A battery assembly

Abstract

The application belongs to the field of batteries, and particularly relates to a battery assembly. The battery assembly solves the problems of complicated assembly process, many welding nodes, large contact resistance and difficult assembly of the existing pole cooling structure. The battery assembly comprises a battery module, a busbar, a heat exchange element and an electrical insulation element. The battery module comprises a plurality of single batteries arranged along a first direction. The busbar is connected with the pole of each single battery. The heat exchange element is arranged on the busbar and is used for temperature control. The electrical insulation element is arranged between the heat exchange element and the busbar, a first through slot is formed in the electrical insulation element, and the heat exchange element is clamped in the first through slot. A limiting structure is arranged on the electrical insulation element and / or the busbar, and is used for limiting the displacement of the electrical insulation element. The whole assembly only needs one welding process, reduces the welding nodes, reduces the contact resistance and the process complexity, the heat exchange element is directly embedded in the through slot, the assembly is simple, the limiting structure ensures the long-term stability of the electrical insulation element, improves the electrical reliability and the cooling efficiency, and the temperature control response is more rapid.

Description

Technical Field

[0001] This invention belongs to the field of batteries, specifically a battery assembly. Background Technology

[0002] In battery module cooling technology, terminal cooling is a common method for achieving effective temperature control. Existing battery modules with terminal cooling structures, such as... Figure 1 and Figure 2 As shown, a typical assembly includes components such as a battery module, a terminal extension 2, a heat exchanger, and a busbar. The specific assembly process is as follows: first, the terminal extension 2 is welded to the terminals of each individual cell constituting the battery module; then, the heat exchanger is inserted into a pre-set groove on the terminal extension 2; and finally, the busbar is welded to the terminal extension 2. However, this existing solution requires two independent welding processes (i.e., welding the terminal extension 2 to the terminals, and welding the busbar to the terminal extension 2). This not only results in a long overall assembly time and low production efficiency, but also significantly increases manufacturing difficulty and cost due to the cumbersome process. More importantly, multiple welding nodes mean multiple potential contact resistances and connection failure risks, adversely affecting the electrical reliability and long-term service life of the battery module.

[0003] Furthermore, in order to achieve electrical isolation between the heat exchanger and the pole extension and busbar, the existing solution requires a ceramic tube to be sleeved on the outside of the heat exchanger. However, this ceramic tube is a slender, thin-walled tube, and the heat exchanger needs to be inserted into the tube during assembly. The sleeve insertion operation is difficult to align, time-consuming and labor-intensive, and reduces the overall assembly efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a battery assembly that addresses the problems of cumbersome assembly processes, numerous welding nodes, high contact resistance, and assembly difficulties caused by the use of ceramic tubes in existing electrode cooling structures, which require electrode extension components.

[0005] The battery assembly of the present invention includes a battery module, a busbar, a heat exchanger, and an electrical insulation component; The aforementioned battery module includes n individual battery cells arranged along a first direction, where n is an integer greater than 1; The aforementioned busbar is connected to the terminals of each individual battery cell to achieve electrical connection between the individual battery cells; The aforementioned heat exchange components are mounted on the busbar to achieve temperature control of the battery module; The aforementioned electrical insulating component is disposed between the aforementioned heat exchange component and the aforementioned busbar, and a first through groove is formed on the aforementioned electrical insulating component along its length direction, and the aforementioned heat exchange component is fitted into the first through groove; The aforementioned electrical insulating component and / or the aforementioned busbar are provided with a limiting structure to limit the displacement of the aforementioned electrical insulating component relative to the aforementioned busbar in at least one direction.

[0006] Compared to existing solutions, this invention eliminates the terminal extension component, allowing the busbar to directly connect to the terminals of each individual battery cell, thus achieving electrical connection between the individual cells. The heat exchange component is fixed to the busbar, and an electrical insulator with a first through slot is provided between them to achieve electrical isolation. In this invention, the entire assembly requires only one welding process (connecting the busbar to the terminal), significantly shortening assembly time and reducing manufacturing costs and process complexity. More importantly, it reduces the number of welding nodes, eliminating multiple potential contact resistances and connection failure points from the source, effectively improving electrical reliability and module lifespan; simultaneously, it shortens the heat transfer path, resulting in better cooling efficiency and faster temperature control response.

[0007] Compared to existing solutions that require a ceramic tube to be fitted over the heat exchanger, this invention directly embeds the heat exchanger into the first through slot of the electrical insulation component, forming a snap-fit ​​connection. Precise positioning is achieved simply by pushing it in during assembly, eliminating the need for a sleeve, significantly simplifying the process and improving production efficiency.

[0008] In addition, by setting a limiting structure, the electrical insulation components and the busbar form a stable positioning fit after assembly, which effectively limits the displacement or detachment of the electrical insulation components during use and ensures the long-term accuracy of the insulation position.

[0009] Furthermore, the aforementioned limiting structure includes a second through slot formed on the aforementioned busbar and extending along its length, and a first concave-convex fitting structure respectively disposed on the two opposite slot walls of the second through slot and on the electrical insulating component; The aforementioned electrical insulating component is fitted into the second through slot and interlocks with the second through slot through the aforementioned first concave-convex fitting structure to limit the displacement of the electrical insulating component relative to the busbar in at least one direction.

[0010] Through the dual constraint of the second through slot and the first concave-convex mating structure, the electrical insulation component is confined, making it less prone to displacement or detachment under vibration, thus ensuring the long-term accuracy of the insulation position and avoiding the risk of short circuits due to misalignment. Simultaneously, the electrical insulation component is embedded in the second through slot of the busbar, without occupying additional space in the module's height direction, which is beneficial for a thinner and lighter design. Assembly only requires snap-fitting, without the need for additional fasteners or adhesives, making the process simple and efficient. Furthermore, the sidewall of the second through slot provides physical protection for the electrical insulation component, effectively reducing edge impact damage, especially suitable for brittle materials such as ceramics, further enhancing the overall structural durability.

[0011] Furthermore, the aforementioned limiting structure includes a cavity disposed on the busbar and recessed along its thickness direction; The aforementioned electrical insulating element is at least partially fitted into the aforementioned cavity to restrict the displacement of the aforementioned electrical insulating element relative to the aforementioned busbar in the horizontal direction, wherein the horizontal direction is perpendicular to the thickness direction.

[0012] The recessed cavity provides a horizontal, enveloping constraint on the electrical insulation components, effectively limiting their displacement in the busbar's length and width (i.e., horizontal direction), ensuring long-term accuracy of the insulation position even under vibration. Simultaneously, the insulation components are at least partially recessed within the cavity, without increasing the module's thickness, facilitating a slimmer design. Assembly is simple: just insert the insulation components into the cavity for positioning, eliminating the need for additional fasteners or adhesives, making the process concise and efficient. Furthermore, the cavity's sidewalls provide physical protection for the insulation components' edges, effectively reducing the risk of impact damage, especially suitable for brittle materials like ceramics, further enhancing the overall structural durability.

[0013] Furthermore, it also includes a first pressure plate; the first pressure plate is fixed on the busbar and presses the heat exchanger onto the electrical insulation component so that the heat exchanger and the electrical insulation component remain in contact.

[0014] By adding a first pressure plate, the heat exchange component is pressed tightly onto the electrical insulation component, ensuring a tight fit between them. This effectively eliminates the air gap between their contact surfaces, significantly reduces interfacial thermal resistance, and improves the heat transfer efficiency from the busbar through the electrical insulation component to the heat exchange component, thereby enhancing the temperature control effect of the battery module. At the same time, the tight fit effectively suppresses the relative displacement or shaking of the heat exchange component and electrical insulation component caused by vibration during use, further improving the long-term reliability and stability of the overall structure.

[0015] Furthermore, if the limiting structure includes a second through groove opened on the busbar and extending along its length, then a second concave-convex fitting structure can be provided on the two opposite groove walls of the second through groove and on the first pressure plate respectively; the first pressure plate is engaged with the second through groove through the second concave-convex fitting structure.

[0016] If the limiting structure includes a cavity provided on the busbar and recessed along its thickness direction; a second concave-convex fitting structure may be provided on the two opposite sidewalls of the cavity and on the first pressure plate; the first pressure plate is fitted into the cavity through the second concave-convex fitting structure.

[0017] The concave-convex mating structure allows the installation of the first pressure plate to be completed without additional fasteners or welding. It can be fixed simply by pushing it in along the direction of the second through groove. The assembly process is simple and quick, reducing manufacturing time and material costs.

[0018] Furthermore, the present invention also provides another limiting structure different from the above, specifically, the limiting structure includes a second pressure plate; The second pressure plate is fixed to the busbar to limit the displacement of the electrical insulation component relative to the busbar in at least one direction and to press the heat exchange component onto the electrical insulation component so that the heat exchange component and the electrical insulation component remain in contact.

[0019] The second pressure plate integrates limiting and clamping functions, restricting the displacement of the electrical insulation component relative to the busbar and pressing the heat exchange component onto it, simplifying the number of parts and assembly steps. Through the clamping action of the second pressure plate, the heat exchange component and the electrical insulation component maintain a tight fit, effectively reducing interfacial contact thermal resistance and improving heat transfer efficiency. Simultaneously, the limiting constraint of the electrical insulation component by the second pressure plate further ensures the long-term accuracy of the insulation position, preventing displacement or detachment due to vibration.

[0020] Furthermore, the second pressure plate is provided with a third through groove along its length, and the outer sides of the groove walls on both sides of the third through groove are respectively provided with folded edges; The aforementioned folded edge is fixedly connected to the busbar, and the aforementioned third through groove and the busbar enclose an electrical insulation component receiving cavity to restrict the displacement of the aforementioned electrical insulation component relative to the aforementioned busbar in the busbar thickness and width directions; The aforementioned electrical insulating component is fitted into the aforementioned receiving cavity, and the bottom of the aforementioned third through groove presses against the heat exchange component so that the aforementioned heat exchange component and the aforementioned electrical insulating component remain in close contact.

[0021] The third through-slot is fixedly connected to the busbar via a folded edge on the second pressure plate, forming an independent receiving cavity between the third through-slot and the busbar. The electrical insulation component is fitted into this cavity, thus simultaneously constraining the electrical insulation component in both the thickness and width directions, effectively preventing displacement or detachment during use. At the same time, the bottom of the third through-slot directly presses against the heat exchanger, ensuring a tight fit between the heat exchanger and the electrical insulation component. This reduces interfacial contact thermal resistance and eliminates the need for additional clamping components.

[0022] Furthermore, the aforementioned limiting structure also includes a second through groove extending along the length of the busbar, and a third concave-convex fitting structure respectively disposed on the two opposite groove walls of the second through groove and on the second pressure plate. The aforementioned second pressure plate is equipped with a blocking mechanism; The aforementioned electrical insulating component is fitted into the second through slot. After the aforementioned second pressure plate is engaged with the aforementioned second through slot through the aforementioned third convex-concave fitting structure, the aforementioned blocking mechanism abuts against the aforementioned electrical insulating component to limit the displacement of the aforementioned electrical insulating component relative to the aforementioned busbar in the length direction of the busbar; and the aforementioned second pressure plate presses the heat exchange component to keep the aforementioned heat exchange component and the aforementioned electrical insulating component in close contact.

[0023] This solution achieves simultaneous length, width, and height limiting of electrical insulation components and tight bonding of heat exchange components on the same structure through multiple combinations of "second through groove + third concave-convex fit + second pressure plate + blocking mechanism". The structure has a high degree of integration, and the functions do not interfere with each other and enhance each other.

[0024] Furthermore, there are multiple busbars, each connected to a different polarity terminal in an adjacent single cell, to achieve series connection between the individual cells; or, there are two busbars, one connected to the positive terminal of all individual cells, and the other connected to the negative terminal of all individual cells, so that the electrolytes of each individual cell are connected.

[0025] Furthermore, the aforementioned electrical insulation component is a ceramic component.

[0026] This invention uses ceramic components as electrical insulation components, which not only utilizes the excellent insulation and thermal conductivity of ceramic materials, but also overcomes the inherent defects of ceramic tubes being brittle and easily damaged through block or sheet structure design. While ensuring electrical safety and cooling efficiency, it significantly improves the durability and ease of assembly of the structure.

[0027] Furthermore, thermally conductive silicone grease is applied between the aforementioned electrical insulating components and heat exchange components, and / or between the electrical insulating components and busbars. By applying thermally conductive silicone grease to the contact interfaces between the electrical insulating components and heat exchange components, and between the electrical insulating components and busbars, the minute gaps between the contact surfaces of each component can be effectively filled, significantly reducing interfacial contact thermal resistance, improving the heat transfer efficiency from the busbars through the electrical insulating components to the heat exchange components, and further enhancing the temperature control effect of the battery module. At the same time, the thermally conductive silicone grease has a certain degree of flexibility and adhesion, and can maintain the interface filling state under vibration environment, which is beneficial to the stability of thermal conductivity during long-term use.

[0028] Furthermore, the aforementioned heat exchanger is a direct cooling pipe, in which the refrigerant provided by the direct cooling system flows to achieve temperature control of the battery module.

[0029] This method has significant advantages: First, it has high cooling efficiency, which can quickly absorb a large amount of heat under high heat load and shorten the temperature control response time; second, it has precise temperature control, which can control the refrigerant state by adjusting the direct cooling system, stabilize the battery at the optimal operating temperature, and reduce the impact of temperature fluctuations on performance and lifespan; third, it has strong environmental adaptability, which can still provide stable cooling in high-temperature environments and avoid temperature control failure.

[0030] Furthermore, the aforementioned single-cell battery casing is provided with a hollow tubular component; The aforementioned battery module also includes an explosion venting manifold; the explosion venting manifold is connected to the hollow tubing of each individual battery cell to ensure that thermal runaway fumes from the individual battery cells are discharged through the explosion venting manifold, thereby improving the safety performance of the battery module.

[0031] Beneficial effects of this invention: Compared to existing solutions, this invention eliminates the terminal extension component, allowing the busbar to directly connect to the terminals of each individual battery cell, thus achieving electrical connection between the individual cells. The heat exchange component is fixed to the busbar, and an electrical insulator with a first through slot is provided between them to achieve electrical isolation. Compared to existing solutions, this invention requires only one welding process (connecting the busbar to the terminals), significantly shortening assembly time and reducing manufacturing costs and process complexity. More importantly, it reduces the number of welding nodes, eliminating multiple potential contact resistances and connection failure points from the source, effectively improving electrical reliability and module lifespan; simultaneously, it shortens the heat transfer path, resulting in better cooling efficiency and faster temperature control response.

[0032] Compared to existing solutions that require a ceramic tube to be fitted over the heat exchanger, this invention directly embeds the heat exchanger into the first through slot of the electrical insulation component, forming a snap-fit ​​connection. Precise positioning is achieved simply by pushing it in during assembly, eliminating the need for a sleeve, significantly simplifying the process and improving production efficiency.

[0033] In addition, by setting a limiting structure, the electrical insulation components and the busbar form a stable positioning fit after assembly, which effectively limits the displacement or detachment of the electrical insulation components during use and ensures the long-term accuracy of the insulation position. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of an existing battery assembly; Figure 2 This is a partial cross-sectional view of an existing battery assembly. Figure 3 This is a schematic diagram of the structure of a battery assembly in Example 1; Figure 4 This is a partial structural diagram of the first type of battery assembly in Example 1; Figure 5 This is a partial cross-sectional view of the first type of battery assembly in Example 1; Figure 6 This is a partial cross-sectional view of the second type of battery assembly in Example 1; Figure 7 This is a partial cross-sectional view of the third type of battery assembly in Example 1; Figure 8 This is a partial structural diagram of the fourth type of battery assembly in Example 1; Figure 9 This is a partial structural diagram of a battery assembly in Example 2; Figure 10 This is a partial structural diagram of another battery assembly in Example 2; Figure 11 This is a partial structural diagram of a battery assembly in Example 3; Figure 12 This is a schematic diagram of the structure of a battery assembly in Example 3; Figure 13 This is a partial structural diagram of a battery assembly in Example 4; Figure 14 This is a partial cross-sectional view of a battery assembly in Example 4; Figure 15 This is a partial structural diagram of another battery assembly in Example 4; Figure 16 This is a magnified schematic diagram of a partial structure of another battery assembly in Example 4; Figure 17 This is a schematic diagram of the structure of a battery assembly in Example 5; Figure 18 This is a schematic diagram of the structure of a battery assembly in Example 6; The attached figures are labeled as follows: 1. Single cell; 11. Terminal post; 2. Terminal post extension; 3. Heat exchanger; 4. Busbar; 41. Second through slot; 42. Fourth through slot; 43. Second protrusion; 44. Protrusion; 45. First notch; 46. Sixth through slot; 47. Limiting platform; 5. Electrical insulation component; 51. First protrusion; 52. Seventh through slot; 53. First through slot; 6. Explosion relief manifold; 7. Electrolyte sharing pipeline; 8. Battery module; 9. Cavity; 91. Second notch; 92. Third notch; 93. Fourth notch; 10. First pressure plate; 12. Fifth through slot; 13. Second pressure plate; 131. Third through slot; 132. Folded edge; 133. Electrical insulation component receiving cavity; 134. Blocking mechanism; 135. Raised ridge. Detailed Implementation

[0035] 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.

[0036] 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.

[0037] In the description of this invention, it should be noted that the terms "top," "bottom," etc., indicating orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] This invention discloses a battery assembly, comprising a battery module, a busbar, a heat exchanger, and an electrical insulator. The battery module is primarily composed of multiple individual battery cells. The busbar is connected to the terminals of each individual battery cell to achieve electrical connection between the cells. The heat exchanger is disposed on the busbar for temperature control of the battery module. The electrical insulator is disposed between the heat exchanger and the busbar, and a first through-slot along its length is formed on the electrical insulator, within which the heat exchanger is fitted. Furthermore, the electrical insulator and / or the busbar are provided with limiting structures to constrain the displacement of the electrical insulator relative to the busbar in at least one direction.

[0039] Compared to existing solutions, this invention eliminates the need for terminal extension components. The busbar connects directly to the terminals of each individual battery cell, and the electrical connection is completed in a single welding process, significantly shortening assembly time and reducing manufacturing costs and process complexity. The reduction in welding nodes also fundamentally reduces the potential risks of contact resistance and connection failure, thereby improving the electrical reliability and lifespan of the battery module.

[0040] Meanwhile, the present invention eliminates the ceramic tube structure that is sleeved on the outside of the heat exchanger in the traditional solution, and uses the method of directly snapping the heat exchanger into the first through groove of the electrical insulation component to achieve fixation and positioning, which eliminates the tube insertion process and makes the assembly operation more convenient.

[0041] In addition, by setting a limiting structure, a reliable positioning relationship can be formed between the electrical insulation component and the busbar, effectively preventing the electrical insulation component from shifting or falling off during use, and ensuring the long-term stability of insulation performance.

[0042] It should be noted that: 1. The aforementioned single-cell battery typically includes a casing, terminals disposed on the casing, and electrode assemblies and electrolyte housed within the casing; 2. The above-mentioned busbars are made of copper or aluminum conductive materials, and copper busbars, aluminum busbars, or copper-aluminum composite busbars can be selected according to current carrying requirements. The busbars and terminals are usually connected by welding to ensure the electrical reliability and mechanical strength of the connection; 3. The heat exchange components mentioned above can be liquid cooling plates, liquid cooling pipes or direct cooling pipes, etc., used for thermal management of the busbar and the connected electrode posts, thereby realizing temperature control of the battery module. 4. The above electrical connections can be series, parallel, or mixed: When using series connection, there are multiple busbars, each busbar connecting the terminals of different polarities in two adjacent individual cells, that is, one busbar connects the positive terminal of the previous cell to the negative terminal of the next cell, and so on; when using parallel connection, there are two busbars, one busbar connecting the positive terminals of all individual cells, and the other busbar connecting the negative terminals of all individual cells, and the electrolytes of each individual cell are interconnected so that each individual cell is in the same electrolyte system; 5. The above-mentioned limiting structure can be of various types, such as a concave-convex mating structure provided on the electrical insulation component and / or busbar, a cavity structure provided on the busbar, or a pressure plate structure provided on the busbar, etc., to limit the displacement of the electrical insulation component relative to the busbar in the thickness direction and / or horizontal direction. 6. The above-mentioned battery modules may include at least the following three types: Type 1 battery module: The first type of battery module includes n individual batteries arranged along a first direction, where n is an integer greater than 1; For ease of description, in this invention, the direction of arrangement of individual cells (i.e., the first direction) is defined as the x-direction; 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. Second type of battery module: The second type of battery module, based on the first type, adds a venting manifold extending along a first direction. To facilitate installation between the venting manifold and individual battery cells, hollow tubing can be added at the venting port of each individual battery cell, and these hollow tubings are connected via the venting manifold. A venting membrane is provided on at least one of the venting ports and hollow tubing. When a single battery cell experiences thermal runaway, the resulting high-temperature, high-pressure flue gas can flow into the venting manifold through the hollow tubing and be discharged in an orderly and directional manner along the manifold, effectively preventing the spread of thermal runaway within the module and significantly improving the safety performance of the battery assembly. Third type of battery module: The third type of battery module, based on the first type, adds a shared electrolyte pipeline. The inner cavity of each individual battery cell is connected to this shared electrolyte pipeline, enabling interconnection of the electrolytes in each cell and placing all cells within the same electrolyte system, thus improving the consistency of each cell.

[0043] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Example 1

[0044] like Figure 3 and Figure 4The diagram shows a schematic diagram and a partial schematic diagram of the battery module in this embodiment, which includes a battery module 8, a busbar 4, a heat exchanger 3, and an electrical insulation component 5. The battery module 8 is the first type of battery module mentioned above.

[0045] The battery module 8 includes 13 individual battery cells 1 arranged along the x-direction. In this embodiment, the individual battery cells 1 are prismatic cells. In other embodiments, the number of individual battery cells 1 can be adjusted according to actual needs, and the shape of the individual battery cells 1 can also be adjusted according to actual needs.

[0046] In this embodiment, there are multiple busbars 4, which are made of conventional aluminum and have a long strip-shaped structure. Their cross-section is usually designed to be rectangular, and the size can be customized according to actual needs.

[0047] Each busbar 4 connects to terminals 11 of different polarities in two adjacent individual cells 1 at both ends along its length, thereby achieving series connection between the individual cells 1. In this embodiment, the busbar 4 and the terminals 11 are connected by welding.

[0048] The heat exchanger 3 is installed on the manifold 4.

[0049] It should be noted that the heat exchanger 3 in this embodiment is made of metal, such as a copper or aluminum tube, which has significantly better thermal conductivity than an insulated tube and can more efficiently conduct heat away from the busbar 4. However, since metal is conductive, electrical insulation must be performed between the metal tube and the busbar 4 when the metal tube is directly fixed to the busbar 4 to prevent the risk of short circuit.

[0050] To further improve heat exchange efficiency, heat exchanger 3 is preferably a direct cooling pipe. In the direct cooling device, the refrigerant, driven by the compressor, flows inside the direct cooling pipe. Through the phase change of the refrigerant, it absorbs the latent heat of vaporization, and the heat exchange efficiency is much higher than that of conventional liquid cooling methods, thereby achieving rapid and efficient temperature control of the battery module 8.

[0051] Specifically, the direct cooling pipe is used as the evaporator of the direct cooling system, allowing the low-temperature refrigerant to flow into the direct cooling pipe and exchange heat with the manifold 4 through the pipe wall, thereby achieving temperature control of the battery module 8.

[0052] It should be noted that: The aforementioned "using the direct cooling pipe as the evaporator of the direct cooling system" can be achieved in the following two ways: 1) The evaporator piping and direct cooling pipes of the direct cooling system are separate components, which are fixedly connected and kept in contact by means of joints or welding; 2) The evaporator piping and the direct cooling pipes of the direct cooling system are integrated into one unit, meaning that the evaporator piping is directly used as the direct cooling pipes.

[0053] The direct cooling pipe can be made of copper or aluminum. Considering factors such as thermal conductivity and direct connection with the evaporator piping, copper pipe is preferred in this embodiment.

[0054] To ensure electrical insulation between the busbar 4 and the heat exchanger 3 (direct cooling pipe), this embodiment provides an independent electrical insulation component 5 between the two.

[0055] The material of the electrical insulation component 5 can be plastic, rubber or ceramic, etc. Since ceramic material has excellent electrical insulation, high temperature resistance and good thermal conductivity, ceramic material is selected in this embodiment.

[0056] from Figure 4 As can be seen from the image, the electrical insulation component 5 in this embodiment is a ceramic sheet or a ceramic block.

[0057] The ceramic sheet or ceramic block can be fixed to the busbar 4 by the following limiting structure (the limiting structure here is the first concave-convex fit structure): Structure 1: such as Figure 4 and Figure 5 As shown, a second through groove 41 is formed along the length direction (x-direction) of the busbar 4. Fourth through grooves 42 extending along the length direction are respectively formed on two opposite groove walls of the second through groove 41. First protrusions 51 extending along the length direction are respectively formed on two opposite side walls of the electrical insulating component 5 (ceramic sheet or ceramic block). During assembly, the electrical insulating component 5 is snapped into the second through groove 41, and the first protrusions 51 are embedded in the corresponding fourth through grooves 42, thereby limiting the displacement of the electrical insulating component 5 relative to the busbar 4 in the thickness direction (z-direction) of the busbar 4. Furthermore, from... Figure 4 As can be seen from the diagram, in this structure, the two ends of the electrical insulation component 5 extend into second through grooves 41 in the length direction to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting the electrical safety requirements.

[0058] Figure 5 To facilitate the display of the second through slot 41 and the fourth through slot 42, the electrical insulation component 5 and the heat exchange component 3 are not shown in the busbar 4 on one side.

[0059] Structure 2: such as Figure 6 As shown, a second through groove 41 is provided on the busbar 4 along its length direction. On the two opposite groove walls of the second through groove 41, a second protrusion 43 extending along its length direction is provided respectively. On the two opposite side walls of the electrical insulating component 5 (ceramic sheet or ceramic block), a sixth through groove extending along its length direction is provided respectively. During assembly, the electrical insulating component 5 is snapped into the second through groove 41 and the second protrusion 43 is embedded in the corresponding sixth through groove, thereby restricting the displacement of the electrical insulating component 5 relative to the busbar 4 in the thickness direction (z direction) of the busbar 4.

[0060] In this structure, the two ends of the electrical insulation component 5 in the length direction also extend into second through grooves 41 to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting the electrical safety requirements.

[0061] Structure 3, such as Figure 7 As shown, a second through groove 41 is formed along the length of the busbar 4, and limiting platforms 47 extending along the length and protruding into the second through groove 41 are respectively provided on both sides of its opening end. During assembly, the electrical insulating component 5 is snapped into the second through groove 41, and the edges of the electrical insulating component 5 on opposite sides are respectively embedded between the corresponding limiting platforms and the bottom of the second through groove 41, thereby restricting the displacement of the electrical insulating component 5 relative to the busbar 4 in the z-direction (the thickness direction of the busbar).

[0062] In the above structure, the two ends of the electrical insulation component 5 in the length direction also extend into second through grooves 41 to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting the electrical safety requirements.

[0063] Structure 4: such as Figure 8 As shown, a second through groove 41 is formed along the length of the busbar 4. On the two opposite walls of the second through groove 41, protrusions 44 (or bosses) protrude into the groove along their width direction. On the two opposite side walls of the electrical insulating component 5 (ceramic sheet or block), seventh through grooves 52 are formed along their thickness direction, corresponding to the positions of the protrusions 44. During assembly, the electrical insulating component 5 is snapped into the second through groove 41, and the protrusions 44 are embedded in the corresponding seventh through grooves 52, thereby restricting the horizontal displacement of the electrical insulating component 5 relative to the busbar 4.

[0064] In the above structure, the two ends of the electrical insulation component 5 in the length direction also extend into second through grooves 41 to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting the electrical safety requirements.

[0065] like Figure 8 As shown, a first notch 45 can also be provided on the busbar 4 at a position directly below the heat exchanger 3 to further increase the creepage distance between the busbar 4 and the heat exchanger 3 and improve electrical safety performance.

[0066] In this embodiment, the electrical insulating component 5 is a ceramic sheet or ceramic block, the shape and size of which match the second through groove 41. During assembly, the electrical insulating component 5 can be directly embedded into the second through groove 41, and the groove wall forms a clamping and limiting effect on the insulating component. The operation is simple and quick, requiring no additional fasteners or adhesives, which significantly improves assembly efficiency.

[0067] Meanwhile, after the electrical insulation component 5 is inserted into the second through groove 41, it forms a stable interlocking engagement with the busbar 4 through the first concave-convex fitting limiting structure. During the use of the battery module 8, even if subjected to external forces such as vibration and impact, the electrical insulation component 5 will not shift or fall off, ensuring the long-term accuracy and reliability of the insulation position.

[0068] In addition, since the electrical insulating component 5 is embedded inside the second through groove 41, the side wall of the second through groove 41 also forms physical protection for the edge of the electrical insulating component 5, which effectively reduces the probability of the insulating component being damaged by bumps during assembly or use. This is especially suitable for brittle materials such as ceramic sheets, further improving the durability of the overall structure.

[0069] like Figures 4 to 7 As shown, this embodiment uses a snap-fit ​​method to fix the direct cooling pipe to the electrical insulation component 5. Specifically, a first through groove 53 is opened on the electrical insulation component 5 along the x-direction, and the direct cooling pipe is snapped into the first through groove 53. During snap-fit, the direct cooling pipe only needs to be pushed into the first through groove 53 along the x-direction, and the fixation is completed by the clamping and limiting of the pipe body by the groove wall, resulting in a stable and reliable connection.

[0070] Compared to Figure 1 and Figure 2 The existing solution shown requires a ceramic tube to be fitted outside the heat exchanger 3. Figure 2 The electrical insulation component 5 (i.e., a ceramic tube) is selected in this invention as an electrical insulation component 5, with a first through groove. The heat exchange component 3 is directly embedded into the first through groove, forming a snap-fit ​​fit. During assembly, precise positioning can be achieved simply by pushing the heat exchange component 3 into the through groove, eliminating the need for a sleeve, thus simplifying the process and improving production efficiency.

[0071] Furthermore, ceramic tubes, being custom-designed slender, thin-walled pipes, are highly susceptible to brittle fracture under radial forces. In contrast, the electrical insulation component 5 in this invention is a block or sheet-like ceramic component with a first through groove. Its cross-sectional thickness is significantly greater than that of the thin-walled ceramic tube, resulting in a substantial increase in structural strength and effectively resisting radial forces without cracking. Simultaneously, the heat exchange component 3 is secured within the groove, preventing relative swaying and localized stress concentration caused by gaps during pipe fitting, further enhancing the long-term reliability of the overall structure.

[0072] Furthermore, to further reduce interfacial thermal resistance and improve thermal conductivity, thermal grease can be applied between the electrical insulation components and heat exchange components, and / or between the electrical insulation components and busbars. Thermal grease can fill the tiny gaps at each contact interface, effectively reducing contact thermal resistance and enhancing the ability of heat to be transferred from the busbars through the electrical insulation components to the heat exchange components, thereby optimizing the temperature control performance of the battery module. Simultaneously, the thermal grease possesses good flexibility and adhesion, maintaining its filled state even in vibrating environments, ensuring continuous stability of thermal conductivity during long-term use.

[0073] The specific installation process in this embodiment is as follows: First, each busbar 4 is welded to the corresponding terminal post 11 of the individual cell 1 to achieve series connection between the individual cells 1.

[0074] Subsequently, each electrical insulating component 5 (ceramic sheet or ceramic block) is embedded into the second through slot 41 of each busbar 4.

[0075] Next, the direct cooling pipes are sequentially inserted into the first through slots of each electrical insulation component 5 located on the same side along the x-direction. Specifically, during operation, simply align the direct cooling pipe with each first through slot and push it in along the x-direction, so that the outer wall of the pipe is embedded in the slot. The side wall of the through slot forms a clamping and limiting effect on the direct cooling pipe, thus completing the installation and positioning of the direct cooling pipe.

[0076] from Figure 3 As can be seen from the diagram, in this embodiment, two direct cooling pipes extending along the x-direction and spaced apart in the y-direction are provided on the top of the battery module 8. The two direct cooling pipes can be connected in series at the cooling channel port on the same side through an external connecting pipe section. This external connecting pipe section can be an integral structure with the pipe body of the two direct cooling pipes to form a U-shaped pipeline. In other embodiments, the two direct cooling pipes can also be connected in parallel according to actual cooling requirements.

[0077] Figure 1 and Figure 2 The existing solution shown requires installation following the procedure below: First, the terminal extension 2 is welded and fixed to the terminal 11 of each individual battery cell 1. Then, the heat exchanger 3 is inserted into the ceramic tube, and then the heat exchanger 3 with the ceramic tube inserted is inserted into the pre-set groove on the terminal extension 2. Finally, the busbar 4 is welded onto the terminal extension 2 to complete the overall assembly. This solution requires two welding processes (welding the terminal extension 2 to the terminal 11 and welding the busbar 4 to the terminal extension 2), and the heat exchanger 3 must be pre-inserted into the ceramic tube before it can be inserted. The overall assembly process is cumbersome and time-consuming.

[0078] Compared to Figure 1 and Figure 2 The advantages of this embodiment compared to the existing solutions shown are mainly reflected in the following aspects: First, the pole extension 2 was eliminated, and the busbar 4 was directly connected to the pole 11, simplifying the two welding processes into one, which greatly shortened the assembly time and reduced the manufacturing cost and process complexity. Secondly, the heat exchanger 3 does not need to be fitted with a ceramic tube; it can be directly inserted into the first through slot, further simplifying the operation steps and improving assembly efficiency. At the same time, the limiting structure ensures that the electrical insulation component 5 and the busbar 4 form a reliable positioning fit, guaranteeing the stability of the insulation effect. Third, the reduction in welding nodes eliminates multiple potential contact resistances and connection failure points from the source, effectively improving electrical reliability and module lifespan. Fourth, the heat transfer path is shortened, resulting in better cooling efficiency and faster temperature control response. Example 2

[0079] The difference between this embodiment and Embodiment 1 lies in the specific implementation method of the limiting structure.

[0080] like Figure 9 and Figure 10 As shown, in this embodiment, the limiting structure includes a recessed cavity 9 disposed on the busbar 4 and recessed along its thickness direction (i.e., the Z direction). The recessed cavity 9 is rectangular, with its opening facing upwards, and is enclosed by a bottom wall and four side walls, having a shape that matches the outline of the electrical insulating component 5. The electrical insulating component 5 is at least partially fitted into the recessed cavity 9, meaning that the bottom and part of the side walls of the electrical insulating component 5 are recessed into the recessed cavity 9. A clearance fit or transition fit is formed between the side walls of the electrical insulating component 5 and the side walls of the recessed cavity 9 to facilitate insertion.

[0081] In addition, to increase the creepage distance between the busbar 4 and the heat exchanger 3 and improve electrical safety performance, the cavity 9 can be optimized as follows: Optimize the structure, such as Figure 9 As shown, a second notch 91 is formed on the sidewall of the cavity 9 in the width direction (i.e., the Y direction). This second notch 91 penetrates both the sidewall and the bottom wall (the notch extends downwards from the top surface of the sidewall, penetrating the entire sidewall, and also penetrates the bottom wall in the thickness direction). A fourth notch 93 is formed on the bottom wall of the cavity 9. This fourth notch 93 extends into the cavity 9 in the x direction from the edge where the second notch 91 penetrates the bottom wall, and is connected to the second notch 91. The fourth notch 93 and the second notch 91 combine to form an L-shaped open structure. This further increases the creepage path length between the busbar 4 and the heat exchanger 3, improving electrical safety performance.

[0082] Optimize the structure, for example... Figure 10 As shown, the height of the sidewalls in the width direction (i.e., the Y direction) of the cavity 9 is reduced, and the height of the sidewalls on both sides in the width direction is reduced to a level lower than the height of the sidewalls in the length direction (i.e., the X direction), so that the cavity 9 forms an open or semi-open structure in the width direction.

[0083] Based on this, third notches 92 are respectively provided at the adjacent connection points of the sidewalls in the width direction and the sidewalls in the length direction (i.e., the four corner positions of the cavity 9), so that the cavity 9 forms an open structure at the four corners. The setting of the third notches 92 further increases the creepage distance between the busbar 4 and the heat exchanger 3, thereby improving the electrical safety performance.

[0084] In addition, a fourth notch (not shown in the figure) can be opened at the corresponding position on the side wall in the width direction and below the heat exchanger 3 to further increase the creepage distance between the busbar 4 and the heat exchanger 3.

[0085] In this embodiment, the recessed cavity 9 forms a horizontally enclosing constraint on the electrical insulation component 5, effectively limiting its displacement in the length and width directions of the busbar 4, ensuring the long-term accuracy of the insulation position under vibration. Simultaneously, the electrical insulation component 5 is at least partially recessed within the cavity 9, without increasing the module's thickness, facilitating a thinner and lighter design. During assembly, positioning is achieved simply by placing or snapping the electrical insulation component 5 into the cavity 9, eliminating the need for additional fasteners or adhesives, making the process simple and efficient. Furthermore, the sidewalls of the cavity 9 provide physical protection for the edges of the electrical insulation component 5, effectively reducing the risk of impact damage, especially suitable for brittle materials such as ceramics, further enhancing the overall structural durability.

[0086] In this embodiment, the connection method between the busbar 4 and the terminal post 11, the snap-fitting method between the direct cooling pipe and the electrical insulation component 5 (i.e., the electrical insulation component 5 has a first through groove for the direct cooling pipe to be snapped in), and the cooling working principle of the direct cooling pipe are all the same as in Embodiment 1, and will not be repeated here. The installation process, except for embedding each electrical insulation component 5 into the cavity 9 of the busbar 4, is the same as in Embodiment 1, and will not be repeated here either. Therefore, compared to... Figure 1 and Figure 2 The existing solution shown in this embodiment also has the advantages described in Embodiment 1. Example 3

[0087] like Figure 9 , Figure 10 , Figure 11 and Figure 12 As shown, this embodiment adds a first pressure plate 10 based on the previous embodiment. Wherein, Figure 9 and Figure 10 Taking the addition of a first pressure plate 10 to the basis of embodiment 2 (i.e., the electrical insulation component 5 is clamped in the cavity 9) as an example, Figure 11 and Figure 12 In Figure 8 The example shown is based on the embodiment where the electrical insulation component 5 is located within the second through groove 41 by means of the structure, with the addition of a first pressure plate 10.

[0088] Combination Figure 11 and Figure 12 It can be seen that the first pressure plate 10 is fixed on the busbar 4 and presses the heat exchanger 3 onto the electrical insulation component 5 so that the heat exchanger 3 and the electrical insulation component 5 are in close contact.

[0089] The first pressure plate 10 can be a flat plate structure, which is simple to process and low in cost; or it can be a plate structure with a groove, the inner wall contour of the groove is adapted to the outer wall shape of the heat exchanger 3, so that when the heat exchanger 3 is embedded in the groove, it can form a surface contact with the inner wall of the groove, increase the pressing area, improve the pressing uniformity, and thus further improve the bonding effect between the heat exchanger 3 and the electrical insulation component 5.

[0090] The contact interface between the heat exchanger 3 and the electrical insulation component 5 is effectively pressed together by the pressing action of the first pressure plate 10, eliminating the air gap between them, significantly reducing the interface contact thermal resistance, and improving the heat transfer efficiency from the busbar 4 through the electrical insulation component 5 to the heat exchanger 3. At the same time, the pressing fit can suppress the relative displacement or shaking of the heat exchanger 3 and the electrical insulation component 5 caused by vibration, avoid poor contact or damage to the insulation layer caused by fretting wear, and further improve the long-term reliability and stability of the overall structure.

[0091] Specifically, the fixing method between the first pressure plate 10 and the busbar 4 can adopt at least the following two schemes: Option 1 (Card-mounted fixing): The first pressure plate 10 and the second through groove 41 or cavity 9 are mutually engaged through a second convex-concave fitting structure. Specifically, this can be achieved in the following two ways: Method 1: A fifth through groove 12 is provided on the two opposite groove walls of the second through groove 41 or on the opposite side walls of the cavity 9. The fifth through groove 12 and the fourth through groove 42 are spatially independent and isolated from each other and do not communicate with each other. The edges of the opposite sides of the first pressure plate 10 are respectively embedded in the corresponding fifth through groove 12, thereby realizing the snap-fit ​​between the first pressure plate 10 and the second through groove 41 or the cavity 9. Method 2: On the opposite side walls of the two grooves of the second through groove 41, there are protrusions extending along their length direction on the opposite side walls of the cavity 9. On the opposite side walls of the first pressure plate 10, through grooves extending along their length direction are respectively opened. During assembly, the two protrusions are respectively embedded into the corresponding through grooves to achieve snap-fit ​​fitting.

[0092] Both of the above methods require no additional fasteners or welding; simply pushing the first pressure plate 10 into the second through slot 41 completes the fitting and fixing process. The assembly process is simple and quick, reducing manufacturing time and material costs. The first pressure plate 10 can be made of plastic and processed as a single piece through injection molding, resulting in lower costs and good electrical insulation properties.

[0093] Option 2 (Welding Fixation): The first pressure plate 10 is welded to the busbar 4. Although this method adds a welding process, this welding is a fixed welding of the pressure plate, which is a structural connection and does not constitute an electrical connection node. Therefore, it will not introduce contact resistance or connection failure risks, and will not have an adverse impact on the electrical reliability and long-term service life of the battery module 8.

[0094] The first pressure plate 10 may be a metal member (such as a copper member or an aluminum member) to ensure the reliability of welded connection and structural strength.

[0095] In this embodiment, the connection manner between the busbar 4 and the pole post 11, the clamping fit manner between the direct cooling pipe and the electrical insulator 5, and the cooling working principle of the direct cooling pipe are all the same as those in the previous embodiments, which will not be repeated herein. Embodiment 4

[0096] As shown in Figure 13 , Figure 14 and Figure 15 , this embodiment provides another limiting structure different from the previous embodiments. Specifically, a second pressure plate 13 fixed on the busbar 4 is used as at least part of the limiting structure, and at the same time, the second pressure plate 13 can also press the heat exchange member 3 against the electrical insulator 5, so that the heat exchange member 3 and the electrical insulator 5 are kept in close contact.

[0097] In this embodiment, the second pressure plate 13 integrates the limiting and pressing functions, eliminating the need for separately providing independent limiting components and pressing components, which simplifies the number of parts and assembly steps. Through the pressing effect of the second pressure plate 13, the heat exchange member 3 and the electrical insulator 5 are kept in close contact, which effectively reduces the interface contact thermal resistance and improves the thermal conduction efficiency; meanwhile, the limiting constraint of the second pressure plate 13 on the electrical insulator 5 ensures the long-term accuracy of the insulation position and avoids displacement or falling off caused by vibration.

[0098] The second pressure plate 13 may adopt at least the following two structures: Structure 1: As shown in Figure 13 and Figure 14 , the second pressure plate 13 is provided with a third through groove 131 along its length direction (x direction), and the outer sides of the groove walls on two opposite sides of the third through groove 131 are respectively provided with folded edges 132, that is, the second pressure plate 13 is integrally in a shape like the Chinese character "几".

[0099] The folded edges 132 are fixedly connected with the busbar 4 (for example, by welding or bolt connection), and an electrical insulator accommodating cavity 133 is defined between the third through groove 131 and the busbar 4. The electrical insulator 5 is clamped in the accommodating cavity to limit the displacement of the electrical insulator 5 relative to the busbar 4 in the thickness direction and the width direction ( Figure 14 , in order to facilitate the display of the electrical insulator accommodating cavity 133, the electrical insulator 5 is not shown on one side); the groove bottom of the third through groove 131 is pressed against the heat exchange member 3, so that the heat exchange member 3 and the electrical insulator 5 are kept in contact.

[0100] The bottom of the third channel 131 can be a flat surface, which is simple to process and low in cost; or it can be a curved surface with a groove, the inner wall contour of which is adapted to the shape of the outer wall of the heat exchanger 3, so that when the heat exchanger 3 is embedded in the groove, it can form a surface contact with the inner wall of the groove, increasing the pressing area and improving the pressing uniformity.

[0101] In this structure, the electrical insulation component 5 extends into an electrical insulation component receiving cavity 133 at both ends along its length to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting electrical safety requirements.

[0102] The flange 132 is fixedly connected to the busbar 4. The third channel 131 and the busbar 4 enclose an independent receiving cavity, in which the electrical insulating component 5 is fitted. The sidewalls and top wall of the receiving cavity (i.e., the bottom of the third channel 131) respectively limit the electrical insulating component 5 in the thickness and width directions, effectively preventing displacement or detachment during use. Simultaneously, the bottom of the third channel 131 directly presses against the upper surface of the heat exchanger 3, pressing the heat exchanger 3 firmly onto the electrical insulating component 5. No additional pressing components are required, resulting in a compact structure and easy assembly. In this structure, the flange 132 and the busbar 4 can be fixed by welding or bolting. When welding is used, this welding is a structural connection and does not constitute an electrical connection node, thus having no adverse impact on the electrical reliability of the battery module 8. When the second pressure plate 13 is a plastic part, bolting is preferred between the flange 132 and the busbar 4 to avoid deformation of the plastic part due to the high temperature of welding.

[0103] Structure 2: like Figure 15 and Figure 16 As shown, the second pressure plate 13 is provided with a blocking mechanism 134. Specifically, the blocking mechanism 134 is a boss provided at the bottom of the second pressure plate 13, and the position of the boss corresponds to the end of the electrical insulation member 5. In this embodiment, two bosses are respectively provided at both ends of the second pressure plate 13 in the length direction, and the two bosses at the same end are arranged at intervals along the width direction of the second pressure plate 13 to form two abutment points at the end of the electrical insulation member 5, thereby enhancing the stability of the limiting.

[0104] Corresponding to this type of second pressure plate 13, the limiting structure also includes a second through groove 41 formed on the busbar 4 and extending along its length, a sixth through groove 46 disposed on two opposite groove walls of the second through groove 41, and a protrusion 135 disposed on two opposite side walls of the second pressure plate 13. The sixth through groove 46 and the protrusion 135 together constitute a third concave-convex fitting structure. The sixth through groove 46 extends along the length of the second through groove 41, and the protrusion 135 extends along the length of the second pressure plate 13, and the two are matched in shape.

[0105] The second pressure plate is made of a material with a certain degree of elastic deformation capability, but the material hardness should not be too low to avoid losing sufficient clamping force due to excessive deformation during the clamping process. For example, it can be made of a material such as plastic that has both appropriate elasticity and rigidity to facilitate installation and ensure the reliability of the clamping effect.

[0106] During assembly, the electrical insulation component 5 is snapped into the second through groove 41, and the second pressure plate 13 is pressed in from above. The elastic deformation of the plate causes the protrusions 135 on both sides to snap and fix in the sixth through groove 46, thereby achieving the fitting and fixing of the second pressure plate 13 and the second through groove 41.

[0107] After the clamp is in place, the blocking mechanism 134 (i.e. the boss at the bottom of the second pressure plate 13) abuts against both ends of the electrical insulation component 5 in the length direction to limit the displacement of the electrical insulation component 5 relative to the busbar 4 in the length direction; at the same time, the bottom surface of the second pressure plate 13 presses against the heat exchange component 3 so that the heat exchange component 3 and the electrical insulation component 5 remain in contact.

[0108] The second pressure plate 13 can be a flat plate structure, which is simple to process and low in cost; or it can be a plate structure with a groove, the inner wall contour of the groove is adapted to the outer wall shape of the heat exchanger 3, so that when the heat exchanger 3 is embedded in the groove, it can form a surface contact with the inner wall of the groove, increase the pressing area, improve the pressing uniformity, and thus improve the bonding effect between the heat exchanger 3 and the electrical insulation component 5.

[0109] In this structure, the two ends of the electrical insulation component 5 in the length direction also extend into second through grooves 41 to increase the creepage distance between the busbar 4 and the heat exchange component 3, thereby meeting the electrical safety requirements.

[0110] Based on the existing positioning of the electrical insulating component 5 in the second through groove 41 (the groove wall of the second through groove 41 already limits the electrical insulating component 5 in the width direction), this scheme adds a second pressure plate 13 and a blocking mechanism 134 to precisely limit the electrical insulating component 5 in the thickness and length directions, thus providing comprehensive constraint on the electrical insulating component 5 in three directions. Simultaneously, the third concave-convex fitting structure ensures that the second pressure plate 13 and the second through groove 41 are fitted and fixed (i.e., the protruding edges on both sides of the second pressure plate are respectively embedded in the corresponding sixth through grooves), ensuring the long-term accurate and reliable positioning of the blocking mechanism 134. The second pressure plate 13 also functions as a clamping device, keeping the heat exchange component 3 and the electrical insulating component 5 in close contact, reducing contact thermal resistance. Through the multiple combinations of "second through groove 41 + third concave-convex fitting + second pressure plate 13 + blocking mechanism 134," the multi-directional limiting of the electrical insulating component 5, the clamping and fitting of the heat exchange component 3, and the fitting and fixing of the second pressure plate 13 itself are simultaneously achieved on the same structure. The structure has a high degree of integration, and the functions do not interfere with each other but rather enhance each other. During assembly, the electrical insulation component 5 only needs to be inserted into the second through slot 41, and the second pressure plate 13 can be fitted into the sixth through slot 46 through a concave-convex fit to simultaneously complete the limiting, pressing and fixing. No additional fasteners or welding are required, resulting in high assembly efficiency. It is especially suitable for the design of battery module 8 with high requirements for space compactness, assembly efficiency and vibration reliability.

[0111] In this embodiment, the connection method between the busbar 4 and the pole post 11, the clamping and fitting method between the direct cooling pipe and the electrical insulation component 5, and the cooling working principle of the direct cooling pipe are all the same as in the previous embodiment, and will not be repeated here. Example 5

[0112] like Figure 17 The diagram shown is a structural schematic of the battery assembly in this embodiment. The difference between this embodiment and the previous embodiments is that the battery module 8 is the second type of battery module described above. In other words, this embodiment adds a venting manifold 6 to the battery assembly structure described in any of the previous embodiments. Figure 17 Taking the addition of a venting manifold 6 to the battery assembly structure of Example 1 as an example.

[0113] The explosion venting manifold 6 extends along the first direction (x direction) and seals over the explosion vents of the n individual cells 1. Specifically, a hollow tube can be provided at the explosion vent of each individual cell 1 casing, and the hollow tubes are connected by the explosion venting manifold 6; wherein an explosion venting membrane is provided on the explosion vent and / or the hollow tube.

[0114] Preferably, in this embodiment, the explosion-venting membrane is disposed at the port where the hollow component connects to the explosion-venting manifold 6, and can be integrally formed with the hollow component and the cover plate body using a stamping process. While simplifying the processing technology, the inner cavity of the hollow component can serve as a gas-containing cavity, reducing the bulging phenomenon of the single-cell battery 1 casing caused by gas generation.

[0115] When any single cell 1 experiences thermal runaway, the high-temperature and high-pressure flue gas it generates can be channeled into the explosion relief manifold 6 through the hollow pipe and discharged in an orderly and directional manner to a safe location or centrally treated, thereby effectively preventing thermal runaway from spreading to adjacent single cells 1 within the module and significantly improving the safety performance of the battery module.

[0116] It should be noted that the connection method between the busbar 4 and the pole post 11, the clamping and fitting method between the direct cooling pipe and the electrical insulation component 5, the setting method of the electrical insulation component 5, and the cooling working principle of the direct cooling pipe in this embodiment can all follow the specific schemes of the aforementioned embodiments, and will not be repeated here. Example 6

[0117] like Figure 18 The image shown is a cross-sectional view of the battery assembly in this embodiment. The difference between this embodiment and the previous embodiments is that the battery module 8 is the aforementioned third type of battery module, and the individual battery cells 1 are connected in parallel.

[0118] Specifically, there are two busbars 4, namely a positive busbar and a negative busbar. The positive busbar is connected to the positive terminal of all individual cells 1, and the negative busbar is connected to the negative terminal of all individual cells 1, thereby realizing the parallel electrical connection between the individual cells 1.

[0119] Meanwhile, the internal cavities of each individual battery cell 1 are interconnected through a shared electrolyte pipeline 7, ensuring that each individual battery cell 1 operates within the same electrolyte system and achieving electrolyte interconnection. As a result, the electrical performance and chemical state of each individual battery cell 1 tend to be consistent, effectively improving the overall consistency and lifespan of the battery module 8.

[0120] In this embodiment, the connection method between the busbar 4 and the terminal of the single cell 1, the arrangement of the electrical insulation component 5 and the busbar 4, the clamping and fitting method between the direct cooling pipe and the electrical insulation component 5, and the cooling working principle of the direct cooling pipe are all the same as in the previous embodiment, and will not be repeated here.

Claims

1. A battery assembly, characterized in that: This includes battery modules, busbars, heat exchangers, and electrical insulation components; The battery module includes n individual batteries arranged along a first direction, where n is an integer greater than 1; The busbar is connected to the terminals of each individual battery cell to achieve electrical connection between the individual battery cells. The heat exchanger is mounted on the busbar and is used to achieve temperature control of the battery module; The electrical insulating component is disposed between the heat exchange component and the busbar to achieve electrical insulation between the heat exchange component and the busbar; and a first through groove is formed on the electrical insulating component along its length direction, and the heat exchange component is fitted into the first through groove. At least one of the electrical insulator and the busbar is provided with a limiting structure to limit the displacement of the electrical insulator relative to the busbar in at least one direction.

2. The battery assembly according to claim 1, characterized in that: The limiting structure includes a second through slot opened on the busbar and extending along its length, and a first concave-convex mating structure respectively disposed on the two opposite slot walls of the second through slot and on the electrical insulating component; The electrical insulating component is fitted into the second through slot and interlocks with the second through slot through the first concave-convex fitting structure to limit the displacement of the electrical insulating component relative to the busbar in at least one direction.

3. The battery assembly according to claim 1, characterized in that: The limiting structure includes a cavity disposed on the busbar and recessed along its thickness direction; The electrical insulator is at least partially fitted into the cavity to restrict the displacement of the electrical insulator relative to the busbar in the horizontal direction, wherein the horizontal direction is perpendicular to the thickness direction.

4. The battery assembly according to claim 2 or 3, characterized in that: It also includes a first pressure plate; the first pressure plate is fixed on the busbar and presses the heat exchanger onto the electrical insulation component so that the heat exchanger and the electrical insulation component remain in contact.

5. The battery assembly according to claim 4, characterized in that: The limiting structure includes a second through groove formed on the busbar and extending along its length; a second concave-convex fitting structure is provided on the two opposite side walls of the second through groove and on the first pressure plate; the first pressure plate is engaged with the second through groove through the second concave-convex fitting structure. Alternatively, the limiting structure includes a cavity disposed on the busbar and recessed along its thickness direction; a second concave-convex fitting structure is respectively provided on the two opposite sidewalls of the cavity and on the first pressure plate; the first pressure plate is mutually fitted with the cavity through the second concave-convex fitting structure.

6. The battery assembly according to claim 1, characterized in that: The limiting structure includes a second pressure plate; The second pressure plate is fixed to the busbar to limit the displacement of the electrical insulation component relative to the busbar in at least one direction and to press the heat exchange component onto the electrical insulation component so that the heat exchange component and the electrical insulation component remain in contact.

7. The battery assembly according to claim 6, characterized in that: The second pressure plate has a third through groove along its length, and the outer sides of the groove walls on opposite sides of the third through groove are respectively provided with folded edges; The folded edge is fixedly connected to the busbar, and the third through groove and the busbar enclose an electrical insulation component receiving cavity to limit the displacement of the electrical insulation component relative to the busbar in the thickness and width directions of the busbar; The electrical insulating component is fitted into the receiving cavity, and the bottom of the third through groove presses against the heat exchange component so that the heat exchange component and the electrical insulating component remain in contact.

8. The battery assembly according to claim 6, characterized in that: The limiting structure also includes a second through groove extending along the length of the busbar, and a third concave-convex fitting structure respectively disposed on the two opposite groove walls of the second through groove and on the second pressure plate. The second pressure plate is equipped with a blocking mechanism; The electrical insulating component is fitted into the second through slot. After the second pressure plate is engaged with the second through slot through the third concave-convex fitting structure, the blocking mechanism abuts against the electrical insulating component to limit the displacement of the electrical insulating component relative to the busbar in the length direction of the busbar. The second pressure plate also presses the heat exchange component to keep the heat exchange component and the electrical insulating component in close contact.

9. The battery assembly according to claim 1, characterized in that: The busbars are multiple, and each busbar is connected to a different polarity terminal in an adjacent single cell to realize series connection between the single cells; or, the busbars are two, one of which is connected to the positive terminal of all single cells, and the other busbar is connected to the negative terminal of all single cells, so that the electrolytes of the single cells are connected.

10. The battery assembly according to claim 1, characterized in that: The electrical insulation component is a ceramic component.

11. The battery assembly according to claim 1, characterized in that: Thermally conductive silicone grease is applied between the electrical insulation component and the heat exchange component and / or between the electrical insulation component and the busbar.

12. The battery assembly according to claim 1, characterized in that: The heat exchanger is a direct cooling pipe, and the refrigerant provided by the direct cooling system flows inside the direct cooling pipe to achieve temperature control of the battery module.

13. The battery assembly according to claim 1, characterized in that: The casing of the individual battery is provided with a hollow tube; The battery module also includes an explosion venting manifold; the explosion venting manifold is connected to the hollow tube of each individual battery cell to ensure that the thermal runaway fumes of the individual battery cells are discharged through the explosion venting manifold.

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