Integrated power battery system

Through modular integrated design, the installation areas of the battery module and electrical components are merged into one box assembly, which solves the problem of multiple box designs in the existing power battery system increasing assembly processes and costs, achieving the effect of simplifying manufacturing, reducing assembly difficulty and saving costs, and at the same time reducing the failure risk of the battery system.

CN222785303UActive Publication Date: 2025-04-22RISESUN MENGGULI NEW ENERGY SCIENCE & TECHNOLOGY CO LTD
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Patent Information

Application Number
CN202420610892.6
Authority / Receiving Office
CN · China
Patent Type
Utility models(China)
Current Assignee / Owner
Filing Date
2024-03-27
Publication Date
2025-04-22
Estimated Expiration
2034-03-27

AI Technical Summary

Technical Problem

In the existing power battery system design, there are two separate box designs, one for installing the battery module and the other for installing electrical components, which increases assembly processes and costs, and also increases potential failure modes.

Method used

Modular integrated design is adopted, with the box assembly as the first module, the battery module assembly and the liquid-cooled tube assembly as the second module, and the electrical component assembly and the flow guide row as the third module, respectively, which are arranged in the two installation areas of the box assembly to realize the integrated design of the battery system.

Benefits of technology

The manufacturing process is simplified, assembly difficulty is reduced, the cost of high-voltage boxes is saved, space utilization is improved, and the failure of the battery system is reduced.

✦ Generated by Eureka AI based on patent content.

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Abstract

The utility model provides an integrated power battery system, and relates to the technical field of batteries, the battery system comprises a box body assembly, the box body assembly comprises a box body and a box cover, the box body and the box cover are connected to form a first module, and two mounting areas are arranged in the first module; a battery module assembly and a liquid cooling pipe assembly, the battery module assembly and the liquid cooling pipe assembly are connected to form a second module, and the second module is arranged in one of the mounting areas; the electrical component assembly and the diversion row are connected to form a third module, and the third module is arranged in the other mounting area; the battery system adopts the modular integrated structural design, so that the battery system is simple to manufacture and convenient to assemble during assembly, the assembly difficulty is reduced, one high-voltage box is saved, the low-cost design is realized, and the whole structure embodies the technical effects of simplicity, convenience, high efficiency and high space utilization rate.
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Description

Technical Field

[0001] The utility model belongs to the technical field of batteries, and more specifically, relates to an integrated power battery system. Background Art

[0002] In the automotive industry, hydrogen fuel, hybrid commercial vehicles, hybrid heavy trucks and hybrid mining trucks have attracted more and more attention in recent years. Because new energy vehicles have the advantages of low noise, low heat radiation and easy operation, people have high expectations for these new energy vehicles. In recent years, the number of power batteries installed on commercial vehicles, heavy trucks and mining trucks has increased significantly, so the power battery system design of new energy truck vehicles is crucial. In the past, the power battery system required both a battery box for installing battery modules and a high-voltage box for installing various electrical components. The two boxes are equivalent to two separate designs, which increases assembly processes and costs, and also increases potential failure modes. Utility Model Content

[0003] The purpose of the utility model is to provide an integrated power battery system in response to the deficiencies in the existing technology, so as to solve the problem that the power battery system in the prior art has two sets of separately designed boxes, one battery box for installing battery modules, and the other high-voltage box for installing various electrical components, which increases the assembly process and cost, and also increases the potential failure modes.

[0004] In order to achieve the above object, the utility model provides an integrated power battery system, the battery system comprising:

[0005] A box assembly, the box assembly comprising a box body and a box cover, the box body and the box cover are connected to form a first module, and two installation areas are provided inside the first module;

[0006] A battery module assembly and a liquid cooling tube assembly, wherein the battery module assembly and the liquid cooling tube assembly are connected to form a second module, and the second module is arranged in one of the installation areas;

[0007] An electrical component assembly and a guide bar, wherein the electrical component and the guide bar are connected and form a third module, and the third module is arranged in another installation area.

[0008] Preferably, the integrated power battery system further comprises a support frame, the electrical component assembly is arranged on the support frame, the support frame is arranged in another installation area, and the water inlet end and the water outlet end of the liquid cooling pipe assembly are respectively arranged on both sides of the support frame.

[0009] Preferably, the guide bar is arranged around the support frame, and the guide bar is used to electrically connect the electrical component assembly and the battery module assembly.

[0010] Preferably, the box assembly further includes:

[0011] A load-bearing beam, the load-bearing beam is arranged at the bottom of the box body, and the battery module assembly and the battery element assembly are arranged on the load-bearing beam;

[0012] A sealing ring is arranged between the box cover and the box body.

[0013] Preferably, the support frame comprises:

[0014] Base plate;

[0015] A side panel connected to the bottom panel and in an L shape;

[0016] Two connecting components, one end of the two connecting components is respectively connected to the two ends of the side plate, and the other end of the two connecting components is respectively connected to the two sides of the box assembly.

[0017] Preferably, the connecting component comprises:

[0018] Two supports, the two supports are respectively connected to the side plate and the box assembly;

[0019] A connecting piece, the two ends of which are respectively connected to the two supports.

[0020] Preferably, the electrical component assembly includes multiple contactors, current fuses, a main control module, a wiring harness connection board, a Hall current sensor and a DC converter, and the multiple contactors, current fuses, Hall current sensors and DC converters are arranged on the base plate, and the main control module and the wiring harness connection board are arranged on the side panel.

[0021] Preferably, the integrated power battery system further comprises a high-voltage interlock connector, which is arranged on the box assembly and at a position close to the electrical component assembly, and the high-voltage interlock connector is electrically connected to the guide bar.

[0022] Preferably, the guide bar is a copper bar.

[0023] Preferably, the box body and the box cover are both formed by bending sheet metal parts.

[0024] The utility model provides an integrated power battery system, which has the beneficial effects of: the battery system is divided into three design modules, wherein the box body and the box cover included in the box body assembly are the first module, the battery module assembly and the liquid cooling pipe assembly are connected as the second module, the electrical component assembly and the guide bar are connected as the third module, the second module and the third module are respectively arranged in two installation areas inside the first module, and the battery system adopts a modular integrated structural design to achieve simple manufacturing, and during assembly, the assembly is convenient, the assembly difficulty is reduced, a high-voltage box is saved, and a low-cost design is achieved. The entire structure embodies the technical effects of simplicity, convenience, high efficiency and high space utilization. At the same time, the integrated design also reduces the failure phenomenon of the battery system itself.

[0025] Other features and advantages of the present invention will be described in detail in the subsequent specific implementation section. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of exemplary embodiments of the present invention in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments of the present invention.

[0027] Figure 1 A schematic diagram of the three-dimensional structure of an integrated power battery system according to an embodiment of the utility model is shown;

[0028] Figure 2 A schematic diagram of a top view of a box body of an integrated power battery system according to an embodiment of the utility model is shown;

[0029] Figure 3 The schematic diagram of the three-dimensional structure of an integrated power battery system according to an embodiment of the utility model is shown. Figure 1 ;

[0030] Figure 4 The schematic diagram of the three-dimensional structure of an integrated power battery system according to an embodiment of the utility model is shown. Figure 2 ;

[0031] Figure 5 A schematic diagram of the three-dimensional structure of a support frame of an integrated power battery system according to an embodiment of the utility model is shown;

[0032] Figure 6 A schematic diagram of the three-dimensional structure of an integrated power battery system when connecting pieces are connected according to an embodiment of the utility model is shown.

[0033] Description of reference numerals:

[0034] 1. Box assembly; 11. Box; 12. Box cover; 13. Load beam; 14. Sealing ring; 2. Battery module assembly; 3. Liquid cooling tube assembly; 4. Electrical component assembly; 41. Contactor; 42. Current fuse; 43. Main control module; 44. Wiring harness connecting plate; 45. Hall current sensor; 46. DC converter; 5. Guide bar; 6. Support frame; 61. Bottom plate; 62. Side plate; 63. Support; 64. Connecting piece; 7. High-voltage interlocking connector. DETAILED DESCRIPTION

[0035] The preferred embodiments of the present invention will be described in more detail below. Although the preferred embodiments of the present invention are described below, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments described herein. On the contrary, these embodiments are provided to make the present invention more thorough and complete, and to fully convey the scope of the present invention to those skilled in the art.

[0036] like Figure 1-4 As shown, the utility model provides an integrated power battery system, the battery system comprising:

[0037] A box assembly, the box assembly comprises a box body and a box cover, the box body and the box cover are connected to form a first module, and two installation areas are arranged inside the first module;

[0038] A battery module assembly and a liquid cooling tube assembly, the battery module assembly and the liquid cooling tube assembly are connected to form a second module, and the second module is arranged in one of the installation areas;

[0039] The electrical component assembly and the guide bar are connected with the electrical component and the guide bar to form a third module, and the third module is arranged in another installation area.

[0040] Specifically, in order to solve the problem that the power battery system in the prior art has two sets of separately designed boxes, one is a battery box for installing a battery module, and the other is a high-voltage box for installing various electrical components, which increases the assembly process and the cost, and the potential failure mode is also increased, the utility model provides an integrated power battery system, the box 11 and the box cover 12 of the battery system are connected by screw connection, the guide bar of the battery system is a copper bar, and the battery system is divided into three design modules, wherein the box 11 and the box cover 12 included in the box assembly 1 are the first module, the battery module assembly 2 and the liquid cooling pipe assembly 3 are connected as the second module, and the electrical component assembly 4 and the guide bar 5 are connected as the third module, and the second module and the third module are respectively arranged in two installation areas inside the first module. The battery system adopts a modular integrated structural design to achieve simple manufacturing, and during assembly, it is easy to assemble, reduces the difficulty of assembly, saves a high-voltage box, and achieves a low-cost design. The whole structure embodies the technical effects of simplicity, convenience, high efficiency and high space utilization. At the same time, the integrated design also reduces the failure phenomenon of the battery system itself.

[0041] Preferably, the integrated power battery system further comprises a support frame, the electrical component assembly is arranged on the support frame, the support frame is arranged in another installation area, and the water inlet end and the water outlet end of the liquid cooling pipe assembly are respectively arranged on both sides of the support frame.

[0042] Specifically, the arrangement of the liquid cooling pipe assembly and the support frame 6 improves space utilization.

[0043] Preferably, the guide bar is arranged around the support frame, and the guide bar is used to electrically connect the electrical component assembly and the battery module assembly.

[0044] Specifically, the guide bar 5 is screwed to the electrical component assembly, and the arrangement of the guide bar 5 and the support frame 6 improves space utilization.

[0045] Preferably, the box assembly further includes:

[0046] A load-bearing beam, which is arranged at the bottom of the box body, and the battery module assembly and the battery element assembly are arranged on the load-bearing beam;

[0047] A sealing ring is arranged between the box cover and the box body.

[0048] Specifically, the load-bearing beam 13 includes a transverse beam and a longitudinal beam, which are distributed at the bottom of the box body 11, and fully consider the overall stiffness and local strength of the box body assembly 1. The battery module assembly 2 and the liquid cooling pipe assembly 3 are connected by quick plugs and then screwed to the load-bearing beam 13 through a screw rod. The support frame 6 is also screwed to the load-bearing beam 13, so that disassembly and installation can be achieved.

[0049] like Figure 5 As shown, preferably, the support frame includes:

[0050] Base plate;

[0051] Side panels, which are connected to the bottom panel and are L-shaped;

[0052] Two connecting components, one end of the two connecting components is respectively connected to the two ends of the side plates, and the other end of the two connecting components is respectively connected to the two sides of the box assembly.

[0053] Specifically, the electrical components can be installed on the bottom plate 61 and the side plates 62. The L-shaped support frame 6 can be used to install the electrical components on the bottom and sides, thereby improving space utilization.

[0054] like Figure 6 As shown, preferably, the connecting component includes:

[0055] Two supports, the two supports are respectively connected to the side plate and the box assembly;

[0056] A connecting piece, two ends of which are respectively connected to two supports.

[0057] Specifically, the two ends of the connecting piece are respectively screwed to the two supports 63, so that disassembly and installation can be achieved.

[0058] Preferably, the electrical component assembly includes multiple contactors, current fuses, a main control module, a wiring harness connection board, a Hall current sensor and a DC converter (DCDC), and the multiple contactors, current fuses, Hall current sensors and DC converters are arranged on the bottom plate, and the main control module and the wiring harness connection board are arranged on the side panel.

[0059] Specifically, the support frame 6 is a sheet metal part, and the L-shaped support frame 6 is riveted with studs to install other electrical components such as contactors, current fuses, main control modules, wiring harness connection plates, Hall current sensors and DC converters. These electrical components can be assembled to the support frame 6 before the support frame 6 is assembled to the box assembly 1, and then placed as a whole into the box assembly 1, which makes the assembly simple and convenient, thereby improving the assembly efficiency.

[0060] Preferably, the integrated power battery system further includes a high-voltage interlock connector (MSD), which is disposed on the box assembly and is disposed near the electrical component assembly, and is electrically connected to the guide bar.

[0061] Specifically, the high-voltage interlocking connector is threadedly connected to the guide bar.

[0062] Preferably, the box body and the box cover are both formed by bending sheet metal parts.

[0063] Specifically, the box body and the box cover formed by bending do not require the development of molds, are simple to manufacture, have a high commonality rate, and save costs.

[0064] In summary, when the integrated power battery system of the utility model is implemented, the battery system is divided into three design modules, wherein the box body 11 and the box cover 12 included in the box body assembly 1 are the first module, the battery module assembly 2 and the liquid cooling pipe assembly 3 are connected as the second module, the electrical component assembly 4 and the guide bar 5 are connected as the third module, the second module and the third module are respectively arranged in two installation areas inside the first module, and other electrical components such as contactors, current fuses, main control modules, wiring harness connection plates, Hall current sensors and DC converters can be assembled to the support frame 6 before the support frame 6 is assembled to the box body assembly 1. The modular integrated structural design of the battery system reduces parts and realizes simple manufacturing. During assembly, it is easy to assemble, reduces the difficulty of assembly, saves a high-voltage box, meets the strength and reduces the cost, achieves a balance between the entire structure and performance, greatly improves work efficiency, and meets the requirements of mass production. At the same time, the integrated design also reduces the failure phenomenon of the battery system itself.

[0065] The above description of various embodiments of the utility model is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. An integrated power battery system, characterized in that: The battery system includes: A box assembly, the box assembly comprising a box body and a box cover, the box body and the box cover are connected to form a first module, and two installation areas are provided inside the first module; A battery module assembly and a liquid cooling tube assembly, wherein the battery module assembly and the liquid cooling tube assembly are connected to form a second module, and the second module is arranged in one of the installation areas; An electrical component assembly and a guide bar, wherein the electrical component and the guide bar are connected and form a third module, and the third module is arranged in another installation area.

2. An integrated power battery system according to claim 1, characterized in that: The integrated power battery system also includes a support frame, the electrical component assembly is arranged on the support frame, the support frame is arranged in another installation area, and the water inlet end and the water outlet end of the liquid cooling pipe assembly are respectively arranged on both sides of the support frame.

3. An integrated power battery system according to claim 2, characterized in that: The guide bar is arranged around the support frame, and the guide bar is used to electrically connect the electrical component assembly and the battery module assembly.

4. The integrated power battery system according to claim 1, characterized in that: The box assembly also includes: A load-bearing beam, the load-bearing beam is arranged at the bottom of the box body, and the battery module assembly and the battery element assembly are arranged on the load-bearing beam; A sealing ring is arranged between the box cover and the box body.

5. The integrated power battery system according to claim 2, characterized in that: The support frame comprises: Base plate; A side panel connected to the bottom panel and in an L shape; Two connecting components, one end of the two connecting components is respectively connected to the two ends of the side plate, and the other end of the two connecting components is respectively connected to the two sides of the box assembly.

6. The integrated power battery system according to claim 5, characterized in that: The connecting component comprises: Two supports, the two supports are respectively connected to the side plate and the box assembly; A connecting piece, the two ends of which are respectively connected to the two supports.

7. The integrated power battery system according to claim 5, characterized in that: The electrical component assembly includes multiple contactors, current fuses, a main control module, a wiring harness connection board, a Hall current sensor and a DC converter. The multiple contactors, current fuses, Hall current sensors and a DC converter are arranged on the base plate, and the main control module and the wiring harness connection board are arranged on the side panel.

8. The integrated power battery system according to claim 3, characterized in that: The integrated power battery system also includes a high-voltage interlock connector, which is arranged on the box assembly and at a position close to the electrical component assembly, and the high-voltage interlock connector is electrically connected to the guide bar.

9. The integrated power battery system according to claim 1, characterized in that: The guide bar is a copper bar.

10. The integrated power battery system according to claim 1, characterized in that: The box body and the box cover are both formed by bending sheet metal parts.