Double-deck module battery pack

Abstract

This application relates to a dual-layer module battery pack, including a housing assembly and a support assembly. The housing assembly has a lower receiving cavity and a lower exhaust cavity that are interconnected. The lower receiving cavity is provided with a middle crossbeam, which divides the lower receiving cavity into two independent lower receiving areas. Each lower receiving area accommodates a set of lower battery modules. The bottom wall of the lower exhaust cavity has a lower exhaust port. The support assembly is stacked on top of the housing assembly and has an upper receiving cavity and an upper exhaust cavity that are interconnected. The upper receiving cavity accommodates the upper battery modules. The middle crossbeam has a main exhaust channel, and the upper exhaust cavity is connected to the lower exhaust cavity through the main exhaust channel, which realizes a functionally compatible design. It eliminates the need for additional independent exhaust pipes, thereby making the internal structure of the dual-layer module battery pack more compact, greatly improving the volume utilization rate, and significantly reducing the weight. It also greatly reduces the number of sealing connection points, resulting in a significant improvement in sealing reliability.

Description

Technical Field

[0001] This application relates to the field of power battery technology for electric aircraft or electric vehicles, and in particular to a dual-layer module battery pack. Background Technology

[0002] With the rapid development of electric aviation technology and the new energy vehicle industry, increasingly higher requirements are being placed on the energy density, space utilization, and safety performance of dual-layer module battery packs. To accommodate more cells within the limited space of a vehicle body or fuselage, dual-layer module stacking has become a common design solution for dual-layer module battery packs. In this design, when a cell experiences thermal runaway, the resulting high-temperature, high-pressure gas needs to be rapidly and safely expelled from the dual-layer module battery pack to prevent chain reactions or explosions. Therefore, the design of the exhaust system is one of the core aspects of dual-layer module battery pack safety technology.

[0003] In existing dual-layer module battery pack designs, the upper and lower battery modules typically have independent venting channels and outlets, which are unrelated to each other. These venting channels often employ external or independent bracket designs, requiring additional installation and clearance space within the dual-layer module battery pack. While this independent channel, externally integrated design can meet basic venting needs, it suffers from bulky structures, low space utilization, and numerous sealing points, becoming a bottleneck restricting the improvement of energy density and reliability of dual-layer module battery packs. Summary of the Invention

[0004] Based on this, the purpose of this application is to provide a dual-layer module battery pack to solve the technical problems of complex structure and low space utilization caused by the independent exhaust channels of the upper and lower battery modules in the prior art.

[0005] According to one aspect of this application, a dual-layer module battery pack is provided, comprising:

[0006] The housing assembly has an interconnected lower receiving cavity and a lower exhaust cavity. The lower receiving cavity is provided with a middle crossbeam, which divides the lower receiving cavity into two independent lower receiving areas. Each lower receiving area accommodates a set of lower battery modules. The bottom wall of the lower exhaust cavity is provided with a lower exhaust port.

[0007] A support assembly is stacked on top of the housing assembly. The support assembly has an upper receiving cavity and an upper exhaust cavity that are interconnected. The upper receiving cavity contains the upper battery module. An exhaust main channel is formed in the middle crossbeam. One end of the exhaust main channel has an upper opening. The bottom wall of the upper exhaust cavity has an upper exhaust port that is coaxially arranged with the upper opening of the main channel. The upper exhaust cavity is connected to the exhaust main channel through the upper exhaust port and the upper opening of the main channel. The opposite end of the exhaust main channel has a lower opening. The lower exhaust cavity is connected to the exhaust main channel through the lower opening of the main channel.

[0008] In one embodiment, the inner diameter of the exhaust main channel gradually increases in the direction from the upper opening of the main channel to the lower opening of the main channel;

[0009] And / or, in the direction from the upper opening of the main channel to the lower opening of the main channel, the dimension between the two sides of the intermediate crossbeam gradually increases.

[0010] In one embodiment, the bottom wall of the upper receiving cavity is provided with a plurality of first through holes, and the upper receiving cavity is connected to the upper exhaust cavity through the plurality of first through holes; the bottom of the upper battery module is provided with a plurality of first explosion-proof valves, and the plurality of first explosion-proof valves correspond one-to-one with the plurality of first through holes; the opening size of the upper opening of the main channel and the lower opening of the main channel are both larger than the diameter of a single first through hole.

[0011] And / or, each of the lower receiving areas has a plurality of second through holes on its bottom wall, and the lower receiving area is connected to the lower exhaust chamber through the plurality of second through holes; each group of lower battery modules has a plurality of second explosion-proof valves at its bottom, and the plurality of second explosion-proof valves correspond one-to-one with the plurality of second through holes.

[0012] In one embodiment, the inner wall of the main exhaust channel is coated with an aerogel insulation layer.

[0013] In one embodiment, the lower exhaust chamber is provided with at least two spaced partitions, all of which divide the lower exhaust chamber into a gas buffer zone and several gas flow zones. The gas buffer zone is located below the lower receiving chamber and is connected to the lower receiving chamber through the lower opening of the main channel. Each partition is provided with a vent hole so that every two adjacent gas flow zones are connected to each other through the vent hole.

[0014] In all the gas flow zones, the gas flow zone closer to the gas buffer zone along the spacing direction of all the partitions is connected to the gas buffer zone through the vent hole opened in one of the partitions, and the gas flow zone farther away from the gas buffer zone is connected to the external environment through the lower exhaust port; the vent holes opened in each pair of adjacent partitions are staggered along the spacing direction of all the partitions, so that the gas can flow in a bend along each gas flow zone in sequence.

[0015] In one embodiment, each partition has multiple vent holes, and the multiple vent holes in each partition are arranged in a matrix at intervals.

[0016] In one embodiment, the support assembly includes a bracket and a bracket cover plate detachably connected to the lower periphery of the bracket, the upper receiving cavity is surrounded by the bracket, and the upper venting cavity is formed by the surface of the bracket facing the bracket cover plate and the surface of the bracket cover plate facing the bracket.

[0017] In one embodiment, the upper receiving cavity includes two upper receiving areas, each of which receives a set of upper battery modules. The bracket includes two spaced-apart sub-brackets and a bracket middle portion located between the two sub-brackets and integrally connected to the two sub-brackets. Each upper receiving area is surrounded by one of the sub-brackets.

[0018] The bracket cover plate includes two spaced-apart sub-bracket cover plates and a cover plate middle portion located between the two sub-bracket cover plates and integrally connected to the two sub-bracket cover plates. The cover plate middle portion is located below the middle portion of the bracket and overlaps the middle crossbeam. The upper exhaust port passes through the cover plate middle portion. The two sub-bracket cover plates are respectively located below the two sub-brackets.

[0019] In one embodiment, the sidewall of the lower receiving cavity is provided with multiple spaced connecting columns, the periphery of the support assembly overlaps with the multiple connecting columns, each of the sub-support covers is respectively accommodated in a corresponding lower receiving area, the middle crossbeam is provided with a groove, the opening of the main channel is opened on the bottom wall of the groove, and the middle part of the support is embedded in the groove.

[0020] In one embodiment, the housing assembly includes a housing and a bottom guard plate detachably connected to the lower perimeter of the housing, the housing forming the lower receiving cavity and having the intermediate crossbeam, the intermediate crossbeam being integrally connected to the rest of the housing; the lower exhaust cavity is formed by the surface of the housing facing the bottom guard plate and the surface of the bottom guard plate facing the housing, and the lower exhaust port is opened on the bottom guard plate.

[0021] The aforementioned dual-layer module battery pack, on the one hand, integrates the main exhaust channel connecting the upper and lower exhaust chambers into the middle crossbeam of the housing. The gas in the upper exhaust chamber can only reach the lower exhaust chamber through the main exhaust channel and then be discharged from the lower exhaust port together with the gas in the lower exhaust chamber. This achieves a functionally compatible design, eliminating the need for additional independent exhaust pipes. As a result, the internal structure of the dual-layer module battery pack is more compact, and the volume utilization rate is greatly improved.

[0022] On the other hand, by eliminating the independent exhaust brackets, multiple exhaust ports, and a large number of redundant seals for the upper and lower battery modules in the traditional solution, the weight of the double-layer module battery pack in this application is greatly reduced, and the number of sealing connection points is greatly reduced, which greatly improves the sealing reliability and significantly enhances the service life and reliability of the battery pack.

[0023] On the other hand, the upper exhaust chamber of the support component is connected to the lower exhaust chamber of the housing, which creates a larger gas release space inside the entire double-layer module battery pack. This effectively reduces the peak pressure of thermal runaway gas, avoids sealing failure or structural damage caused by excessive local pressure, and improves exhaust safety and reliability. Attached Figure Description

[0024] Figure 1 This is an exploded view of a dual-layer module battery pack provided in an embodiment of this application.

[0025] Figure 2 This is a cross-sectional view of a dual-layer module battery pack provided in an embodiment of this application.

[0026] Figure 3 This is a perspective cross-sectional view of a support component in a dual-layer module battery pack provided in an embodiment of this application.

[0027] Figure 4 A perspective cross-sectional view of the housing assembly in a dual-layer module battery pack provided in an embodiment of this application. Figure 1 .

[0028] Figure 5 A perspective cross-sectional view of the housing assembly in a dual-layer module battery pack provided in an embodiment of this application. Figure 2 .

[0029] Figure 6 for Figure 4 An enlarged schematic diagram of region A in the middle.

[0030] Figure 7 This is a perspective view of a support component in a dual-layer module battery pack provided in an embodiment of this application.

[0031] Figure 8 This is a schematic diagram of the structure of the bottom protective plate in a support component provided in an embodiment of this application.

[0032] Figure 9 for Figure 8 Enlarged schematic diagram of region B in the middle.

[0033] Explanation of reference numerals in the attached figures:

[0034] 10. Double-layer module battery pack; 100. Housing assembly; 101. Lower receiving cavity; 101a. Lower receiving area; 102. Lower exhaust cavity; 103. Lower exhaust port; 104. Gas buffer area; 105. Gas flow area; 110. Housing; 110a. Second through hole; 111. Connecting post; 120. Bottom guard plate; 130. Intermediate crossbeam; 131. Main exhaust channel; 131a. Upper opening of main channel; 131b. Lower opening of main channel; 132. Groove; 140. Partition; 141. Vent hole; 200. Support assembly; 201. Upper receiving cavity; 201a. Upper receiving area; 202. Upper exhaust cavity; 203. Upper exhaust port; 210. Bracket; 210a. First through hole; 211. Sub-bracket; 212. Middle part of bracket; 220. Bracket cover plate; 221. Sub-bracket cover plate; 222. Middle part of cover plate; 300. Upper battery module; 400. Lower battery module. Detailed Implementation

[0035] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0036] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application 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 this application.

[0037] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0038] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0039] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0040] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0041] This application provides a dual-layer module battery pack, which is applied in the fields of electric aviation or electric vehicles to provide power for vehicles such as electric aircraft or electric vehicles.

[0042] The structure of the dual-layer module battery pack is described below. It is understood that, in other embodiments, the dual-layer module battery pack of this application is not limited to the electric aviation or electric vehicle fields, but can also be used in any electrical device, and is not limited herein.

[0043] See Figure 1 and Figure 2 , Figure 1 An exploded view of a dual-layer module battery pack 10 provided in an embodiment of this application is shown. Figure 2 This is a cross-sectional view of the internal structure of the dual-layer module battery pack 10 provided in this embodiment. The dual-layer module battery pack 10 provided in one embodiment of this application includes a housing assembly 100 and a support assembly 200. The housing assembly 100 is located below the entire dual-layer module battery pack 10, serving as the load-bearing structure for supporting and fixing the lower battery module 400. The support assembly 200 is stacked on top of the housing assembly 100, supporting and fixing the upper battery module 300. Both the upper battery module 300 and the lower battery module 400 each include multiple cells arranged in a matrix for storing electrical energy.

[0044] As described in the background section, in some extreme cases, when a battery cell experiences thermal runaway, the high-temperature, high-pressure gas it generates needs to be rapidly and safely discharged from the outside of the double-layer module battery pack 10 to prevent a chain reaction or explosion. Therefore, in the embodiments of this application, both the housing assembly 100 and the support assembly 200 are designed with exhaust channels connected to the external environment to discharge the high-temperature, high-pressure gas to the external environment.

[0045] Specifically, such as Figure 2As shown, the support assembly 200 has an upper receiving cavity 201 and an upper exhaust cavity 202 that are interconnected. The upper battery module 300 is disposed in the upper receiving cavity 201, and the upper exhaust cavity 202 constitutes an exhaust channel in the support assembly 200. The housing assembly 100 has a lower receiving cavity 101 and a lower exhaust cavity 102 that are interconnected. The lower battery module 400 is disposed in the lower receiving cavity 101, and the lower exhaust cavity 102 is connected to the external environment through a lower exhaust port 103 opened on the bottom wall of the lower exhaust cavity 102, thus constituting an exhaust channel in the housing assembly 100. Meanwhile, the lower housing assembly 100 is also provided with an exhaust main channel 131. The upper exhaust chamber 202 is connected to the lower exhaust chamber 102 through the exhaust main channel 131. This allows the high-temperature and high-pressure gas generated by the failure of the upper battery module 300 to enter the upper exhaust chamber 202 and then enter the lower exhaust chamber 102 through the exhaust main channel 131. Together with the high-temperature and high-pressure gas generated when the lower battery module 400 undergoes thermal runaway and enters the lower exhaust chamber 102, it is discharged through the lower exhaust port 103. This integrated design with the upper and lower layers and interconnected exhaust paths eliminates the need for additional exhaust pipes to connect the support assembly 200 and the housing assembly 100, ensuring efficient and safe exhaust function within a limited space.

[0046] It should be noted that the lower exhaust port 103 can only exhaust in one direction, that is, it can only allow the high-pressure gas in the lower exhaust chamber 102 to be discharged to the outside of the battery pack, while the air outside the battery pack cannot enter the lower exhaust chamber 102. This can prevent moisture or impurities from the outside air from entering the battery pack.

[0047] More specifically, see Figure 3 In the structure of the support assembly 200, the support assembly 200 includes a bracket 210 and a bracket cover plate 220. The bracket cover plate 220 is detachably connected to the lower perimeter of the bracket 210 by means of bolts, riveting, or adhesive. As shown in the figure, the upper receiving cavity 201 is surrounded by the bracket 210. The side of the bracket cover plate 220 facing the bracket 210 is concave. Its surface facing the bracket 210 and the surface of the bracket 210 facing the bracket cover plate 220 (i.e., the outer surface of the bottom wall of the bracket 210) form the upper exhaust cavity 202. In other words, the upper exhaust cavity 202 is a sandwich space, making the upper exhaust cavity 202 a relatively closed flat space. The advantages of this design are: firstly, the bottom wall of the bracket 210 can be designed to be thinner or have reinforcing ribs to reduce weight; secondly, when it is necessary to clean or maintain the upper exhaust cavity 202, only the bracket cover plate 220 needs to be removed, which is very convenient.

[0048] Meanwhile, the bracket cover plate 220 has an upper exhaust port 203 that connects to the main exhaust channel 131, allowing the upper exhaust chamber 202 to connect to the main exhaust channel 131 via the upper exhaust port 203. The upper exhaust chamber 202 is connected to the upper receiving chamber 201 by having multiple first through holes 210a on the bottom wall of the upper receiving chamber 201 (i.e., the bottom wall of the bracket 210). The positions of these first through holes 210a correspond one-to-one with the positions of multiple first explosion-proof valves at the bottom of the upper battery module 300 housed in the upper receiving chamber 201. In this way, when a cell in the upper battery module 300 experiences thermal runaway, and its first explosion-proof valve opens, it can ensure that the high-temperature gas generated during the thermal runaway of the cell can enter the lower upper exhaust chamber 202 through the multiple first through holes 210a with the shortest path and least resistance, avoiding the accumulation of gas inside the module and preventing a more serious chain reaction.

[0049] See Figure 4 and Figure 5 In terms of the specific structure of the housing assembly 100, the housing assembly 100 includes a housing 110 and a bottom protective plate 120. As can be seen from the figure, the housing 110 is a deep groove-shaped component with four side walls and a bottom wall, which encloses a lower receiving cavity 101. The lower battery module 400 is disposed in the lower receiving cavity 101. The lower receiving cavity 101 has a middle crossbeam 130, which divides the lower receiving cavity 101 into two independent lower receiving areas 101a. Each lower receiving area 101a contains a set of lower battery modules 400. This separation design helps to improve the overall structural rigidity of the battery pack and plays a role in lateral positioning and isolation of the lower battery modules 400, preventing the failure of the lower battery module 400 located in one lower receiving area 101a from spreading too quickly to the lower battery module 400 located in the other lower receiving area 101a.

[0050] Optionally, the intermediate crossbeam 130 is integrally formed with the rest of the housing 110, for example by large-scale casting or welding. The integral design ensures the structural strength and rigidity of the intermediate crossbeam 130, which can reliably support the support assembly 200 located above.

[0051] The lower exhaust chamber 102 is formed in a similar manner to the upper exhaust chamber 202, consisting of the housing 110 and the bottom protective plate 120. Specifically, the bottom protective plate 120 is also a sheet material, detachably connected to the four edges of the housing 110. The side of the bottom protective plate 120 facing the housing 110 and the side of the housing 110 facing the bottom protective plate 120 (i.e., the outer surface of the bottom wall of the housing 110) together form a relatively closed and flat lower exhaust chamber 102. The lower exhaust port 103 is opened on the bottom protective plate 120 and penetrates through it. Similar to the bracket 210 of the support assembly 200, each lower receiving area 101a has multiple second through holes 110a on its bottom wall. The positions of these second through holes 110a correspond one-to-one with the positions of multiple second explosion-proof valves at the bottom of the lower battery module 400 contained therein. In this way, if a cell in the lower battery module 400 experiences thermal runaway, when its second explosion-proof valve opens, the high-temperature gas can first enter the lower exhaust chamber 102 through the second through hole 110a.

[0052] It is worth noting that this application features a special design for the intermediate crossbeam 130, which differs from conventional solid or simply hollow crossbeams, such as... Figure 6 As shown, the intermediate crossbeam 130 of this application has a cavity with a certain cross-sectional size that extends along its height. This cavity is the exhaust main channel 131 mentioned above, which is the only channel connecting the upper exhaust chamber 202 and the lower exhaust chamber 102. Specifically, an opening, namely the upper opening 131a of the main channel, is opened at the top of the intermediate crossbeam 130 (on the side facing the support assembly 200). The upper opening 131a of the main channel is coaxially arranged with the upper exhaust port 203. Another opening, namely the lower opening 131b of the main channel, is opened at the bottom of the intermediate crossbeam 130 (on the side near the bottom of the housing 110). The upper exhaust chamber 202 is connected to the exhaust main channel 131 in sequence through the upper exhaust port 203 and the upper opening 131a of the main channel, and the lower exhaust chamber 102 is connected to the exhaust main channel 131 through the lower opening 131b of the main channel.

[0053] Thus, as Figure 2 As indicated by the dotted line with arrows, the gas in the upper exhaust chamber 202 sequentially enters the main exhaust channel 131 through the upper exhaust port 203 and the upper opening 131a of the main channel, and then enters the lower exhaust chamber 102 and is discharged to the outside of the battery pack through the lower exhaust port 103. At the same time, the gas discharged from the lower battery module 400 enters the lower exhaust chamber 102 through the second through hole 110a on the bottom wall of the lower receiving area 101a, and can also be discharged to the outside of the battery pack through the lower exhaust port 103.

[0054] Thus, the entire battery pack forms two complete through paths that eventually converge. This design cleverly utilizes the internal space of the intermediate crossbeam 130, which was originally a structural component, eliminating the need for independent external exhaust brackets and multiple exhaust ports. This eliminates the need to occupy valuable internal space of the battery pack for exhaust channels, greatly improving the volume utilization rate of the battery pack. It effectively solves the problem of low space utilization rate of battery packs mentioned in the background technology and achieves significant weight reduction of the battery pack.

[0055] To further improve exhaust efficiency and reduce gas flow resistance, based on the above embodiment, the upper opening 131a of the autonomous channel points in the direction of the lower opening 131b of the main channel (i.e., from top to bottom), and the inner diameter of the main exhaust channel 131 gradually increases. In other words, the cross-section of the main exhaust channel 131 gradually increases from top to bottom, forming a trapezoidal or trumpet-shaped channel. This design has significant hydrodynamic advantages: when thermal runaway gas enters from the smaller upper opening and then flows downward along the channel, as the inner diameter of the channel gradually increases, the gas velocity gradually decreases, and the pressure is effectively released, thereby preventing the gas from impacting the exhaust port and downstream sealing structure at extremely high speed and pressure, reducing the risk of the sealing structure bursting. At the same time, this variable diameter design also allows the upper part of the main exhaust channel 131 to accommodate a smaller upper exhaust port 203 size, while the lower part can quickly diffuse the gas to a larger lower exhaust chamber 102 or exhaust port, improving the smoothness of exhaust.

[0056] Accordingly, to ensure the structural strength of the intermediate crossbeam 130 and accommodate the variable diameter design of the main exhaust channel 131, the opening 131a of the main exhaust channel points in the direction of the lower opening 131b of the main exhaust channel. The dimensions between the two sides of the intermediate crossbeam 130 also gradually increase, meaning the overall cross-section of the intermediate crossbeam 130 is narrower at the top and wider at the bottom. This allows the intermediate crossbeam 130 to accommodate the variable diameter main exhaust channel 131 while maintaining sufficient mechanical strength to support the weight of the upper support assembly 200 and the upper battery module 300, and also to resist internal pressure shocks during thermal runaway.

[0057] Considering the extremely high temperature of the thermal runaway gas (reaching hundreds or even thousands of degrees Celsius), if the high-temperature gas directly contacts the intermediate crossbeam 130, it may lead to a decrease in the structural strength of the crossbeam, or even conduct heat to adjacent battery cells, causing thermal runaway to spread. Therefore, in this embodiment, the inner wall of the main exhaust channel 131 is coated with an aerogel insulation layer. Aerogel is a nanoporous material with extremely low thermal conductivity, which can efficiently isolate heat transfer.

[0058] By coating the inner wall of the main exhaust channel 131 with an aerogel insulation layer, on the one hand, the aerogel insulation layer can effectively block the heat of the high-temperature gas from being conducted to the middle crossbeam 130 and to the surrounding modules through the crossbeam, significantly reducing the risk of thermal runaway propagation; on the other hand, the smooth surface of the aerogel insulation layer can also reduce the frictional resistance of gas flow, further improving exhaust efficiency; at the same time, the coating also has certain high temperature resistance and corrosion resistance properties, which can protect the structural integrity of the main exhaust channel 131.

[0059] Furthermore, this application also optimizes the structural design of the bracket 210 and bracket cover 220 of the support assembly 200. Specifically, as... Figure 3 As shown, the upper receiving cavity 201 includes two independent upper receiving areas 201a, each of which accommodates a set of upper battery packs (one set on the left and one set on the right in the figure). Correspondingly, the bracket 210 includes two spaced-apart sub-brackets 211 and a bracket intermediate portion 212 located between the two sub-brackets 211. The bracket intermediate portion 212 integrally connects the two sub-brackets 211 to form a whole. Each sub-bracket 211 encloses an upper receiving area 201a, making the bracket 210 approximately "I" or "H" shaped.

[0060] Similarly, as Figure 7 As shown, the bracket cover 220 also includes two spaced-apart sub-bracket covers 221 and a cover middle portion 222 located between the two sub-bracket covers 221. The cover middle portion 222 integrally connects the two sub-bracket covers 221, making the bracket cover 220 roughly "I" or "H" shaped. After installation, the cover middle portion 222 is located directly below the bracket middle portion 212 and directly overlaps the upper surface of the middle crossbeam 130 of the housing assembly 100. The upper exhaust port 203 is not opened on the sub-bracket covers 221, but penetrates through the cover middle portion 222. This means that the gas discharged from the thermal runaway of the two upper battery modules 300 will be collected through the first through hole 210a below them and gathered at the upper exhaust port 203 of the cover middle portion 222, and then enter the exhaust main channel 131 of the middle crossbeam 130. Furthermore, two sub-support covers 221 are respectively located below the two sub-supports 211, so that the upper exhaust chamber 202 includes the left and right sides. By designing the support assembly 200 into this integrated symmetrical structure, the support assembly 200 can stably support the two upper battery modules 300 simultaneously, and efficiently converge the exhaust from both to a single exhaust port in the middle, further simplifying the structure and realizing synchronous exhaust processing of the left and right upper battery modules 300.

[0061] Furthermore, to ensure the stability and sealing of the entire battery pack, good sealing is required between the support assembly 200 and the housing assembly 100, between the bracket 210 and the bracket cover 220 in the support assembly 200, and between the housing 110 and the bottom protective plate 120 in the housing assembly 100. Specifically, in the sealing structure between the support assembly 200 and the housing assembly 100, multiple spaced connecting posts are provided on the side wall of the lower receiving cavity 101 of the housing assembly 100. These connecting posts extend upwards, with their tops at the same height, forming a support plane. The support assembly 200 is placed entirely within the housing assembly 100, with its four edges overlapping the tops of these connecting posts and secured by bolts or similar means. This multi-point support connection method ensures the installation flatness and load-bearing stability of the support assembly 200.

[0062] Furthermore, in order to accurately install and utilize the supporting effect of the intermediate crossbeam 130, each sub-support cover plate 221 is not suspended, but extends downward and is accommodated in a corresponding lower accommodating area 101a. In other words, the left sub-support cover plate 221 extends into the left lower accommodating area 101a, and the right sub-support cover plate 221 extends into the right lower accommodating area 101a. This nested design increases the compactness of the structure.

[0063] Most importantly, the top of the intermediate crossbeam 130 is not flat, but has a downwardly recessed groove 132. The main channel opening 131a is located on the bottom wall of this groove 132. Correspondingly, the middle part 212 of the bracket does not simply rest on the intermediate crossbeam 130, but is precisely embedded in this groove 132. This positioning method has extremely high assembly precision, ensuring that the upper exhaust port 203 and the main channel opening 131a automatically maintain coaxial alignment during installation without complex adjustments. At the same time, the side wall of the groove 132 also provides lateral restraint, preventing the support assembly 200 from shifting in the horizontal direction, thereby achieving quick, accurate positioning and stable connection between the support assembly 200 and the housing assembly 100, while ensuring the sealing of the exhaust channel, improving assembly efficiency and reliability.

[0064] For the sealing of the support assembly 200 itself, the connection between the bracket 210 and the bracket cover plate 220 (i.e., the four edges) adopts a sealing method of applying glue and riveting or bolting to ensure that the upper exhaust chamber 202 has no other leakage points except for the designed upper exhaust port 203 and the first through hole 210a; similarly, for the sealing of the housing assembly 100 itself, the connection between the housing 110 and the bottom guard plate 120 also adopts a sealing method of applying glue and riveting or bolting to ensure the sealing of the lower exhaust chamber 102; between the support assembly 200 and the housing assembly 100, especially at the mating point between the middle part 222 of the cover plate and the groove 132 of the middle crossbeam 130, a special sealing gasket or sealant is provided to ensure the airtightness of the connection between the upper exhaust port 203 and the upper opening 131a of the main channel. Through these designs, the sealing points along the entire exhaust path are limited to a few core sealing locations, such as the sealing of the support component 200 itself, the sealing between the support component 200 and the upper surface of the crossbeam, the sealing between the bottom guard plate 120 and the housing 110, and the sealing between the bottom guard plate 120 and the lower exhaust port 103. The number of sealing points is reduced by more than 60% compared to the traditional double-layer module independent exhaust scheme (which can have 8-16 sealing points), greatly reducing the risk of sealing failure.

[0065] Additionally, it is important to note that after the gas enters the lower cavity, in order to lower the gas temperature and prevent the sparking gas from igniting, please refer to [reference needed]. Figure 8 The exhaust chamber is provided with at least two spaced baffles 140. These baffles 140 are vertically arranged perpendicular to the bottom protective plate 120, and all the baffles 140 divide the lower exhaust chamber 102 into a gas buffer zone 104 and several gas flow zones 105.

[0066] Specifically, the gas buffer zone 104 is located directly below the lower receiving cavity 101 and is directly connected to the lower opening 131b of the main channel. Gas flowing out from the main exhaust channel 131 first enters this relatively large gas buffer zone 104, where it undergoes initial expansion and decompression. Each of the partitions 140 has a vent hole 141, and adjacent gas flow zones 105 are interconnected through these vent holes 141. Along the spacing direction of all the partitions 140, the gas flow zone 105 closer to the gas buffer zone 104 is connected to the gas buffer zone 104 through the vent hole 141 of one of the partitions 140, while the gas flow zone 105 farther from the gas buffer zone 104 is connected to the external environment through the lower exhaust port 103. That is, the gas needs to pass through the vent hole 141 of the first partition 140 to enter the first gas flow zone 105, then through the vent hole 141 of the second partition 140 to enter the second gas flow zone 105, and so on. Finally, the last gas flow zone 105, which is far from the gas buffer zone 104, is connected to the external environment through the lower exhaust port 103.

[0067] More importantly, the vent holes 141 of each pair of adjacent partitions 140 are staggered along the spacing direction of all partitions 140, so that the gas can flow in a bend along each gas flow zone 105 in sequence. For example, the vent hole 141 of the first partition 140 is close to Figure 8 The second partition 140 has its vent 141 located on the right side, while the vent 141 of the second partition 140 is located on the left side. This prevents the gas from passing straight through all the partitions 140; instead, it must travel along... Figure 8 The dotted line with arrows indicates an "S" or "Z" shaped flow path (as shown in the figure). This bend in the path design forces the high-temperature gas to flow along a specific path, repeatedly changing direction during exhaust. This increases the flow path length within the cavity and the contact time with the walls of the partition 140 and housing 110, effectively reducing the gas temperature and dissipating its kinetic energy. This lowers the temperature and pressure of the final exhaust gas, improving safety. Simultaneously, this design effectively blocks the direct propagation of flames, acting as a "fire stopper." Furthermore, in the event of external anomalies, this bend in the path effectively prevents external water, dust, or flames from entering the battery pack through the lower exhaust port 103, significantly enhancing the battery pack's safety under extreme conditions.

[0068] Further, see Figure 9 Each partition 140 has multiple vent holes 141, which are arranged in a matrix (i.e., a multi-row, multi-column grid). This porous matrix design has significant advantages over a single large hole: First, multiple small holes can disperse a concentrated high-speed airflow into multiple dispersed, lower-speed airflows, which helps reduce the impact force and noise of the airflow; second, the matrix-shaped small holes provide a larger total ventilation area, ensuring that while achieving bent exhaust, the exhaust back pressure is not excessively increased; finally, this porous structure, while ensuring structural strength, divides the flame into numerous small flame bundles, reducing the temperature below the ignition point of the combustible material; at the same time, the free radicals that sustain combustion in the flame collide with the pore walls of the multiple vent holes 141, interrupting the chain reaction, thereby blocking the propagation and reducing the possibility of large-area combustion.

[0069] In summary, the dual-layer module battery pack 10 provided in this application integrates and functionalizes the housing assembly 100 and the support assembly 200. In particular, by opening the main exhaust channel 131 inside the middle crossbeam 130, the exhaust paths of the upper and lower battery modules are integrated, achieving significant advantages over the prior art in terms of space utilization, lightweighting, sealing reliability, and exhaust safety.

[0070] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0071] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A dual-layer module battery pack, characterized in that, include: The housing assembly has an interconnected lower receiving cavity and a lower exhaust cavity. The lower receiving cavity is provided with a middle crossbeam, which divides the lower receiving cavity into two independent lower receiving areas. Each lower receiving area accommodates a set of lower battery modules. The bottom wall of the lower exhaust cavity is provided with a lower exhaust port. A support assembly is stacked on top of the housing assembly. The support assembly has an upper receiving cavity and an upper exhaust cavity that are interconnected. The upper receiving cavity contains the upper battery module. An exhaust main channel is formed in the middle crossbeam. One end of the exhaust main channel has an upper opening. The bottom wall of the upper exhaust cavity has an upper exhaust port that is coaxially arranged with the upper opening of the main channel. The upper exhaust cavity is connected to the exhaust main channel through the upper exhaust port and the upper opening of the main channel. The opposite end of the exhaust main channel has a lower opening. The lower exhaust cavity is connected to the exhaust main channel through the lower opening of the main channel.

2. The dual-layer module battery pack according to claim 1, characterized in that, The inner diameter of the exhaust main channel gradually increases from the upper opening of the main channel to the lower opening of the main channel; And / or, in the direction from the upper opening of the main channel to the lower opening of the main channel, the dimension between the two sides of the intermediate crossbeam gradually increases.

3. The dual-layer module battery pack according to claim 1, characterized in that, The bottom wall of the upper receiving cavity is provided with a plurality of first through holes, and the upper receiving cavity is connected to the upper exhaust cavity through the plurality of first through holes; the bottom of the upper battery module is provided with a plurality of first explosion-proof valves, and the plurality of first explosion-proof valves correspond one-to-one with the plurality of first through holes; the opening size of the upper opening of the main channel and the lower opening of the main channel are both larger than the diameter of a single first through hole. And / or, each of the lower receiving areas has a plurality of second through holes on its bottom wall, and the lower receiving area is connected to the lower exhaust chamber through the plurality of second through holes; each group of lower battery modules has a plurality of second explosion-proof valves at its bottom, and the plurality of second explosion-proof valves correspond one-to-one with the plurality of second through holes.

4. The dual-layer module battery pack according to claim 1, characterized in that, The inner wall of the main exhaust channel is coated with an aerogel insulation layer.

5. The dual-layer module battery pack according to claim 1, characterized in that, The lower exhaust chamber is provided with at least two spaced partitions, which divide the lower exhaust chamber into a gas buffer zone and several gas flow zones. The gas buffer zone is located below the lower receiving chamber and is connected to the lower receiving chamber through the lower opening of the main channel. Each partition is provided with a vent hole so that each two adjacent gas flow zones are connected to each other through the vent hole. In all the gas flow zones, the gas flow zone closer to the gas buffer zone along the spacing direction of all the partitions is connected to the gas buffer zone through the vent hole opened in one of the partitions, and the gas flow zone farther away from the gas buffer zone is connected to the external environment through the lower exhaust port; the vent holes opened in each pair of adjacent partitions are staggered along the spacing direction of all the partitions, so that the gas can flow in a bend along each gas flow zone in sequence.

6. The dual-layer module battery pack according to claim 5, characterized in that, Each of the partitions has multiple vent holes, which are arranged in a matrix at intervals.

7. The dual-layer module battery pack according to claim 1, characterized in that, The support assembly includes a bracket and a bracket cover plate detachably connected to the lower perimeter of the bracket. The upper receiving cavity is surrounded by the bracket, and the upper exhaust cavity is formed by the surface of the bracket facing the bracket cover plate and the surface of the bracket cover plate facing the bracket.

8. The dual-layer module battery pack according to claim 7, characterized in that, The upper accommodating cavity includes two upper accommodating areas, each of which accommodates a set of upper battery modules. The bracket includes two spaced-apart sub-brackets and a bracket middle portion located between the two sub-brackets and integrally connected to the two sub-brackets. Each upper accommodating area is enclosed by one of the sub-brackets. The bracket cover plate includes two spaced-apart sub-bracket cover plates and a cover plate middle portion located between the two sub-bracket cover plates and integrally connected to the two sub-bracket cover plates. The cover plate middle portion is located below the middle portion of the bracket and overlaps the middle crossbeam. The upper exhaust port passes through the cover plate middle portion. The two sub-bracket cover plates are respectively located below the two sub-brackets.

9. The dual-layer module battery pack according to claim 8, characterized in that, The lower receiving cavity has multiple spaced connecting columns on its sidewalls. The periphery of the support assembly overlaps with the multiple connecting columns. Each sub-support cover plate is accommodated in a corresponding lower receiving area. The middle crossbeam has a groove. The opening of the main channel is opened on the bottom wall of the groove. The middle part of the support is embedded in the groove.

10. The dual-layer module battery pack according to claim 1, characterized in that, The enclosure assembly includes an enclosure and a bottom guard plate detachably connected to the lower perimeter of the enclosure. The enclosure forms the lower receiving cavity and has the intermediate crossbeam, which is integrally connected to the rest of the enclosure. The lower exhaust cavity is formed by the surface of the enclosure facing the bottom guard plate and the surface of the bottom guard plate facing the enclosure. The lower exhaust port is opened on the bottom guard plate.

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