductive element 11 and the pole extension 222. As can be seen from the figure, this embodiment uses a rectangular second through groove 23, and the cross-section of the conductive element 11 adapted to it is rectangular.

[0132] The specific installation process is as follows: First, connect each terminal extension 222 to the corresponding terminal 221 of the single cell 21. After all terminal extensions 222 are fixed, fix the heat exchanger 1 along the x-direction into the second through groove 23 of each terminal extension 222 located on the same side, and weld the conductive element 11 to the two side walls of the second through groove 23. Figure 4 As can be seen from the image, in this embodiment, two heat exchange components 1 are provided on the top of the battery module 2.

[0133] To improve welding quality and connection stability, and to ensure efficient heat conduction and uniform current transmission, in this embodiment, the horizontal plane of the stepped structure 111 on the conductive component 11 is flush with the end face of the side wall of the second through groove 23. Welding is performed at the joint between the horizontal plane of the stepped structure 111 and the end face of the side wall of the second through groove 23. Figure 6 The region shown in Figure a.

[0134] A stepped structure 111 is provided on the outer wall of the conductive component 11, and the horizontal plane of the stepped structure 111 is flush with the end face of the side wall of the second through groove 23. At the same time, the joint is welded together, which has at least the following advantages:

[0135] Improved stability: The stepped structure 111 provides a larger welding contact area, making the welded connection more robust, reducing the risk of connection loosening due to vibration, and improving the overall stability of the battery components.

[0136] Optimize thermal conductivity and electrical conductivity: The horizontal plane of the stepped structure 111 is flush with the side wall end face of the second through groove 23, ensuring a tighter contact between the conductive component 11 and the pole extension 222, reducing the tiny gaps between the contact interfaces, significantly reducing thermal resistance, and improving thermal conductivity. At the same time, the tight contact between the two significantly reduces the contact resistance, allowing the current to be evenly distributed between the conductive component 11 and the pole extension 222, avoiding local current concentration or hot spots caused by poor contact.

[0137] Furthermore, during the welding process, conventional welding operations may damage the structure of the conductive component 11 due to factors such as high temperature and stress concentration, thus causing potential leakage hazards. The stepped structure 111, with its horizontal plane flush with the sidewall end face of the second through groove 23, provides an ideal operating plane for laser welding along the z-direction, effectively avoiding leakage problems caused by damage to the heat exchanger 1 structure during the welding process. When cooling water flows within the heat exchanger 1, this design effectively prevents cooling water leakage from the joints.

[0138] In this embodiment, the inner cavity of the metal pipe 14 is used as the cooling water channel 16. When the heat of the electrode post 221 is conducted to the electrode post extension 222, it will be further transferred to the cooling water in the cooling water channel 16 of the heat exchanger 1 to achieve heat dissipation of the battery module 2.

[0139] Meanwhile, in this embodiment, the conductive component 11 is connected to the polarity terminals 22 of different polarities of adjacent individual cells 21 in the battery component, thereby realizing the series connection of multiple individual cells 21.

[0140] Therefore, in this embodiment, the heat exchanger 1 not only serves as a heat exchange component but also as a conductive component 11 to realize the series connection of multiple individual cells 21, which has at least the following advantages:

[0141] Firstly, the elimination of the need for a dedicated busbar simplifies the overall structure of the battery module. In traditional battery modules, heat exchange and conductivity are often handled by different components, requiring complex structural layouts and connection designs. In this embodiment, however, heat exchanger 1 integrates both heat exchange and conductivity functions, reducing the need for a dedicated busbar design and making the overall structure of the battery module simpler and more compact, thus reducing design complexity and the probability of errors.

[0142] Secondly, since heat exchanger 1 performs both heat exchange and electrical conduction functions, it reduces the number of components in the battery assembly, thereby lowering assembly difficulty and cost. Previously, separate heat exchange tubes and manifolds were used, resulting in a large number of components, increased procurement costs, and the need for precise installation of each component during assembly, which placed high demands on the assembly workers' skills and resulted in a long assembly time.

[0143] Thirdly, the heat exchanger 1, as a series connector, is directly embedded in the second through slot 23 of the pole post extension 222, making full use of the space of the pole post extension 222 and avoiding the problem of additional busbars occupying space, which is conducive to improving the integration of battery components.

[0144] like Figures 7 to 9 As shown, this is the second type of battery component in this embodiment. Its structure differs from that of the first type of battery component in that the battery module 2 is the second type of battery module described above.

[0145] In this embodiment, the second type of battery module arranges 12 individual batteries 21 inside the housing 3, and each terminal extension 222 is located outside the housing 3. The heat exchanger 1 is fixed on the terminal extension 222 located on the same side. The structure of the terminal extension 222 and its installation structure with the heat exchanger 1 are the same as those of the first type of battery component, and will not be described again here.

[0146] On the top plate of the outer casing 3, there is a boss extending in the x direction. An explosion venting channel 5 is opened on the boss. The explosion venting channel 5 seals and covers the explosion venting port of each individual battery 21. When any individual battery 21 experiences thermal runaway, the thermal runaway smoke is discharged in an orderly manner through the explosion venting channel 5 to the explosion venting port. This can effectively prevent the thermal runaway smoke from spreading into the casing and affecting other individual batteries 21, thus preventing the occurrence of thermal runaway.

[0147] The assembly of such battery components can be achieved through the following process:

[0148] First, place 12 individual batteries 21 inside the outer casing 3, and fix and seal the top plate of the outer casing 3 corresponding to the clearance hole to the top cover plate of the individual battery 21.

[0149] In this embodiment, a sealed connection can be achieved by welding the edge of the clearance hole near the single cell 21 to the top cover plate of the single cell 21 using filler wire welding; alternatively, laser welding can be used to weld the area around each clearance hole on the top plate of the outer casing 3 to the area around the corresponding electrode post 221 on the top cover plate of the single cell 21. Hollow components can also be used to seal the area of ​​the top plate of the outer casing corresponding to the clearance hole to the top cover plate of each single cell 212. Specifically, each hollow component is inserted through the clearance hole and fitted around each electrode post 221. The bottom of the hollow component is laser-welded to the first area of ​​the corresponding single cell 21, and the top of the hollow component is laser-welded to the second area of ​​the top plate of the outer casing 3. The first area is the area around any electrode post 221 in the top cover plate of any single cell 21; the second area is the area corresponding to any clearance hole on the top plate of the outer casing 3. The area corresponding to the clearance hole can be the wall of the clearance hole or the area around the clearance hole on the top plate of the outer casing 3.

[0150] Furthermore, due to the small gap between the terminal 221 of the individual battery 21 and the clearance hole, the insulation between the terminal 221 of the individual battery 21 and the top plate of the casing 3 may be difficult to ensure. Additionally, if thermal runaway occurs, cracks may appear at the weld between the clearance hole and the top cover of the individual battery 21, causing thermal runaway fumes to leak from that location. Therefore, if... Figure 9 As shown, in this embodiment, an insulating seal 6 is provided in the gap between each clearance hole and the pole post 221. The insulating seal 6 can ensure the insulation between the polarity terminal 22 and the top plate of the housing 3. At the same time, even if leakage occurs at the welding position, the insulating seal 6 can also serve as a second barrier to prevent the leakage of thermal runaway flue gas.

[0151] Therefore, after fixing and sealing the top plate of the outer casing 3 corresponding to the clearance hole to the upper cover plate of the single cell 21, the insulating seal 6 is set between each clearance hole and the terminal post 221. Then, the terminal post extension 222 is pressed tightly against the insulating seal 6, and finally the terminal post extension 222 is connected to the terminal post 221 of the single cell 21.

[0152] In some other embodiments, the insulating seal 6 may also be an insulating seal layer disposed at the gap between the clearance hole and the pole post 221 by a casting process.

[0153] Finally, the heat exchanger 1 is fixed in the second through groove 23 of the pole extension 222.

[0154] like Figure 10 and Figure 11 The diagram shown is a schematic of the battery pack structure in this embodiment, including four battery components arranged along the y-direction (represented in the diagram as being of the above type). Figures 7 to 9 (Taking the battery component shown as an example), in other embodiments, the number of battery components can be adjusted according to actual needs.

[0155] For ease of description, the two heat exchangers 1 on each battery component are defined as the first heat exchanger 19 and the second heat exchanger 10, respectively.

[0156] In the entire battery pack, multiple first heat exchangers 19 are connected in series to form a total water inlet path; multiple second heat exchangers 10 are connected in series to form a total water outlet path; the end of the total water inlet path is connected to the beginning of the total water outlet path through an external pipe section.

[0157] After entering the main inlet, the cooling water flows through the first heat exchanger 19 of each battery component in sequence, and then through the outer pipe section, it flows through the second heat exchanger 10 of each battery component in sequence, and flows out from the main outlet.

[0158] This series-connected fluid flow design allows cooling water to flow sequentially through each battery component, carrying away the heat generated by each component. During the cooling water flow, each battery component receives relatively even cooling, avoiding temperature differences caused by insufficient or excessive cooling of some components, and achieving uniform temperature distribution across the entire battery pack.

[0159] In some other embodiments, the heat exchangers 1 may be connected in series.

[0160] Example 2

[0161] This embodiment is also a heat exchanger 1, but it differs from embodiment 1 in that, as Figure 12 As shown, in this embodiment, a ceramic pipe 17 is nested inside the installation channel 13. The inner cavity of the ceramic pipe 17 serves as a cooling water flow channel 16, and the insulation and isolation between the cooling water and the conductive component 11 can be achieved based on the ceramic pipe 17.

[0162] Ceramic itself is an excellent insulating material, which ensures the insulation between cooling water and conductive component 11 by its material nature. It can provide reliable electrical insulation for battery components without the need for additional complicated insulation treatment processes, thereby improving the safety of battery components.

[0163] Furthermore, the ceramic pipe 17 has a low coefficient of thermal expansion, which allows it to maintain dimensional stability during frequent temperature changes in battery operation. It is less prone to deformation due to thermal expansion and contraction, ensuring the structural integrity and flow stability of the cooling water channel 16. Simultaneously, the ceramic material has excellent thermal conductivity, enabling it to quickly transfer heat from the conductive component 11 to the cooling water inside the pipe, thus improving overall heat dissipation efficiency and maintaining the battery's optimal operating temperature.

[0164] Although ceramic materials have high hardness, they are relatively brittle and prone to cracking when subjected to external impact or vibration. To overcome this problem, this embodiment provides a metal reinforcing layer 18 on the inner wall of the ceramic pipe 17 to enhance its mechanical strength. The metal reinforcing layer 18 can be made of a material with good toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing the ceramic pipe 17 from cracking, and extending its service life.

[0165] Specifically, in this embodiment, an aluminum layer is selected as the metal reinforcement layer 18. Aluminum not only has excellent thermal conductivity, but also good plasticity, making it easy to process and shape.

[0166] In some other embodiments, other metal-formed metal reinforcement layers 18 may also be selected, such as titanium alloys, nickel-based alloys, etc., to improve the mechanical strength of ceramic pipes 17.

[0167] In this embodiment, the metal reinforcing layer 18 and the conductive component 11 can both be cast onto the inner and outer walls of the ceramic pipe 17, respectively, with the casting temperature strictly controlled to be lower than the heat deformation temperature of the ceramic pipe 17. This casting method allows the aluminum metal layer and the conductive component 11 to fit tightly against the inner and outer walls of the ceramic pipe 17, respectively, forming a stable composite structure.

[0168] In some other embodiments, thermal spraying technology can also be used to form a metallic aluminum layer on the inner wall of the ceramic pipe 17.

[0169] The structure of the conductive element 11 in this embodiment is the same as that in Embodiment 1, and will not be described again here.

[0170] Similar to Example 1, the battery components adapted to the heat exchanger 1 described above can also be of two types:

[0171] The first type of battery component includes a battery module 2 and a heat exchanger 1. Except for the structure of the heat exchanger 1, which differs from that of Embodiment 1, the rest are the same as the first type of battery component in Embodiment 1, and will not be described again here.

[0172] The second type of battery component is the same as that in Example 1, except that the structure of the heat exchanger 1 is different from that in Example 1. It will not be described again here.

[0173] In this embodiment, the battery pack is identical to that in Embodiment 1, except that the structure of the heat exchanger 1 is different from that in Embodiment 1. Therefore, it will not be described again here.

[0174] Example 3

[0175] The heat exchanger 1 in this embodiment differs from the one in the above embodiment in that the conductive component 11 in this embodiment is provided with two mounting channels 13.

[0176] like Figure 13 As shown, in this embodiment, the two installation channels 13 are parallel to each other, and the structure of each installation channel 13 and the water-cooling pipe 12 nested within it are the same as in the above embodiment.

[0177] like Figure 14 As shown, the structure of each installation channel 13 and the water-cooling pipes therein are the same as in Embodiment 1 above; a metal pipe 14 is nested inside each installation channel 13, and an insulating layer 15 is provided on the outer wall of the metal pipe 14. The insulating layer 15 is tightly fitted to the inner wall of the installation channel 13 to achieve insulation isolation between the cooling water and the conductive component 11. The detailed structure of the insulating layer 15 has been described in Embodiment 1 and will not be repeated here.

[0178] like Figure 15As shown, the structure of each mounting channel 13 and the water-cooling pipes within it are the same as in Embodiment 2 above; a ceramic pipe 17 is nested inside the mounting channel 13 to achieve insulation isolation between the cooling water and the conductive component 11. Specific structural details have been described in Embodiment 2 and will not be repeated here.

[0179] Similar to the above embodiments, the battery components adapted to the heat exchanger 1 can also be of two types, the only difference being the heat exchanger 1, while the rest of the structure is the same, and will not be described in detail here.

[0180] like Figure 16 and Figure 17 The diagram shown is a structural schematic of the battery pack from different perspectives in this embodiment. The battery pack includes four battery components arranged along the y-direction (the diagram uses the second type of battery component as an example). In practical applications, the number of battery components can be flexibly adjusted according to specific needs.

[0181] In this embodiment, for ease of description, the two cooling water channels 16 on each heat exchanger 1 are defined as an inlet channel 163 and an outlet channel 164, respectively. The inlet channels 163 of the four battery components are connected end to end in sequence to form a total inlet path; and the outlet channels 164 are also connected in series in sequence to form a total outlet path. The end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section, thus constructing a complete cooling circulation loop.

[0182] The specific cooling process is as follows: Cooling water enters from the main inlet end and flows sequentially through the inlet channel 163 of each heat exchanger 1. Then, its flow direction changes at the outer pipe section, and it flows sequentially through the outlet channel 164 of each heat exchanger 1, finally exiting from the main outlet end. Inside a single heat exchanger 1, the coolant achieves efficient heat exchange through adjacent inlet channels 163 and outlet channels 164, ensuring uniform heat dissipation for each polarity terminal 22. For all heat exchangers 1 in the entire battery pack, the temperature difference between the inlet channel 163 and outlet channel 164 remains stable, effectively overcoming the problem of localized overheating or undercooling at both ends of the battery pack caused by the gradual temperature increase of the coolant during flow in traditional series cooling methods.

Claims

1. A heat exchange member, characterized by: Includes water-cooled pipes and multiple conductive components; The inner cavity of the water-cooled pipe serves as a cooling water flow channel; The multiple conductive components are spaced apart along the length of the water-cooling pipe on the outer wall of the water-cooling pipe; each conductive component is used to connect the polarity terminals of two adjacent single cells with different polarities, so as to realize the series connection of each single cell. The water-cooled pipes are insulated from each conductive component.

2. The heat exchange member according to claim 1, characterized by: An installation channel is provided on the conductive component, and a water-cooled pipe is nested into the installation channel.

3. The heat exchanger according to claim 1 or 2, characterized in that: The water-cooled pipe includes a metal pipe, and the outer wall of the metal pipe is provided with an insulating layer.

4. The heat exchanger according to claim 3, characterized in that: The insulating layer is an enamel insulating layer or an insulating and thermally conductive adhesive layer.

5. The heat exchanger according to claim 1 or 2, characterized in that: The water-cooled pipes are ceramic pipes.

6. The heat exchanger according to claim 5, characterized in that: The inner wall of the ceramic pipe is reinforced with a metal layer.

7. The heat exchanger according to claim 6, characterized in that: The metal reinforcement layer is an aluminum layer.

8. The heat exchanger according to any one of claims 1 to 7, characterized in that: There are two water-cooled pipes, which are parallel to each other; one of them is the inlet water channel and the other is the outlet water channel. Two parallel mounting channels are provided on each conductive component; Two water-cooled pipes are nested into the two mounting channels of each conductive component.

9. The heat exchanger according to claim 1, characterized in that: The conductive component is provided with a welding part, which is used to weld and connect to the polarity terminal of the individual battery.

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