Power battery system top cover plate, power battery system and vehicle

Abstract

The application discloses a power battery system top cover plate, a power battery system and a vehicle. The power battery system top cover plate comprises an upper cover and a clamping piece. The upper cover is a planar plate formed by a sheet-shaped plate material. The clamping piece is used for connecting the upper cover and a support located below the upper cover. The power battery system top cover plate has the advantages that the upper cover is directly cut in a sheet shape, and a mold forming upper cover required by the prior art is no longer needed, so that the upper cover is convenient to process and has high universality. Regardless of the size of a module, only the base material used for processing needs to be cut, and then the standardized buckle structure is matched to be applied.

Description

Technical Field

[0001] This invention relates to the field of power battery technology, and in particular to a power battery system top cover, a power battery system, and a vehicle. Background Technology

[0002] The power battery systems used in current electric vehicles typically employ two internal structures: CTM (Cell to Module), where cells are first assembled into battery modules and then into battery packs, and CTP (Cell to Pack), where cells are directly installed into the battery pack. When using the traditional CTM assembly method, if the cell voltage acquisition scheme uses a CCS integrated busbar solution, a CCS thermoformed cover is required to protect the series aluminum busbars from electric shock or short circuits caused by falling foreign objects during process transfer. The size of the CCS thermoformed cover varies depending on the size of the cells and the number of series and parallel connections in the module. Different cell sizes and different numbers of series and parallel connections affect the overall module length, ultimately affecting the size and structure of the CCS cover. Different projects require different CCS cover thermoforming molds, increasing costs. In addition to the external dimensions, the CCS thermoformed cover also needs to have a thermoformed fastening structure for attaching with the CCS bracket.

[0003] Currently, the entire electric vehicle industry chain is facing the continuous challenge of cost reduction. It is of great significance to delve into the cost of each material and explore cost reduction potential throughout the entire process of design, production, manufacturing, and transportation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings and defects of the prior art and to provide a power battery system top cover, a power battery system and a vehicle. The provided power battery system top cover can be adapted to different sizes of cells and modules according to different project requirements, while improving the utilization rate of materials and achieving extreme cost reduction.

[0005] In a first aspect, the present invention provides a top cover for a power battery system, including a top cover and a snap-fit ​​component, wherein the top cover is a flat plate formed of a sheet material, and the snap-fit ​​component is used to connect the top cover to a bracket located below the top cover.

[0006] Preferably, the surface of the top cover is pre-formed with a first snap-fit ​​hole, and the surface of the bracket is provided with a second snap-fit ​​hole, the second snap-fit ​​hole being arranged corresponding to the first snap-fit ​​hole.

[0007] Preferably, the top cover is formed by cutting a selected sheet material into a preset rectangular shape.

[0008] Preferably, the top cover is formed by cutting a non-metallic polymer sheet material.

[0009] Preferably, the snap-fit ​​component includes a connecting post and a limiting disk coaxially connected to the connecting post, wherein the diameter of the limiting disk is larger than the diameter of the snap-fit ​​post.

[0010] Preferably, the snap-fit ​​component includes an elastic buckle formed of an elastic material.

[0011] Preferably, there are multiple snap-fit ​​components arranged periodically to connect and fix the top cover and the bracket together.

[0012] Preferably, the battery cell electrode conductive connector includes multiple conductive connection bars.

[0013] A second aspect of the present invention provides a power battery system, including a top cover plate of the power battery system.

[0014] A third aspect of the present invention provides a vehicle including the aforementioned power battery system.

[0015] The top cover of the power battery system of this invention is formed by directly cutting a sheet, eliminating the need for mold forming required in current technology. This simplifies processing and enhances versatility. Regardless of the module size, it can be applied simply by cutting the base material and using a standardized snap-fit ​​structure. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the top cover of the power battery system of the present invention.

[0017] Figure 2 This is a schematic diagram of the top cover of the power battery system of the present invention after being connected to the snap-fit ​​component. Figure 1 (Enlarged view of section C).

[0018] Figure 3 This is a schematic diagram of the top cover of the power battery system of the present invention before it is connected to the snap-fit ​​component.

[0019] Figure 4 This is a schematic diagram of the second snap-fit ​​hole on the bracket of the top cover plate of the power battery system of the present invention. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0021] In an exemplary embodiment of this application, the present invention provides a top cover plate for a power battery system, including an upper cover 1 and a snap-fit ​​member 5. The upper cover 1 is a flat plate formed of a sheet material, and the snap-fit ​​member 5 is used to connect the upper cover 1 to a bracket 3 located below the upper cover 1.

[0022] The surface of the bracket 3 near the upper cover 1 is used to set the battery cell electrode conductive connector 3 and the flexible circuit board 4.

[0023] The top cover of the power battery system of this invention is formed by directly cutting a sheet, eliminating the need for mold forming required in current technology. This simplifies processing and enhances versatility. Regardless of the module size, it can be applied simply by cutting the base material and using a standardized snap-fit ​​structure.

[0024] In one embodiment, the surface of the upper cover has a pre-formed first snap-fit ​​hole 11, and the surface of the bracket has a second snap-fit ​​hole 21. The second snap-fit ​​hole 21 is arranged correspondingly to the first snap-fit ​​hole 11. The first snap-fit ​​hole can be a circular hole or a hole with other cross-sectional shapes, and the second snap-fit ​​hole can be a circular hole or a hole with other cross-sectional shapes, such as... Figure 4 The plum blossom-shaped hole shown has a tapered opening structure on the inlet side that tapers from top to bottom, which facilitates insertion and guidance. It is also easy to connect and fix. The first snap-fit ​​holes may be the same or different. The first snap-fit ​​hole and the second snap-fit ​​hole are interference-fitted with the snap-fit ​​component.

[0025] In one embodiment of this application, the top cover is formed by cutting a selected sheet material into a preset rectangular shape. That is, after cutting, the sheet material with uniform thickness is rectangular with chamfered corners, and the first snap-fit ​​hole is processed by a punching device, which facilitates the processing of the top cover and overcomes the problems of the existing CCS top cover adopting a vacuum forming structure, which requires the production of molds, is complicated to process, and has high cost.

[0026] The top cover is made of non-metallic polymer sheet material, such as polymer plastic, PC sheet or similar material, which has a high material utilization rate.

[0027] In the embodiments of this application, the snap-fit ​​component 5 includes a connecting post 51 and a limiting disk 51 coaxially connected to the connecting post. The diameter of the limiting disk is larger than the diameter of the snap-fit ​​post. Other universal snap-fit ​​components can also be used. Any snap-fit ​​component that connects two plates by cooperating with a hole can be used or is not limited to this.

[0028] The connecting column 51 can be a hollow structure, extending from one end to the other and protruding at the center of the limiting plate 51.

[0029] The snap-fit ​​component 5 includes an elastic snap made of elastic material. The contact position between the snap-fit ​​component and the snap-fit ​​hole on the top cover and the bracket can be provided with a limiting structure or an anti-loosening structure. Any available snap that matches the hole can be used, and is not limited to the structure or shape shown in the figure.

[0030] In one embodiment of this application, multiple snap-fit ​​components are arranged periodically to connect and fix the top cover and the bracket together, such as... Figure 1 The diagram shows eight arranged in a cyclical pattern. Of course, the same number can also be designed according to the size of the top cover plate.

[0031] Specifically, during installation, apply glue (or double-sided tape) to the edge of the fixing hole on the top cover and stick it to the standardized buckle hole, or directly insert the pre-shaped buckle and let it be limited by the limiting structure to fix the top cover and the bracket.

[0032] This application optimizes the existing CCS cover vacuum forming process, eliminating the need for a vacuum forming mold. It is applicable to any size battery cell or module requiring a CCS cover structure. Besides eliminating the need for a CCS cover vacuum forming mold, thus saving mold costs, the traditional CCS cover vacuum forming process requires an edge trimming step to ensure the overall product dimensions meet drawing requirements. This step results in material waste; for example, approximately 10mm wide pieces of material are cut off, leading to waste. Using the plate trimming solution in this application, there is no material waste, and in addition to eliminating the need for a mold, material utilization is extremely high.

[0033] Therefore, this application uses the same standardized snap-on fixing structure to fix the CCS cover. The CCS cover does not use a vacuum forming method; the PC sheet can be punched and trimmed directly, which saves the mold cost of the CCS cover.

[0034] In one embodiment, the battery cell electrode conductive connector includes multiple conductive connection bars for connecting the battery cell electrodes, such as using an aluminum bar or similar structure.

[0035] An embodiment of the present invention also provides a power battery system, including a top cover plate of the power battery system, the power battery system including a battery box, the battery box including a battery module, and the terminal side of the battery module being connected to the top cover plate of the power battery system.

[0036] Embodiments of the present invention also provide a vehicle including the aforementioned power battery system.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention.

[0038] Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of the equivalents of the claims be included within the invention.

[0039] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A top cover plate for a power battery system, characterized in that It includes a top cover and a snap-fit ​​component. The top cover is a flat plate formed from a sheet material, and the snap-fit ​​component is used to connect the top cover to a bracket located below the top cover.

2. The top cover of the power battery system according to claim 1, characterized in that, The surface of the top cover has a first snap-fit ​​hole, and the surface of the bracket has a second snap-fit ​​hole, which is arranged corresponding to the first snap-fit ​​hole.

3. The top cover of the power battery system according to claim 1, characterized in that, The top cover is formed by cutting a selected sheet material into a preset rectangular shape.

4. The top cover of the power battery system according to claim 1, characterized in that, The top cover is formed by cutting a non-metallic polymer sheet material.

5. The top cover of the power battery system according to claim 1, characterized in that, The snap-fit ​​component includes a connecting post and a limiting plate coaxially connected to the connecting post, wherein the diameter of the limiting plate is larger than the diameter of the snap-fit ​​post.

6. The top cover of the power battery system according to claim 1, characterized in that, The snap-fit ​​component includes an elastic buckle made of an elastic material.

7. The top cover of the power battery system according to claim 1, characterized in that, The snap-fit ​​components are multiple and arranged periodically to connect and fix the top cover and the bracket together.

8. The top cover of the power battery system according to claim 1, characterized in that, The battery cell electrode conductive connector includes multiple conductive connection bars.

9. A power battery system, characterized in that, Includes the top cover of the power battery system as described in any one of claims 1-8.

10. A vehicle, characterized in that, Includes the power battery system as described in claim 9.

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