A large capacity battery assembly and battery pack

Abstract

This invention belongs to the field of batteries, specifically a high-capacity battery module and battery pack. It overcomes the problem of excessive localized heat at the battery terminals, leading to thermal runaway, in existing batteries. The high-capacity battery module includes a high-capacity battery and two heat exchangers. The high-capacity battery comprises multiple interconnected individual cells. The heat exchangers are made of ceramic and have cooling channels. Each heat exchanger is connected to a polarity terminal on one side. The battery pack includes multiple high-capacity battery modules. The heat exchangers on each high-capacity battery module are interconnected to form a battery pack liquid circuit system. This invention fixes the heat exchangers to the polarity terminals. Heat generated at the battery polarity terminals is conducted to the heat exchangers and dissipated through heat exchange, achieving efficient heat dissipation. Simultaneously, the use of ceramic as the heat exchanger material effectively avoids the risk of short circuits caused by conductivity of the heat exchangers; it also prevents the cooling medium from becoming charged, fundamentally ensuring the electrical safety of the battery system.

Description

Technical Field

[0001] This invention belongs to the field of batteries, specifically a high-capacity battery component and battery pack. Background Technology

[0002] Battery temperature control has always been a hot topic in this field, and most existing batteries use air cooling or liquid cooling methods for temperature control. However, since the terminals are the areas in the battery where heat is most concentrated, excessive local heat at the terminals can easily cause thermal runaway, seriously affecting the safety and performance of the battery and the battery pack it constitutes. Summary of the Invention

[0003] The purpose of this invention is to provide a high-capacity battery component and battery pack that overcomes the problem of excessive local heat at the battery terminals, which leads to thermal runaway.

[0004] The first aspect of the present invention provides a large-capacity battery assembly, including a large-capacity battery and two heat exchange components;

[0005] The aforementioned high-capacity battery comprises n individual cells arranged along a first direction; the internal cavities of the n individual cells are interconnected, and the electrolyte and / or gas are shared among the individual cells; where n is an integer greater than 1.

[0006] The heat exchanger includes a heat exchanger body; the heat exchanger body is made of ceramic material and has at least one cooling channel, which extends along the length of the heat exchanger body and passes through both ends of the heat exchanger body.

[0007] Two heat exchange components are parallel to each other and both extend along a first direction; the heat exchange component body of one heat exchange component is connected to one polarity terminal of n individual cells, and the heat exchange component body of the other heat exchange component is connected to the other polarity terminal of n individual cells.

[0008] The present invention fixes a heat exchange component on the polar terminal (the polar terminal mentioned here 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, so as to achieve efficient heat dissipation.

[0009] Cooling channels are provided within the heat exchanger body for the flow of liquid cooling medium, preferably cooling water, to achieve efficient heat dissipation.

[0010] Meanwhile, to prevent the heat exchanger body from becoming conductive and potentially causing a short circuit, and to prevent the cooling water flowing in the cooling channel from becoming electrified and affecting the electrical safety of the battery system, this invention selects ceramic material as the material for the heat exchanger body. On the one hand, ceramic material has good insulation properties, which can effectively avoid the risk of short circuit caused by the heat exchanger body becoming conductive; on the other hand, it can prevent the cooling water flowing in the cooling channel from becoming electrified, thus ensuring the electrical safety of the battery system from the root.

[0011] In addition, the electrolyte and / or gas inside each individual cell are interconnected, so that the electrolyte and / or gas of all individual cells are in the same system, reducing the differences between individual cells and improving the consistency between individual cells to a certain extent, thereby improving the cycle life of the battery components to a certain extent.

[0012] Furthermore, through slots extending along a first direction are formed on the aforementioned polarity terminals; the heat exchanger body of one heat exchanger is fitted into the through slots of n positive polarity terminals on one side; the heat exchanger body of the other heat exchanger is fitted into the through slots of n negative polarity terminals on the other side.

[0013] A through-slot is made in the polarity terminal to hold the heat exchanger in place, ensuring good thermal contact between the heat exchanger and the polarity terminal. When heat is conducted to the polarity terminal, it is further transferred to the heat exchanger. The heat rapidly diffuses within the heat exchanger and is dissipated through the liquid cooling medium inside the heat exchanger cavity and through heat exchange with the surrounding environment, thus achieving heat dissipation for the battery.

[0014] Furthermore, a flexible thermally conductive layer is provided between the heat exchanger body and the through groove of the polarity terminal. This flexible thermally conductive layer is made of a material with high thermal conductivity and flexibility, which can closely fit the outer wall of the heat exchanger body and fill the thermal resistance caused by unevenness of the outer wall surface of the heat exchanger body or the installation gap between the heat exchanger body and the polarity terminal. On the one hand, the flexible thermally conductive layer can enhance the heat conduction efficiency between the battery polarity terminal and the outer wall of the heat exchanger body, so that heat can be transferred more smoothly from the polarity terminal to the heat exchanger body, and then carried away by the liquid cooling medium in the cooling channel; on the other hand, the flexibility of the flexible thermally conductive layer can buffer external impacts and vibrations, further protecting the brittle heat exchanger body. At the same time, during the installation process, it can effectively make up for the gaps caused by installation errors, ensure close contact between the components, and enhance the structural stability and reliability of the entire heat exchange system.

[0015] Furthermore, the aforementioned flexible heat-conducting layer is a silicone sleeve fitted onto the outer wall of the heat exchanger body; there are n silicone sleeves, and the n silicone sleeves are spaced apart along the length direction of the heat exchanger body on the outer wall of the heat exchanger body.

[0016] In terms of materials, silicone has wide temperature range stability. Compared with organic flexible materials, it can withstand sudden changes in battery charging and discharging temperatures and is not prone to hardening or aging. In addition, its high insulation enhances the electrical isolation performance between the heat exchanger body and the polar terminals.

[0017] In terms of structure, its annular sleeve structure is tightly integrated with the heat exchanger body, ensuring a stable fit even when the battery vibrates or expands and contracts due to thermal expansion and contraction, thus ensuring a stable heat conduction path.

[0018] Meanwhile, the silicone sleeve utilizes the elastic properties of its material to provide all-around protection for the brittle heat exchanger body. This avoids stress concentration and, compared to the single-sided protection of sheet-like thermal conductive layers, significantly reduces the risk of breakage of the brittle heat exchanger body, ensuring the performance of the heat exchanger body and the stable operation of the heat exchange system.

[0019] In addition, the multiple silicone sleeves spaced apart ensure effective heat conduction with the polar terminals, while reducing the amount of silicone sleeve material used compared to a single silicone sleeve that completely covers the outer wall of the heat exchanger body, thus lowering costs.

[0020] Furthermore, the heat exchanger also includes a metal pipe; the metal pipe is nested into the cooling channel along the length of the cooling channel.

[0021] The use of metal pipes significantly enhances the mechanical strength of the ceramic heat exchanger body. While ceramic materials are hard, they are relatively brittle and prone to cracking under external impact or vibration. Metal pipes, on the other hand, possess excellent toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing the ceramic heat exchanger body from cracking, and extending its service life.

[0022] Furthermore, the aforementioned metal pipe is an aluminum pipe. Compared to other metals, aluminum has better thermal conductivity, and is also highly malleable and easy to process.

[0023] Furthermore, a thermally conductive adhesive layer is provided between the contact surfaces of the outer wall of the aforementioned metal pipe and the inner wall of the cooling channel.

[0024] From a thermal conductivity perspective, the contact thermal resistance generated by the direct contact between the ceramic heat exchanger body and the metal pipe may affect heat transfer efficiency. A thermally conductive adhesive layer can fill gaps and eliminate air gaps between them, improving thermal conductivity and enhancing heat dissipation at the battery polarity terminals thanks to its excellent thermal conductivity.

[0025] In terms of structural stability, the adhesion of the thermally conductive adhesive layer can firmly bond the heat exchanger body and the metal pipe, improving the bonding stability between the two.

[0026] In terms of buffering performance, the thermally conductive adhesive layer has a certain degree of flexibility, which can buffer vibration stress and prevent damage to the ceramic heat exchanger body; its flexibility can also adapt to the thermal expansion of the component, relieve stress, ensure tight connection, and maintain heat conduction efficiency.

[0027] Furthermore, the metal pipe and the aforementioned heat exchanger body can be integrated as a single unit. Compared to a separate structure, this integrated unit completely eliminates the assembly gap between the metal pipe and the heat exchanger body, avoiding the air insulation layer caused by the gap. This allows heat to be conducted between the metal and ceramic in a more direct and efficient manner, significantly improving heat dissipation efficiency. In addition, the integrated structure reduces the number of component assembly steps, lowering the risk of performance loss due to assembly errors. Moreover, during long-term use, there will be no loosening of the metal pipe and ceramic body due to vibration or other factors, ensuring the reliability and stability of the heat exchanger.

[0028] Furthermore, the aforementioned cooling channels consist of two separate channels, which are isolated from each other; one cooling channel is the liquid inlet channel, and the other is the liquid outlet channel.

[0029] Furthermore, the aforementioned high-capacity battery also includes a casing; n individual cells are arranged inside the casing along a first direction; the top plate of the casing 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 casing is sealed and connected to the top cover plate of the corresponding individual cell.

[0030] Two heat exchangers are located outside the housing, and the body of each heat exchanger is connected to the part of the corresponding polarity terminal that extends out of the clearance hole.

[0031] A second aspect of the present invention provides a battery pack comprising a plurality of the above-mentioned high-capacity battery components; heat exchange components on each high-capacity battery component are interconnected to form a battery pack liquid circuit system to realize heat exchange of the battery pack.

[0032] Furthermore, the liquid inlet channels in multiple heat exchangers are connected in series to form a total liquid inlet path; the liquid outlet channels in multiple heat exchangers are connected in series to form a total liquid outlet path; the end of the total liquid inlet path is connected to the beginning of the total liquid outlet path through an external pipe section.

[0033] After the coolant enters the inlet end of the main inlet path, it flows through the inlet channel of each heat exchanger in sequence, and then through the outer pipe section, it flows through the outlet channel of each heat exchanger in sequence, and flows out from the outlet end of the main outlet path.

[0034] 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).

[0035] The beneficial effects of this invention are:

[0036] The present invention fixes a heat exchange component on the polar terminal (the polar terminal mentioned here 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, so as to achieve efficient heat dissipation.

[0037] Cooling channels are provided within the heat exchanger body for the flow of liquid cooling medium, preferably cooling water, to achieve efficient heat dissipation.

[0038] Meanwhile, to prevent the heat exchanger body from becoming conductive and potentially causing a short circuit, and to prevent the cooling water flowing in the cooling channel from becoming electrified and affecting the electrical safety of the battery system, this invention selects ceramic material as the material for the heat exchanger body. On the one hand, ceramic material has good insulation properties, which can effectively avoid the risk of short circuit caused by the heat exchanger body becoming conductive; on the other hand, it can prevent the cooling water flowing in the cooling channel from becoming electrified, thus ensuring the electrical safety of the battery system from the root.

[0039] In addition, the electrolyte and / or gas inside each individual cell are interconnected, so that the electrolyte and / or gas of all individual cells are in the same system, reducing the differences between individual cells and improving the consistency between individual cells to a certain extent, thereby improving the cycle life of the battery components to a certain extent. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the structure of the large-capacity battery module in Example 1;

[0041] Figure 2 This is a schematic diagram of the exploded structure of the large-capacity battery module in Example 1;

[0042] Figure 3 This is a schematic diagram of the heat exchanger in Example 1;

[0043] Figure 4 This is a schematic diagram of the structure of the large-capacity battery module in Example 2;

[0044] Figure 5 This is a schematic diagram of the heat exchanger structure in Example 2;

[0045] Figure 6 This is an exploded structural diagram of the heat exchanger in Example 3;

[0046] Figure 7 This is a cross-sectional view of the heat exchanger in Example 3;

[0047] Figure 8 This is a schematic diagram of the structure of the large-capacity battery module in Example 6;

[0048] Figure 9 This is a schematic diagram of the exploded structure of the large-capacity battery module in Example 6;

[0049] Figure 10 This is a cross-sectional view of the high-capacity battery assembly in Example 6;

[0050] Figure 11 This is a schematic diagram of the battery pack structure in Example 7.

[0051] The attached figures are labeled as follows:

[0052] 1. Heat exchanger; 11. Heat exchanger body; 12. Cooling channel; 121. Liquid inlet channel; 122. Liquid outlet channel; 2. High-capacity battery; 21. Single cell; 22. Polar terminal; 221. Through slot; 222. Terminal post; 223. Terminal post extension; 224. Clearance hole; 3. Flexible thermal conductive layer; 4. Metal pipe; 5. Electrical connector; 6. Outer shell; 61. Electrolyte shared chamber; 62. Gas shared chamber. Detailed Implementation

[0053] 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.

[0054] 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.

[0055] In the description of this invention, it should be noted that the terms "top" and "bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this 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. Therefore, they should not be construed as limiting this invention.

[0056] This invention provides a high-capacity battery assembly, including a high-capacity battery and a heat exchanger. The high-capacity battery is mainly composed of multiple individual cells, whose internal cavities are interconnected, and the electrolyte and / or gas are shared among the individual cells. The heat exchanger is connected to the polarity terminals of the individual cells, and the polarity terminals are cooled by liquid cooling to ensure stable battery operation.

[0057] Since the heat exchanger is directly connected to the polarity terminal, the traditional solution can use a metal heat exchanger body and set an insulation structure on the outer wall of the heat exchanger body (see Chinese patent CN221885213U) to avoid short circuit problems. However, this solution has certain drawbacks. On the one hand, the additional insulation structure makes the overall structure more complex, increasing the complexity of the production process and manufacturing costs. On the other hand, the insulation structure is at risk of aging, falling off, or wearing off. Once the insulation structure fails, the metal heat exchanger body is very likely to cause a short circuit, posing a significant safety hazard.

[0058] To address the aforementioned problems, this invention directly uses ceramic material to fabricate the heat exchanger body. Due to its inherently excellent insulating properties, ceramic material can block current conduction at its source without relying on additional insulating components, completely eliminating the risk of short circuits. Compared to traditional solutions, this invention not only significantly simplifies the structural design and reduces manufacturing difficulty, but also significantly improves insulation safety by relying on the stable and reliable insulating properties of ceramic material.

[0059] In terms of the heat dissipation structure design of the heat exchanger, the present invention provides a flow path for the liquid cooling medium by opening at least one cooling channel running through both ends along the length direction on the heat exchanger body.

[0060] In practical applications, the heat exchanger is fixed to the battery polarity terminal. When the battery generates heat during operation, the heat from the polarity terminal is conducted to the heat exchanger body in close contact. The liquid cooling medium flowing through the cooling channel completes efficient heat exchange through continuous circulation, thereby reducing the temperature of the polarity terminal and effectively preventing thermal runaway.

[0061] In the selection of liquid cooling media, water and insulating oil are the most common, relying on a circulation system to achieve heat exchange. Among them, water has significant advantages compared to liquid cooling media such as insulating oil.

[0062] Regarding cooling efficiency: the specific heat capacity of water is 4.2 × 10⁻⁶. 3The 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.

[0063] In terms of cost: insulating oil is relatively expensive; water is widely available and inexpensive.

[0064] In terms of environmental protection: Insulating oil leaks are difficult to degrade and pollute the environment; water leaks are harmless and produce no waste.

[0065] It is evident that water cooling has significant advantages over insulating oil cooling in meeting the cooling requirements of battery systems in terms of high efficiency, economy, and environmental friendliness. Therefore, this invention prioritizes water cooling.

[0066] It should be noted that:

[0067] 1. In this invention, the ceramic heat exchanger body, with its excellent electrical insulation properties, blocks the path of current conduction to the cooling water from the source, ensuring that the cooling water remains uncharged throughout the entire heat exchange process, thus providing a reliable guarantee for the safe operation of the battery system.

[0068] 2. Although this invention focuses on water cooling, it is not limited to this and does not exclude the use of non-cooling water as the liquid cooling medium.

[0069] 3. The polar terminal described in this invention can be a battery terminal post, or it can be an integral structure of a battery terminal post and a terminal post extension member connected thereto.

[0070] 4. The above-mentioned cooling channels can be two, one of which is a liquid inlet channel and the other is a liquid outlet channel; in the battery pack, multiple liquid inlet channels are connected in series to form a total liquid inlet path; multiple liquid outlet channels are connected in series to form a total liquid outlet path; the end of the total liquid inlet path is connected to the beginning of the total liquid outlet path through an external pipe section.

[0071] After the coolant enters the main inlet end of the main inlet path, it flows through one inlet channel of each heat exchanger in sequence, and then through the external pipe section, it flows through the outlet channel of each heat exchanger in sequence, and flows out from the main outlet end of the main outlet path.

[0072] 5. The aforementioned high-capacity batteries can include at least the following two types:

[0073] Type 1 high-capacity batteries:

[0074] The first type of high-capacity battery includes n individual cells arranged along a first direction, where n is an integer greater than 1; the internal cavities of the n individual cells are interconnected. Specifically, the electrolyte regions of the internal cavities of multiple individual cells can be connected based on at least one electrolyte sharing pipeline to achieve electrolyte sharing, reduce the differences between individual cells, and optimize the cycle performance of the high-capacity battery; the gas regions of the internal cavities of multiple individual cells can also be connected based on a gas sharing pipeline to achieve gas balance and further optimize the cycle performance of the high-capacity battery.

[0075] 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.

[0076] Type II high-capacity batteries:

[0077] The second type of high-capacity battery includes a casing and n individual cells; the n individual cells are arranged along the x-direction and placed inside the casing cavity.

[0078] The outer casing is equipped with an explosion vent, through which thermal runaway fumes are discharged.

[0079] This invention does not specifically limit the above-mentioned shell structure, but at least the following two structures can be adopted:

[0080] 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).

[0081] 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).

[0082] 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.

[0083] Inside the casing, the internal cavities of each individual cell are interconnected, enabling electrolyte sharing and / or gas balance, thereby reducing the differences between individual cells within the casing and improving the performance of high-capacity batteries.

[0084] The internal cavities of individual cells can usually be connected through a shared chamber located within the casing.

[0085] It should be noted that:

[0086] The aforementioned shared chamber can be an electrolyte sharing chamber, with its inner cavity connected to the inner cavities of each individual battery cell. This shared chamber ensures that each individual battery cell operates within a uniform electrolyte environment, guaranteeing electrolyte homogeneity and improving the performance and charge-discharge cycle life of the high-capacity battery. The electrolyte sharing chamber described here is a liquid channel extending along the length (x-direction) of the casing between the casing's bottom plate and each individual battery cell. This liquid channel can be integrally formed with the casing's bottom plate or formed by a support structure between the individual battery's lower cover and the casing's bottom plate. It should be noted that in the first type of casing structure, the casing's bottom plate here is the first cylindrical bottom plate; in the second type of casing structure, the casing's bottom plate here is simply the bottom plate.

[0087] The aforementioned shared chamber can also be a gas-sharing chamber located on the top plate of the outer casing, covering the gas inlets on the top of each individual battery cell.

[0088] It should be noted that in the first type of shell structure, the shell top plate here is the first cylinder top plate; in the second type of shell structure, the shell top plate here is the top plate.

[0089] It should also be noted that the gas port here has the following two meanings:

[0090] 1) The gas port is a through hole directly opened on the top cover of the single cell and penetrating the inner cavity of the single cell;

[0091] At this time, the gas-sharing chamber is connected to the gas region of each individual cell through the gas port. Based on the gas-sharing chamber, the gas regions of each individual cell can be connected to achieve gas balance, so that the gas of each individual cell is shared to ensure the consistency of each individual cell and improve the cycle life of the large-capacity battery to a certain extent. When any individual cell experiences thermal runaway, the flue gas in the inner cavity of that individual cell enters the gas-sharing chamber and is discharged through the gas-sharing chamber, improving the safety of the large-capacity battery.

[0092] 2) The gas port is a vent or explosion-proof port installed on the top cover of the individual battery, and a vent membrane is provided at the vent or explosion-proof port.

[0093] At this time, the gas sharing chamber is used as a venting channel. When the venting membrane at the gas port of any single cell is ruptured by the flue gas in the inner cavity, the inner cavity of that single cell is connected to the gas sharing chamber, and the flue gas inside is discharged through the gas sharing chamber, thereby improving the safety of the large-capacity battery.

[0094] The aforementioned shared chamber can also be a gas-liquid shared chamber. Through a gas-liquid shared chamber, each individual battery cell can be placed in a unified electrolyte environment and gas environment, which improves the performance and charge-discharge cycle life of large-capacity batteries.

[0095] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0096] Example 1

[0097] like Figure 1 and Figure 2 The diagram shows a schematic diagram and an exploded view of the large-capacity battery assembly in this embodiment, including a large-capacity battery 2 and two heat exchange components 1. The large-capacity battery 2 is the first type of large-capacity battery described above. It should be noted that the related shared piping is not shown in the diagram.

[0098] As shown in the figure, the high-capacity battery 2 in this embodiment includes 12 individual cells 21 arranged along the x-direction. In this embodiment, the individual cells 21 are prismatic cells, and the internal cavity of each individual cell 21 includes an electrolyte region and a gas region. In other embodiments, the number of individual cells 21 can be adjusted according to actual needs, and the shape of the individual cells 21 can also be adjusted according to actual needs.

[0099] Each individual cell 21 has a terminal extension 223 connected to its terminal post 222 as a polarity terminal 22.

[0100] Each pole extension 223 is provided with a heat exchanger 1 mounting structure to fix the heat exchanger 1, and heat exchange of the large-capacity battery 2 is realized based on the heat exchanger 1.

[0101] from Figure 2 As can be seen from the diagram, in this embodiment, a through groove 221 is formed on the pole extension 223 as a mounting structure for the heat exchanger 1. The through groove 221 extends along the x-direction, that is, the length direction of the through groove 221 is parallel to the x-axis. The inner cavity shape of the through groove 221 is adapted to the cross-sectional shape of the heat exchanger body 11, and it is necessary to ensure that the heat exchanger body 11 is tightly clamped in it to ensure installation stability while also ensuring the heat transfer effect between the heat exchanger 1 and the pole extension 223.

[0102] In some other embodiments, additional snap-fit ​​structures can be fixed on the pole extension 223 as mounting structures for the heat exchanger 1. However, compared to this embodiment, installing the heat exchanger 1 requires precise alignment of the snap-fit ​​structure, and often requires tools to snap the heat exchanger 1 in. Slight carelessness during this process can lead to deformation of the snap-fit ​​structure or improper installation of the heat exchanger 1. In this embodiment, the heat exchanger 1 can be initially positioned simply by placing it directly along the through groove 221, significantly reducing operational difficulty, greatly shortening installation time, and significantly improving production efficiency. From the perspective of thermal contact, due to the limitations of the snap-fit ​​structure's opening shape and installation method, gaps easily exist between the heat exchanger 1 and the pole extension 223, making it impossible to guarantee tight thermal contact. In contrast, the through groove 221 achieves large-area surface contact between the heat exchanger 1 and the pole extension 223. For example, some clip-on mounting structures only fix the heat exchanger 1 through a few contact points, limiting heat transfer to these small areas and resulting in high thermal resistance. The large-area contact of the through groove 221 allows heat to be quickly and evenly conducted from the electrode extension 223 to the heat exchanger 1, greatly improving the heat transfer rate and making the heat dissipation effect far superior to point and line contact structures, thus more effectively maintaining the appropriate operating temperature of the battery.

[0103] like Figure 3 As shown, the heat exchanger 1 in this embodiment includes a heat exchanger body 11, which is a long columnar structure. Its cross-section is usually designed as rectangular or circular, and the size can be customized according to actual needs.

[0104] Because ceramic materials have excellent electrical insulation, high temperature resistance and good thermal conductivity, this embodiment selects ceramic material as the material of the heat exchanger body 11.

[0105] A cooling channel 12 is formed on the heat exchanger body 11. The cooling channel 12 extends along the length of the heat exchanger body 11 and passes through both ends of the heat exchanger body 11, providing a path for the flow of liquid cooling medium.

[0106] Combination Figure 2 The specific installation process of the large-capacity battery assembly in this embodiment is as follows: First, each terminal extension 223 is connected to the corresponding terminal 222 of the single cell 21. After all terminal extensions 223 are fixed, the heat exchanger 1 is fixed along the x-direction into the through slots 221 of each terminal extension 223 located on the same side. Specifically, the heat exchanger body 11 is inserted into the through slots 221 of the polarity terminals 22 on the same side. Figure 2 As can be seen from the diagram, in this embodiment, two heat exchange components 1 are provided on the top of the large-capacity battery 2. The two heat exchange components 1 can be connected in series at the port of the cooling channel 12 on the same side through an external connecting pipe section; in some other embodiments, the two heat exchange components 1 can also be connected in parallel.

[0107] After the battery pack is constructed from the aforementioned high-capacity battery components, the heat exchange components 1 on each high-capacity battery component are connected in a set manner to form a battery pack cooling system, which can realize temperature control at the entire battery pack level.

[0108] Example 2

[0109] This embodiment, based on Embodiment 1, optimizes the thermal conductivity between the heat exchanger 1 and the polar terminal 22. Specifically, as follows: Figure 4 As shown, a flexible heat-conducting layer 3 is provided between the through groove 221 of each heat exchanger body 11 and the polar terminal 22.

[0110] The flexible heat-conducting layer 3 can be fixed on the inner surface of the through groove 221 of the polar terminal 22, or it can be clamped between the heat exchanger body 11 and the through groove 221 of the polar terminal 22, or it can be fixed on the outer wall of the heat exchanger body 11.

[0111] like Figure 5 As shown, this embodiment mainly takes the flexible heat-conducting layer 3 being disposed on the outer wall of the heat exchanger body 11 as an example.

[0112] The flexible thermal conductive layer 3 can adopt at least the following two structures:

[0113] First structure:

[0114] The flexible thermally conductive layer 3 is a thermally conductive adhesive layer. This adhesive layer can tightly adhere to the heat exchanger body 11 and the polar terminal 22. Unlike traditional direct solid contact methods, the thermally conductive adhesive layer can better adapt to different surface shapes and roughnesses. At the microscale, even if there are slight unevennesses on the outer wall of the heat exchanger body 11 and the inner wall of the groove of the polar terminal 22, the adhesive layer can fill these gaps through its own fluidity, forming an efficient thermal conduction path. This effectively avoids hot spots caused by local thermal resistance differences, further improving the heat dissipation efficiency of the heat exchanger 1. Secondly, the thermally conductive adhesive layer can also fix the heat exchanger 1, greatly improving the structural stability of the heat exchanger 1 on the high-capacity battery 2.

[0115] The second structure:

[0116] The flexible heat-conducting layer 3 is a flexible heat-conducting sleeve sleeved on the outer wall of the heat exchanger body 11. For example, it can be a silicone sleeve, or a silicone rubber sleeve, a polyurethane heat-conducting sleeve, etc.

[0117] Silicone rubber sleeves combine the high elasticity and good thermal conductivity of silicone rubber, maintaining stable thermal conductivity and cushioning performance in complex vibration environments; polyurethane thermally conductive sleeves, on the other hand, have high strength and wear resistance, making them suitable for scenarios with high mechanical performance requirements.

[0118] Silicone sleeves also have good elasticity and thermal conductivity. At the same time, compared with silicone rubber sleeves and polyurethane thermal conductive sleeves, their manufacturing cost is lower, which helps to control the overall production cost.

[0119] In this embodiment, a silicone sleeve is used. Based on its good elasticity, the silicone sleeve can fill the tiny gap between the heat exchanger body 11 and the through groove 221. Through its own deformation, it tightly fits the surfaces of the two, eliminating the assembly gap caused by manufacturing tolerances, thereby enhancing the stability of the connection and preventing the heat exchanger 1 and the polar terminal 22 from becoming loose due to vibration, shaking or other factors during the operation of the battery system.

[0120] Meanwhile, the silicone sleeve has certain thermal conductivity, which significantly reduces thermal resistance compared to air, allowing heat to be transferred more efficiently from the heat exchanger 1 to the polarity terminal 22, thereby improving the overall heat dissipation efficiency of the large-capacity battery 2. It is necessary to ensure that the silicone sleeve completely covers the contact area between the through-slot 221 and the heat exchanger body 11.

[0121] Meanwhile, the silicone sleeve can also wrap and protect the heat exchanger body 11 with its own elasticity, reducing the risk of the heat exchanger body 11 breaking due to external impact and ensuring the stable operation of the battery system.

[0122] As can be seen from the figure, this embodiment includes 12 silicone sleeves corresponding to 12 polarity terminals 22 on one side. The 12 silicone sleeves are spaced apart on the outer wall of the heat exchanger body 11 along its length. During installation, each silicone sleeve is tightly fitted to the groove wall of the through groove 221 on the corresponding polarity terminal 22.

[0123] In other embodiments, a single silicone sleeve can be used to completely cover the outer wall of the heat exchanger body 11, achieving the same effect of enhanced thermal conductivity and stable connection. However, compared to the 12 spaced silicone sleeves used in this embodiment, this solution requires more silicone sleeve material, leading to increased costs. In practical applications, a suitable arrangement can be flexibly selected based on cost budget and performance requirements.

[0124] Example 3

[0125] Based on the above embodiments, this embodiment optimizes the structure of heat exchanger 1 to improve the overall structural strength of heat exchanger 1.

[0126] Specifically, such as Figure 6 and Figure 7 As shown, in this embodiment, a metal pipe 4 is nested inside the cooling channel 12 of the heat exchanger body 11. Figure 6 and Figure 7Taking the addition of a metal pipe 4 to the heat exchanger 1 in Embodiment 2 as an example, in the above embodiments, although the ceramic heat exchanger body 11 has high hardness, it is relatively brittle and prone to cracking when subjected to external impact or vibration. To overcome this problem, this embodiment incorporates a metal pipe 4 within the cooling channel 12 of the heat exchanger body 11, thereby improving the mechanical strength of the ceramic heat exchanger body 11. The metal pipe 4 can be made of a material with good toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing the ceramic heat exchanger body 11 from cracking, and extending its service life.

[0127] Specifically, in this embodiment, aluminum tubing is selected as the metal pipe 4. Aluminum not only has excellent thermal conductivity but also good plasticity, making it easy to process and shape.

[0128] In some other embodiments, other metal-formed metal pipes 4 can also be selected, such as titanium alloys, nickel-based alloys, etc., to improve the mechanical strength of the ceramic heat exchanger body 11.

[0129] The other structures of the heat exchanger 1 in this embodiment are the same as those in the above embodiments, and will not be described again here.

[0130] The large-capacity battery assembly and battery pack in this embodiment are identical in structure to those in the above embodiments, except for the heat exchanger 1, and will not be described again here.

[0131] Example 4

[0132] To further enhance heat transfer efficiency, this embodiment, based on heat exchanger 1 in embodiment 3, provides a thermally conductive adhesive layer between the metal pipe 4 and the heat exchanger body 11.

[0133] This thermally conductive adhesive layer can tightly adhere to the heat exchanger body 11 and the metal pipe 4, significantly optimizing thermal conductivity. Unlike traditional direct solid-to-metal contact methods, the thermally conductive adhesive layer can better adapt to different surface shapes and roughnesses. At the microscopic scale, even if there are minute unevennesses on the inner wall of the heat exchanger body 11 and the outer wall of the metal pipe 4, the adhesive layer can fill these gaps through its own fluidity, forming an efficient thermal conduction path. This effectively avoids hotspots caused by local thermal resistance differences, further improving the heat dissipation efficiency of the heat exchanger 1. Simultaneously, the thermally conductive adhesive layer also serves to fix the metal pipe 4, greatly improving the structural stability of the heat exchanger 1. Furthermore, the thermally conductive adhesive layer has a certain degree of flexibility, which can buffer vibration stress and prevent damage to the ceramic heat exchanger body 11; its flexibility can also adapt to the thermal expansion of the components, relieving stress, ensuring a tight connection, and maintaining heat conduction efficiency.

[0134] The thermally conductive adhesive can be any commonly used thermally conductive adhesive in the battery field, such as at least one of thermally conductive silicone grease, thermally conductive epoxy resin adhesive, and thermally conductive polyurethane adhesive. Among them, the thermally conductive silicone grease has excellent thermal conductivity and insulation properties, which can effectively reduce the thermal resistance between the contact surface between the metal pipe 4 and the heat exchanger body 11; the thermally conductive epoxy resin adhesive has high bonding strength, which can effectively improve the stability of the metal pipe 4 on the heat exchanger body 11; the thermally conductive polyurethane adhesive has the advantages of good flexibility and weather resistance, making it suitable for coping with the deformation and heat dissipation requirements of the battery in different environments.

[0135] The thickness of the thermally conductive adhesive layer is generally controlled between 0.01-1mm. If the thickness is too thin, it may not be able to fully fill the gap between the metal pipe 4 and the heat exchanger body 11, affecting heat conduction and insulation. If the thickness is too thick, it will increase thermal resistance, reduce heat transfer efficiency, and may also affect installation accuracy and stability.

[0136] The other structures of the heat exchanger 1 in this embodiment are the same as those in the above embodiments, and will not be described again here.

[0137] The large-capacity battery assembly and battery pack in this embodiment are identical in structure to those in the above embodiments, except for the heat exchanger 1, and will not be described again here.

[0138] Example 5

[0139] Unlike Embodiment 4, in this embodiment, the metal pipe and the heat exchanger body are integrated as a single unit. Compared to the separate structure in Embodiment 4, the integrated design completely eliminates the assembly gap between the metal pipe and the heat exchanger body, thus avoiding the air insulation layer caused by the gap. This gapless characteristic allows heat to be conducted more directly and efficiently between the metal and ceramic, significantly improving heat dissipation efficiency. Simultaneously, the integrated structure reduces the number of component assembly steps, effectively reducing the risk of performance loss due to assembly errors. During long-term use, the metal pipe and ceramic body will not loosen due to vibration or other factors, fully ensuring the reliability and stability of the heat exchanger. Furthermore, the integrated structure avoids the use of thermally conductive adhesive layers, eliminating the thermal resistance and aging problems that adhesive layers may cause. Compared to the adhesive layer solution in Embodiment 4, this design significantly improves both heat dissipation performance and structural stability.

[0140] Specifically, this embodiment can be implemented through the following three processes:

[0141] Ceramic-coated metal pipe process: A metal pipe (preferably an aluminum metal pipe) is placed in a mold cavity, and liquid ceramic raw material is injected into the mold cavity to cover the outer wall of the metal pipe. After the ceramic raw material solidifies, a ceramic pipe (heat exchanger body) is formed on the outer wall of the metal pipe.

[0142] Injection molding process for aluminum inner wall of ceramic tube: A pre-formed ceramic tube (heat exchanger body) is then injected into the inner wall of the ceramic tube using injection molding equipment. After the metal cools and solidifies, a metal pipe is formed on the inner wall of the ceramic tube, creating an integrated structure.

[0143] The process of firing ceramic tubes on metal pipes: First, prepare a metal pipe (preferably an aluminum metal pipe) as the inner core, then coat the outside of the metal pipe with ceramic slurry, and after sintering, form a tightly bonded ceramic tube on the outside of the metal pipe.

[0144] Example 6

[0145] like Figures 8 to 10 As shown, this is a high-capacity battery module in this embodiment. Its structure differs from that of the high-capacity battery module in the above embodiment in that the high-capacity battery 2 is the second type of high-capacity battery mentioned above.

[0146] In this embodiment, the second type of high-capacity battery arranges 12 individual cells 21 in the inner cavity of the outer casing 6. Each terminal extension 223 passes through the clearance hole 224 and connects to the corresponding terminal 222. The part of the terminal extension 223 with the through groove 221 is located outside the outer casing 6. A heat exchanger 1 is fixed on the through groove 221 of the terminal extension 223 with the same polarity on the same side. The structure of the heat exchanger 1, the structure of the terminal extension 223, and the installation structure between the terminal extension 223 and the heat exchanger 1 are the same as in the above embodiment, and will not be described again here.

[0147] It should be noted that, in this embodiment, the pole extension 223 and the top plate of the outer casing 6 maintain a safe electrical conductivity distance.

[0148] A support extending in the x-direction is provided between the bottom plate of the outer casing 6 and each individual battery cell 21 to form a liquid channel, serving as an electrolyte sharing chamber 61.

[0149] The top plate of the outer casing 6 may also be provided with a boss extending in the x direction, and a gas channel is opened on the boss, which serves as a gas sharing chamber 62.

[0150] Example 7

[0151] The heat exchanger 1 in this embodiment differs from the one described above in that the heat exchanger body 11 in this embodiment has two cooling channels 12, which are isolated from each other. The rest of the structure of the heat exchanger 1 is the same as that in the above embodiment, and will not be described again here.

[0152] The only difference between the large-capacity battery assembly adapted to the heat exchanger 1 described above and the one described in the above embodiment is the heat exchanger 1; the rest of the structure is the same and will not be described again here.

[0153] like Figure 11The diagram shows the structure of the battery pack in this embodiment. The battery pack includes three high-capacity battery modules arranged along the y-direction. In practical applications, the number of high-capacity battery modules can be flexibly adjusted according to specific needs.

[0154] In this embodiment, for ease of description, the two cooling channels 12 on each heat exchanger 1 are defined as the liquid inlet channel 121 and the liquid outlet channel 122, respectively. The liquid inlet channels 121 of the three large-capacity battery modules are connected end to end in sequence to form a total liquid inlet path; and the liquid outlet channels 122 are also connected in series in sequence to form a total liquid outlet path. The end of the total liquid inlet path is connected to the beginning of the total liquid outlet path through an external pipe section, thus constructing a complete cooling circulation loop.

[0155] The specific cooling process is as follows: the liquid cooling medium enters from the inlet end of the main inlet path, flows sequentially through the inlet channel 121 of each heat exchanger 1, then changes direction at the outer pipe section, and then flows sequentially through the outlet channel 122 of each heat exchanger 1, finally flowing out from the outlet end of the main outlet path. Inside a single heat exchanger 1, the coolant achieves efficient heat exchange through adjacent inlet channels 121 and outlet channels 122, ensuring that each polarity terminal 22 receives uniform heat dissipation. For all heat exchangers 1 in the entire battery pack, the temperature difference between the inlet channel 121 and outlet channel 122 remains stable, effectively overcoming the problem of local overheating or overcooling at both ends of the battery pack caused by the gradual temperature rise of the coolant during flow in traditional series cooling methods.

[0156] exist Figure 11 In the process, electrical connectors 5 are used to achieve parallel connection between individual cells 21, while also applying pressure to the heat exchanger 1 to ensure full contact between the heat exchanger 1 and the polar terminal 22, thereby further improving the heat exchange effect of the heat exchanger 1.

Claims

1. A high-capacity battery module, characterized in that: Includes a large-capacity battery and two heat exchangers; The high-capacity battery includes n individual cells arranged along a first direction; the internal cavities of the n individual cells are interconnected, and the electrolyte and / or gas are shared among the individual cells; where n is an integer greater than 1. The heat exchanger includes a heat exchanger body; the heat exchanger body is made of ceramic material and has at least one cooling channel, which extends along the length of the heat exchanger body and passes through both ends of the heat exchanger body. Two heat exchange components are parallel to each other and both extend along a first direction; the heat exchange component body of one heat exchange component is connected to one polarity terminal of n individual cells, and the heat exchange component body of the other heat exchange component is connected to the other polarity terminal of n individual cells.

2. The high-capacity battery module according to claim 1, characterized in that: A through slot extending in the first direction is formed on the polar terminal; In one heat exchanger, the heat exchanger body is fitted into a through slot with n positive terminals on one side; in the other heat exchanger, the heat exchanger body is fitted into a through slot with n negative terminals on the other side.

3. The high-capacity battery module according to claim 2, characterized in that: A flexible heat-conducting layer is provided between the heat exchanger body and the through groove of the polar terminal.

4. The high-capacity battery module according to claim 3, characterized in that: The flexible heat-conducting layer is a silicone sleeve fitted on the outer wall of the heat exchanger body; there are n silicone sleeves, which are spaced apart along the length of the heat exchanger body on the outer wall of the heat exchanger body.

5. The high-capacity battery module according to any one of claims 1 to 4, characterized in that: The heat exchanger also includes a metal pipe; the metal pipe is nested into the cooling channel along the length of the cooling channel.

6. The high-capacity battery module according to claim 5, characterized in that: The metal pipe is an aluminum pipe.

7. The high-capacity battery module according to claim 5, characterized in that: A thermally conductive adhesive layer is provided between the contact surfaces of the outer wall of the metal pipe and the inner wall of the cooling channel.

8. The high-capacity battery module according to claim 5, characterized in that: The metal pipe and the heat exchanger body are an integral part.

9. The high-capacity battery module according to claim 1, characterized in that: The cooling channel consists of two isolated channels; one channel is the liquid inlet channel, and the other is the liquid outlet channel.

10. The high-capacity battery module according to claim 1, characterized in that: The high-capacity battery also includes a casing; n individual cells are arranged in the casing along a first direction; the top plate of the casing 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 casing is sealed to the top cover plate of the corresponding individual cell. Two heat exchangers are located outside the housing, and the body of each heat exchanger is connected to the part of the corresponding polarity terminal that extends out of the clearance hole.

11. A battery pack, characterized in that: It includes a plurality of large-capacity battery components as described in any one of claims 1 to 10; the heat exchange components on each large-capacity battery component are interconnected to form a battery pack liquid circuit system to realize battery pack heat exchange.

12. The battery pack according to claim 11, characterized in that: The liquid inlet channels of multiple heat exchangers are connected in series to form a total liquid inlet path; the liquid outlet channels of multiple heat exchangers are connected in series to form a total liquid outlet path; the end of the total liquid inlet path is connected to the beginning of the total liquid outlet path through an external pipe section. After the coolant enters the inlet end of the main inlet path, it flows through the inlet channel of each heat exchanger in sequence, and then through the outer pipe section, it flows through the outlet channel of each heat exchanger in sequence, and flows out from the outlet end of the main outlet path.

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