A power battery pack and a mounting method

Abstract

The application discloses a power battery pack and a mounting method, the battery pack comprises a battery cell assembly, a battery shell, full-coated damping foam, a double-layer waterproof pressure relief structure, a weak current switch with a lamp, a CAN communication port and a front side integrated circuit assembly, the battery cell is formed by an insulating end plate, a pressing strip and a binding belt, the bottom shell is provided with a whole machine fixing hole and a multi-pack parallel fixing hole, the damping foam buffers vibration in all directions, a waterproof pad cooperates with a waterproof and breathable valve to balance the air in the shell, the integrated bus arrangement is neat, and the supporting mounting method comprises seven standardized procedures of battery cell binding, module shell entering, shell sealing, component assembly, circuit docking, whole machine fixing and multi-pack parallel connection, and a heating film can be arranged to realize low-temperature preheating. The application solves the problems of poor shock resistance, easy sealing failure, complicated operation and maintenance and no unified standard for assembly of the existing battery pack, and has the advantages of safe and stable structure, high assembly consistency and adaptation to batch production of low-speed power equipment.

Description

Technical Field

[0001] This invention relates to the field of lithium-ion battery technology, specifically a power battery pack and its installation method. Background Technology

[0002] Square aluminum-cased lithium batteries are currently the mainstream cell solution for energy storage and low-speed power equipment. They have advantages such as high shell structural strength, excellent planar heat dissipation, high degree of standardization, and individual cell replacement and maintenance. In the industry, CTC / CTB integration, large-capacity cells, highly stable electrolytes, and BMS full-domain intelligent management are the mainstream development directions.

[0003] Existing low-speed power battery packs generally suffer from several shortcomings: First, there is no complete buffer and protection structure between the cell module and the outer casing. Continuous vibrations generated during vehicle operation and equipment work can easily cause the cell terminals and busbars to loosen, leading to poor contact and the risk of thermal runaway. Second, the sealing and waterproofing structure is simplistic, relying solely on sealant at the casing seams. Changes in internal air pressure can easily cause seal failure, and water ingress can directly damage the cells and BMS circuitry. Third, the battery operating status cannot be visually displayed, and fault diagnosis and charge / discharge status assessment require external specialized equipment, resulting in low on-site maintenance efficiency. Fourth, the lack of standardized fixed connection structures for multi-pack parallel expansion leads to messy wiring during on-site assembly, posing a short-circuit safety hazard. Fifth, the BMS, fuses, and positive and negative busbars are scattered, with intertwined internal wiring, making assembly and maintenance operations cumbersome. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the above-mentioned technical defects and provide a power battery pack and installation method.

[0005] To solve the above problems, the technical solution of the present invention is: a power battery pack, characterized in that: it includes... A battery cell assembly, comprising a square battery cell, end plates, pressure strips, and strapping straps, wherein the end plates are disposed at both ends of the square battery cell, the pressure strips are fitted to the sides of the square battery cell, and the strapping straps surround and bind the end plates, pressure strips, and square battery cell; The battery case includes a bottom shell and a top cover, the bottom shell and the top cover are fastened together, the inner wall of the bottom shell is provided with shock-absorbing foam, and the battery cell assembly is located inside the bottom shell and within the receiving space formed by the shock-absorbing foam. The fixing hole is located on the long side wall of the bottom shell; A waterproof and breathable valve is provided on the side wall of the bottom shell; Waterproof gasket assembly, wherein the waterproof gasket assembly is disposed on the inner edge of the upper cover. A low-voltage switch with an integrated light, wherein the low-voltage switch with an integrated light is disposed on the outer wall of the bottom shell; A communication port is provided on the side wall of the bottom shell; The front side of the bottom shell has an external parallel fixing hole, a B-bus, a fuse, a BMS, and a P-bus arranged in a concentrated manner. The B-bus, fuse, BMS, and P-bus are electrically connected in sequence. The external parallel fixing hole is located next to the busbar and is used for parallel connection of multiple battery packs.

[0006] Furthermore, the end plate and pressure strip are attached to the surface of the square battery cell, and both are insulated and separated from the square battery cell.

[0007] Furthermore, the shock-absorbing foam completely covers the bottom surface and surrounding sidewalls of the battery cell assembly, and the battery cell assembly has no direct contact with the inner metal wall of the bottom shell.

[0008] Furthermore, the waterproof pad assembly is arranged around the entire circumference of the upper cover, and after the upper cover is pressed down, the waterproof pad assembly is sandwiched between the mating end faces of the upper cover and the bottom shell.

[0009] Furthermore, the lighted low-voltage switch and the communication port are arranged adjacent to each other along the same outer side wall of the bottom shell, and both are fixedly connected to the outer wall of the bottom shell.

[0010] Furthermore, the B-bus, fuse, BMS, and P-bus are arranged horizontally along the front side of the bottom shell and are directly connected to each other through conductive components.

[0011] Furthermore, the external parallel fixing holes are formed on the bottom shell wall surface on the side of the B-bus and P-bus, and are arranged adjacent to the conductive area of ​​the busbar.

[0012] A method for installing a power battery pack, characterized by comprising the following steps: S1. Battery cell module bundling and forming: The square battery cells are arranged in series and parallel, end plates are assembled at both ends of the battery cells, pressure strips are attached to both sides, and the bundling straps are wrapped around and locked to form a battery cell assembly. S2, Module insertion and buffer assembly: Cover the bottom surface and four walls of the inner side of the bottom shell with shock-absorbing foam, and put the battery cell assembly into the cavity enclosed by the shock-absorbing foam. S3. Shell sealing assembly: A complete ring of waterproof gaskets is assembled on the inside of the upper cover. The upper cover and the bottom shell are aligned, fastened, and locked. A waterproof and breathable valve is assembled on the side wall of the bottom shell. S4. External component assembly: Install a low-voltage switch with lights and a CAN communication port adjacent to each other on the same outer side wall of the bottom shell, and connect the lines of the two to the internal BMS; S5. Internal circuit connection: The B-bus, fuse, BMS, and P-bus are sequentially assembled on the front side of the bottom shell and connected to conduct electricity in sequence. External parallel fixing holes are processed on the side of the bottom shell of the busbar. The battery core harness is electrically connected to the busbar and BMS. S6. External Fixing of the Whole Unit: Move the battery pack to the equipment compartment to be installed, align it with the fixing holes on the long side wall of the bottom shell, and use bolts to lock and fix the whole unit. S7. Parallel expansion installation of multiple battery packs: Multiple battery packs are placed side by side, and conductive copper busbars are locked to the external parallel fixing holes of each battery pack to achieve electrical parallel connection. The battery parameters are uniformly adjusted and balanced by connecting to the host computer through the CAN communication port.

[0013] Furthermore, in step S5, a heating film is installed in the gap between the battery cell and the casing, and the heating film control line is connected to the BMS. The BMS controls the start and stop of the heating film to achieve low-temperature preheating.

[0014] Furthermore, during the sealing assembly of the housing in step S3, the fasteners are tightened evenly in stages along the diagonal perimeter of the upper cover and the bottom cover to ensure that the waterproof gasket assembly is evenly stressed and free from warping.

[0015] The advantages of this invention compared to existing technologies are as follows: the outer side of the battery cell assembly is fully covered with shock-absorbing foam, which buffers operational vibrations from all directions, reduces the probability of loosening of the terminals and busbars, extends the service life of the battery cell, and reduces the risk of fire due to malfunction. The double-layer waterproof pressure relief structure of the waterproof pad combination and waterproof vent valve not only blocks the infiltration of external moisture but also balances the pressure brought by the gas generated during charging and discharging inside the casing, ensuring stable sealing during long-term use. The low-voltage switch with indicator light intuitively displays the battery's operating status, allowing for quick fault diagnosis without the need for external testing equipment, and significantly improving on-site maintenance efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the square battery cell structure of the present invention.

[0017] Figure 2 This is a schematic diagram of the overall module package after the battery cells of the present invention are bundled and formed.

[0018] Figure 3 This is a schematic diagram of the location and structure of the waterproof and breathable valve of the present invention.

[0019] Figure 4 This is a schematic diagram of the battery cell module assembly being installed inside the bottom shell according to the present invention.

[0020] Figure 5 This is a schematic diagram of the communication port structure of the present invention.

[0021] Figure 6 This is a schematic diagram of the overall appearance of the power battery pack after complete assembly according to the present invention.

[0022] As shown in the figure: 1. Square battery cell; 2. End plate; 3. Pressure strip; 4. Bundling strap; 5. Battery casing; 6. Shock-absorbing foam; 7. Fixing hole; 8. Waterproof and breathable valve; 9. Waterproof pad assembly; 10. Low-voltage switch with light; 11. Communication port; 12. External parallel fixing hole; 13. B-bus; 14. Fuse; 15. BMS; 16. P-bus. Detailed Implementation

[0023] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals.

[0024] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions shown in the attached diagram, while the terms “inside” and “outside” refer to the directions toward or away from the geometric center of a specific component, respectively.

[0025] To make the content of this invention easier to understand, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0026] like Figures 1 to 4 As shown, a power battery pack is provided. The square battery cell 1 is a square aluminum shell lithium iron phosphate battery cell. First, insulating end plates 2 are installed at the left and right ends of the battery cell assembly. Insulating pressure strips 3 are attached to both sides of the battery cell assembly. Then, high-strength plastic strapping 4 is used to wrap around and bind the battery cell along the width direction. After locking, a stable series-parallel structure battery cell assembly is formed. The battery casing 5 is divided into two parts: the bottom shell and the top cover. EVA material shock-absorbing foam 6 is completely pasted on the inner wall and bottom of the bottom shell. The bundled battery cell assembly is placed smoothly into the inner cavity surrounded by the shock-absorbing foam 6. The foam completely wraps the side wall and bottom of the battery cell assembly to achieve all-directional buffer protection. Multiple sets of fixing holes 7 are opened on the long side wall of the bottom shell. The entire battery pack can be locked in the equipment compartment by using bolts through the fixing holes 7. Waterproof and breathable valves 8 are installed in the openings on the side wall of the bottom shell. Waterproof gasket assembly 9 is installed along the edge of the inner side of the top cover. The top cover is fastened to the top of the bottom shell and the joint is pressed with stainless steel locking screws. The waterproof gasket assembly fits tightly against the end face of the bottom shell to achieve water-proof sealing. The waterproof and breathable valve continuously balances the air pressure generated by charging and discharging inside the shell to prevent the sealing gasket from being delaminated by pressure. A low-voltage switch 10 with an indicator light is installed on the outer wall of the bottom shell. The switch has a built-in red, green and blue indicator light. A solid green light corresponds to normal discharge, a solid blue light corresponds to charging, and a solid red light or high-frequency flashing light corresponds to cell overvoltage, undervoltage, overtemperature and other faults. A CAN communication port 11 is opened at the lower adjacent position of the switch. After the data cable is inserted into the communication port 11, an external host computer can be connected to read the cell voltage, temperature and capacity data, and at the same time modify the protection threshold and upgrade the BMS control program. The front integrated area of ​​the bottom shell is sequentially equipped with external parallel fixing hole 12, B-bus 13, one-time fuse 14, BMS15, and P-bus 16. The electrical connection sequence is that one end of B-bus 13 is conductively connected to one end of fuse 14, the other end of fuse 14 is connected to the negative circuit of BMS15, and the positive circuit of BMS15 is conductively connected to P-bus 16. The external parallel fixing hole 12 is located next to the busbar. When multiple battery packs are connected in parallel for capacity expansion, the conductive copper busbar is directly locked onto the external parallel fixing hole 12, and the wiring is neat and without crossing, avoiding the risk of short circuit. After the module is assembled, a heating film is installed in the gap between the cell and the casing. In low-temperature environments, the heating film is controlled by the BMS to ensure the discharge capacity of the cell. The casing is equipped with stainless steel pressure strips and aluminum strips to help press the top cover and the module together, further improving the overall structural stability. After the entire battery pack is assembled, it can be directly used to power low-speed electric vehicles, factory transfer vehicles and other power equipment.

[0027] A method for installing a power battery pack includes the following steps: S1. Battery cell module bundling and forming: Stack multiple 105Ah square battery cells 1 in 2 strings of 10 and align them. Add insulating end plates 2 at both ends, attach insulating pressure strips 3 on both sides, and wrap and tighten two high-strength binding straps 4 around the top and bottom. Cut off the excess binding straps 4 to obtain a complete battery cell module. S2. Module insertion and buffer assembly: Cut EVA shock-absorbing foam 6 of the corresponding size, use adhesive to completely stick it to the bottom and four side walls of the bottom shell, with no gaps at the splicing point, and smoothly put the battery cell module into the inner cavity, confirming that the module is completely wrapped by foam around and at the bottom, with no exposed metal in contact with the bottom shell. S3. Shell sealing assembly: Cut the ring-shaped waterproof gasket assembly 9 and stick it to the inner edge of the top cover. Align and fit the top cover with the four sides of the bottom shell. Tighten the stainless steel screws diagonally along the screw holes around the shell step by step to ensure that the waterproof gasket is evenly stressed and has no warping. Wrap waterproof PTFE tape around the threaded part of the side hole of the bottom shell and screw in the waterproof vent valve 8 to complete the pressure relief sealing assembly. S4. External component assembly: Make holes in the reserved mounting positions on the bottom shell, embed the light-up low-voltage switch 10 and CAN communication port 11, pass the wire harness into the inside of the shell, reserve the wiring length to connect to the BMS15 main board, and seal the gaps of the holes with sealant for waterproofing. S5. Internal circuit connection: B-bus, fuse 14, BMS15, and P-bus are sequentially fixed in the slot on the front side of the bottom shell. Copper busbars connect the busbars to fuse 14 and BMS15. The battery cell electrode acquisition harness is connected to the acquisition port of BMS15. After the heating film is laid, the control line is plugged into the temperature control port of BMS15. Drill and tap holes on both sides of the housing of the busbar to process the external parallel fixing holes 7. S6. External fixing of the whole machine: hoist the battery pack into the low-speed electric vehicle mounting compartment, align the fixing holes 7 on both sides of the long side of the bottom shell, and use the matching M8 bolts to pass through the fixing holes 7, install flat washers and spring washers to lock and ensure that the whole machine does not shake. S7. Parallel expansion installation of multiple battery packs: Place two battery packs side by side, align the two ends of the conductive copper busbars with the external parallel fixing holes 7 of the two battery packs respectively, and tighten the bolts to fix the copper busbars; connect the CAN communication ports 11 of the two battery packs in parallel to the same host computer, read the voltage of each cell, start the BMS15 equalization program, calibrate the voltage difference, and complete the parallel installation and debugging.

[0028] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A power battery pack, characterized in that: include The battery cell assembly includes a square battery cell (1), an end plate (2), a pressure strip (3), and a strapping strap (4). The end plate (2) is located at both ends of the square battery cell (1), the pressure strip (3) is attached to the side of the square battery cell (1), and the strapping strap (4) surrounds and binds the end plate (2), the pressure strip (3), and the square battery cell (1). Battery housing (5), the battery housing (5) includes a bottom shell and a top cover, the bottom shell and the top cover are fastened together, the inner wall of the bottom shell is provided with shock-absorbing foam (6), the battery cell assembly is located inside the bottom shell and is located in the accommodating space formed by the shock-absorbing foam (6); Fixing hole (7), the fixing hole (7) is opened to the long side wall of the bottom shell; Waterproof and breathable valve (8), the waterproof and breathable valve (8) is provided on the side wall of the bottom shell; Waterproof pad assembly (9), the waterproof pad assembly (9) is located on the inner edge of the upper cover. A low-voltage switch with a light (10) is provided on the outer wall of the bottom shell; Communication port (11), the communication port (11) is opened on the side wall of the bottom shell; The front side of the bottom shell has an external parallel fixing hole (12), a B-bus, a fuse (14), a BMS (15), and a P-bus arranged in a concentrated manner. The B-bus, fuse (14), BMS (15), and P-bus are connected in a conductive manner in sequence. The external parallel fixing hole (12) is located next to the busbar and is used for parallel connection of multiple battery packs.

2. The power battery pack according to claim 1, characterized in that: The end plate (2) and pressure strip (3) are attached to the surface of the square battery cell (1), and both are insulated from the square battery cell (1).

3. A power battery pack according to claim 1, characterized in that: The shock-absorbing foam (6) completely covers the bottom surface and the four sides of the battery cell assembly, and the battery cell assembly has no direct contact with the inner metal wall of the bottom shell.

4. A power battery pack according to claim 1, characterized in that: The waterproof pad assembly (9) is arranged around the entire circle of the upper cover. After the upper cover is pressed down, the waterproof pad assembly (9) is sandwiched between the mating end face of the upper cover and the bottom shell.

5. A power battery pack according to claim 1, characterized in that: The lighted low-voltage switch (10) and the communication port (11) are arranged adjacent to each other along the same outer side wall of the bottom shell, and both are fixedly connected to the outer wall of the bottom shell.

6. A power battery pack according to claim 1, characterized in that: The B-bus, fuse (14), BMS (15), and P-bus are arranged horizontally along the front side of the bottom shell and are directly connected to each other through conductive components.

7. A method for installing a power battery pack, characterized in that, Includes the following steps: S1. Battery cell module bundling and forming: The square battery cells (1) are arranged in series and parallel, the end plates (2) are assembled at both ends of the battery cells, the pressure strips (3) are attached to both sides, and the bundling straps (4) are wrapped around and locked to form a battery cell assembly. S2, Module housing buffer assembly: Cover the bottom surface and four walls of the inner side of the bottom shell with shock-absorbing foam (6), and put the battery cell assembly into the cavity enclosed by the shock-absorbing foam (6); S3. Shell sealing assembly: A full ring of waterproof gaskets (9) is assembled on the inside of the upper cover. The upper cover and the bottom shell are aligned, fastened and locked. A waterproof and breathable valve (8) is assembled on the side wall of the bottom shell. S4. External component assembly: Install a low-voltage switch with lights (10) and a CAN communication port (11) adjacent to each other on the same outer side wall of the bottom shell, and connect the lines of the two to the internal BMS (15). S5. Internal circuit connection: Install B-bus, fuse (14), BMS (15) and P-bus in sequence on the front side of the bottom shell and complete the sequential conductive connection. Process external parallel fixing holes on the side of the bottom shell of the busbar. Complete the electrical connection between the battery core harness and the busbar and BMS (15). S6. External Fixing of the Whole Unit: Move the battery pack to the equipment compartment to be installed, align it with the fixing holes on the long side wall of the bottom shell, and use bolts to lock and fix the whole unit. S7. Parallel expansion installation of multiple battery packs: Place multiple battery packs side by side, lock the conductive copper busbars to the external parallel fixing holes of each battery pack to achieve electrical parallel connection, and connect to the host computer through the CAN communication port (11) to complete the unified debugging and equalization of battery parameters.

8. The method for installing a power battery pack according to claim 6, characterized in that: In step S5, a heating film is installed in the gap between the battery cell and the casing. The heating film control line is connected to the BMS (15), and the BMS (15) controls the start and stop of the heating film to achieve low-temperature preheating.

9. The method for installing a power battery pack according to claim 6, characterized in that: During the sealing assembly of the housing in step S3, the fasteners are tightened evenly in steps along the diagonal perimeter of the top cover and bottom cover to ensure that the waterproof gasket assembly (9) is subjected to uniform force and has no warping edges.

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