High-voltage busbar structure and battery pack

Abstract

The utility model provides a high-voltage busbar structure and a battery pack. The high-voltage busbar structure comprises a support assembly and a busbar body. Wherein the supporting assembly is arranged in the battery pack; the busbar body is arranged on the supporting assembly and abuts against the surface of the battery pack cold plate due to the limitation of the supporting assembly. According to the utility model, the heat dissipation efficiency of the high-voltage busbar is improved without increasing the size of the cross section of the high-voltage busbar, so that the working temperature of the high-voltage busbar is maintained in a proper range, and the service life of the high-voltage busbar is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of energy storage devices, and in particular to a high-voltage busbar structure. The present invention also relates to a battery pack comprising the high-voltage busbar structure. Background Art

[0002] A battery pack is a device commonly used in electric vehicles to store electrical energy. It typically consists of multiple battery cells, along with a battery management system, thermal management system, electrical connectors, and structural components. The design and performance of the battery pack directly impact an electric vehicle's range, power performance, safety, and service life, making it a core component in electric vehicles.

[0003] In a battery pack, copper busbars conduct current between multiple cells, allowing them to store or release electrical energy to the outside world. Depending on the operating voltage, copper busbars are divided into busbars, which connect to the cells, and high-voltage busbars, which connect to the battery pack terminals. Compared to busbars, high-voltage busbars operate at higher voltages and currents, generating more heat. With advancements in battery pack manufacturing technology and increases in energy density, battery packs are becoming increasingly integrated, further exacerbating the heating of high-voltage busbars.

[0004] In the prior art, there is a related patent with publication number CN116799363A, entitled A Battery Pack and Electric Vehicle, which discloses a technical solution for overcoming the problem of excessively high-voltage busbar temperature. It increases the cross-sectional size of the copper busbar, thereby reducing its own resistance while having a larger surface area, in order to obtain higher heat dissipation efficiency, thereby alleviating the phenomenon of high-voltage busbar heating. However, a battery pack with this structure can only maintain the temperature of the high-voltage busbar at a low level within a certain range. As the current increases and the operating time increases, the high-voltage busbar will still overheat. In addition, copper busbars with larger cross-sectional dimensions will not only increase the production cost of the battery pack, but also occupy space inside the battery pack. Utility Model Content

[0005] In view of this, the present invention aims to propose a high-voltage busbar structure that can improve the heat dissipation efficiency of the high-voltage busbar without increasing the cross-sectional size of the high-voltage busbar, so that the operating temperature of the high-voltage busbar is maintained within an appropriate range.

[0006] In order to achieve the above-mentioned purpose, the technical solution of the utility model is achieved as follows:

[0007] The utility model provides a high-voltage busbar structure, comprising a support assembly, which is arranged in a battery pack;

[0008] The busbar body is arranged on the support assembly and abuts against the surface of the battery pack cold plate due to the limitation of the support assembly.

[0009] Furthermore, the busbar body includes a conductor portion;

[0010] The insulating portion is covered on the outside of the conductor portion to form insulation protection for the conductor portion, and at least a portion of the conductor portion is exposed outside the insulating portion.

[0011] Furthermore, a mounting hole is provided in a portion of the conductor portion exposed outside the insulating portion.

[0012] Furthermore, a heat conducting layer is provided between the insulating portion and the surface of the battery pack cold plate.

[0013] Furthermore, the heat-conducting layer is a heat-conducting silicone pad;

[0014] The insulating portion is provided with a mounting groove, the heat conducting layer is arranged in the mounting groove and is in contact with the conductor portion.

[0015] Furthermore, the support assembly includes a support beam vertically arranged in the battery pack along a vertical direction;

[0016] The support member is arranged on the support beam and connected to the busbar body.

[0017] Furthermore, the supporting member is an elastic member.

[0018] Furthermore, the support members are constructed to be multiple and evenly distributed along the length direction of the support beam.

[0019] Furthermore, a positioning groove is provided on the support beam.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] The high-voltage busbar structure and battery pack described in the present invention have a supporting assembly that limits the busbar body, so that the busbar body is close to the surface of the battery pack cold plate. The greater heat generated by the busbar body due to increased working time or increased working current can be transferred to the heat transfer medium in the cold plate through heat exchange, and finally transferred to the outside of the battery pack by the battery pack cold plate. Compared with the existing solution of increasing the busbar cross-sectional area to obtain higher heat dissipation efficiency, the active heat dissipation of the battery pack cold plate replaces the original passive heat dissipation method, which has obvious advantages in heat dissipation efficiency and heat dissipation effect. It achieves the purpose of the invention to improve the heat dissipation efficiency of the high-voltage busbar without increasing the cross-sectional size of the high-voltage busbar, so that the operating temperature of the high-voltage busbar is maintained within an appropriate range, thereby increasing the service life of the high-voltage busbar.

[0022] Furthermore, by configuring the busbar body as a conductor portion and an insulating portion surrounding the conductor portion, the conductor portion performs the basic functions of the busbar body, conducting current and transmitting electrical energy, while the insulating portion surrounding the conductor portion provides insulation and protection for the conductor portion, thereby preventing leakage during current conduction and improving the overall electrical safety of the battery pack. Exposing at least a portion of the conductor portion outside the insulating portion facilitates electrical connection between the conductor portion and the battery pack terminals or other components, enhancing the ease of installation and removal.

[0023] By setting mounting holes on the portion of the conductor part exposed outside the insulating part, the staff can more conveniently realize the electrical connection structure between the conductor part and other parts in the battery pack through the mounting holes, thereby achieving the purpose of further improving the convenience of the installation and disassembly process of the busbar body.

[0024] Secondly, by providing a thermally conductive layer between the insulating portion of the busbar body and the surface of the battery pack cold plate, the heat generated by the busbar body can be more evenly transferred to the battery pack cold plate, helping to avoid inconsistent heat dissipation efficiency and uneven temperature across the busbar body due to poor contact between the insulating portion of the busbar body and the battery pack cold plate. By providing the thermally conductive layer with a rectangular thermally conductive silicone pad that matches the shape of the contact area between the insulating portion and the battery pack cold plate, instead of a thermally conductive structural adhesive, the busbar body is bonded and fixed to the battery pack cold plate surface without significantly affecting heat dissipation, thereby improving the structural stability of the busbar body.

[0025] By providing a mounting groove on the insulating portion, the thermally conductive layer can be embedded in the mounting groove, which serves to define the position of the thermally conductive layer, thereby improving the structural stability of the thermally conductive layer and preventing misalignment between the thermally conductive layer and the insulating portion. Furthermore, the provision of the mounting groove allows the thermally conductive layer to directly contact the conductor portion. The thermally conductive layer, itself made of an insulating material, can replace the insulating portion to provide insulation protection for the conductor portion, while also being in direct contact with the conductor portion, resulting in higher heat dissipation efficiency and better heat dissipation.

[0026] Furthermore, by configuring the support assembly as a combination of support beams and support members, the support beams can limit the placement of the support members, while the support members can support the busbar body, placing it against the surface of the battery pack cold plate. By configuring the support members as elastic members, they provide elastic support for the busbar body, which, compared to a rigid connection, can reduce potential damage to the busbar body during assembly and use.

[0027] By arranging multiple support members evenly spaced along the length of the support beam, the stability of the support members' support for the busbar body can be improved, providing stable support for the busbar body at all locations along the length of the support beam. Providing positioning slots on the support beam not only facilitates the installation process and simplifies the positioning of the support beam, but also allows the internal components of the battery pack to pass through the support beam through the positioning slots, avoiding structural interference caused by the support beam.

[0028] In addition, the present invention also proposes a battery pack provided with the above-mentioned high-voltage busbar structure.

[0029] The battery pack described in the present invention has the same beneficial effects as the high-voltage busbar structure described above relative to the prior art, and will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying drawings, which constitute part of the present invention, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0031] Figure 1 This is a structural diagram of the high-voltage busbar structure in an embodiment of the present utility model;

[0032] Figure 2 This is a schematic structural diagram of the support assembly in an embodiment of the present utility model;

[0033] Figure 3 It is a structural schematic diagram of the busbar body in an embodiment of the present utility model.

[0034] Description of reference numerals:

[0035] 1. Support components;

[0036] 101. Support beam; 102. Support member; 103. Positioning groove;

[0037] 2. Busbar body;

[0038] 201, conductor part; 202, insulation part; 203, mounting hole; 204, heat conducting layer. DETAILED DESCRIPTION

[0039] It should be noted that, unless there is a conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the specific implementation methods of the present invention will be described below with reference to the accompanying drawings. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings and other implementation methods can be obtained based on these drawings without inventive work.

[0040] In the description of this utility model, it should be noted that if terms such as "upper," "lower," "inner," and "outer" appear to indicate orientation or positional relationships, these are based on the orientation or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this utility model and simplify the description. They do not indicate or imply that the device or component referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, if terms such as "first" and "second" appear, they are used solely for descriptive purposes and should not be construed as indicating or implying relative importance.

[0041] Taking the high-voltage busbar structure and battery pack described in this utility model as an example, the directional terms used in the embodiments, such as "up," "down," "left," "right," "front," and "rear," are defined relative to the battery pack's up-down (also known as the height direction, or the Z-direction), left-right (also known as the width direction, or the Y-direction), and front-to-back (also known as the length direction, or the X-direction). "Inside" and "outside" are defined relative to the contours of the corresponding components. For example, when "inside" and "outside" are defined relative to the battery pack contour, the side of the battery pack contour closest to the center is considered "inside," and the opposite side is considered "outside."

[0042] Furthermore, in the description of this utility model, unless otherwise explicitly defined, the terms "mounted," "connected," "connection," and "connector" should be interpreted broadly. For example, they can refer to fixed, removable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediary; and internal communication between two components. Those skilled in the art will understand the specific meanings of these terms in this utility model based on specific circumstances.

[0043] The following will refer to the attached Figures 1 to 3 The present invention is described in detail with reference to the embodiments.

[0044] Example 1

[0045] This embodiment relates to a high-voltage busbar structure. By providing a support structure at the bottom of the high-voltage busbar, the high-voltage busbar is positioned to limit its position while also abutting against the surface of a battery pack cold plate. Heat generated by the high-voltage busbar is transferred to the exterior of the battery pack through the active heat dissipation of the cold plate, thereby improving the heat dissipation efficiency of the high-voltage busbar without increasing its cross-sectional size. This maintains the operating temperature of the high-voltage busbar within an appropriate range, thereby increasing the service life of the high-voltage busbar.

[0046] In terms of overall structure, refer to Figure 1 The high-voltage busbar structure of this embodiment includes a support assembly 1 and a busbar body 2. The support assembly 1 is fixedly mounted inside the battery pack, and the busbar body 2 is fixedly mounted on the support assembly 1 and abuts against the surface of the battery pack cold plate under the restraining action of the support assembly 1.

[0047] As configured above, due to the limiting effect of the support assembly 1 on the busbar body 2, the busbar body 2 is closely attached to the surface of the battery pack cold plate. The busbar body 2 generates more heat due to the increase in working time or working current, which can be transferred to the heat transfer medium in the cold plate through heat exchange, and finally transferred to the outside of the battery pack by the battery pack cold plate. Compared with the prior art solution of increasing the cross-sectional area of ​​the busbar in order to obtain higher heat dissipation efficiency, the active heat dissipation of the battery pack cold row replaces the original passive heat dissipation method, which has obvious advantages in heat dissipation efficiency and heat dissipation effect, and realizes the purpose of the invention of improving the heat dissipation efficiency of the high-voltage busbar without increasing the cross-sectional size of the high-voltage busbar, maintaining the working temperature of the high-voltage busbar within an appropriate range, thereby increasing the service life of the high-voltage busbar.

[0048] Based on the above design ideas, specifically, in this embodiment, refer to Figure 1 and Figure 3 The busbar body 2 includes a conductor part 201 and an insulating part 202. The conductor part 201 can be made of a metal material with good electrical conductivity and mechanical properties, such as copper or aluminum alloy. The conductor part 201 can be a strip of metal with a rectangular cross-section, and the conductor part 201 can be bent into a bow shape according to the requirements of the actual installation structure. The insulating part 202 can be made of a polymer material with good insulating properties. The insulating part 202 is coated on the outside of the conductor part 201, and at least part of the conductor part 201 is exposed on the outside of the insulating part 202. The insulating part 202 constitutes an insulating protection for the coated part of the conductor part 201.

[0049] By configuring the busbar body 2 as a conductor portion 201 and an insulating portion 202 surrounding the conductor portion 201, the conductor portion 201 performs the basic functions of the busbar body 2, namely, current conduction and power transmission. The insulating portion 202 surrounding the conductor portion 201 provides insulation and protection for the conductor portion 201, thereby preventing leakage during current conduction and improving the overall electrical safety of the battery pack. Exposing at least a portion of the conductor portion 201 outside the insulating portion 202 facilitates electrical connection between the conductor portion 201 and the battery pack terminals or other components, thereby enhancing the ease of installation and removal of the present application.

[0050] Reference Figure 1 and Figure 3 To further enhance the ease of installation and removal of the busbar body 2, in this embodiment, mounting holes 203 are defined in the portion of the conductor portion 201 exposed outside the insulating portion 202. In this embodiment, both ends of the conductor portion 201 extend beyond the insulating portion 202, each with a mounting hole 203. The mounting holes 203 can be circular through-holes extending along the thickness of the conductor portion 201. The diameter of the mounting holes 203 can be determined by the diameter of the pole or locating bolt.

[0051] By setting a mounting hole 203 on the portion of the conductor part 201 exposed outside the insulating part 202, the staff can more conveniently realize the electrical connection structure between the conductor part 201 and other parts in the battery pack through the mounting hole 203, thereby achieving the purpose of further improving the convenience of the installation and disassembly process of the busbar body 2.

[0052] Reference Figure 1 and Figure 3 To improve the heat dissipation effect of the battery pack cold plate on the busbar body 2, in this embodiment, a thermally conductive layer 204 is provided between the insulating portion 202 and the surface of the battery pack cold plate. The thermally conductive layer 204 can be made of a flexible material with good thermal conductivity. In this embodiment, the thermally conductive layer 204 is a rectangular thermally conductive silicone pad that matches the shape of the contact area between the insulating portion 202 and the battery pack cold plate surface.

[0053] By providing a thermally conductive layer 204 between the insulating portion 202 of the busbar body 2 and the surface of the battery pack cold plate, the heat generated by the busbar body 2 can be more evenly transferred to the battery pack cold plate, helping to avoid inconsistent heat dissipation efficiency and uneven temperatures across different parts of the busbar body 2 due to poor contact between the insulating portion 202 of the busbar body 2 and the battery pack cold plate. By providing the thermally conductive layer 204 as a rectangular thermally conductive silicone pad that matches the shape of the contact area between the insulating portion 202 and the battery pack cold plate, instead of a thermally conductive structural adhesive, the busbar body 2 is bonded and fixed to the battery pack cold plate surface without significantly affecting heat dissipation, thereby improving the structural stability of the busbar body 2.

[0054] Reference Figure 1 and Figure 3 In order to improve the stability of the heat-conducting layer 204 and prevent misalignment between the heat-conducting layer 204 and the insulating portion 202, in this embodiment, a mounting groove is formed on the insulating portion 202. The shape of the mounting groove is consistent with the shape of the heat-conducting layer 204. Due to the provision of the mounting groove, the heat-conducting layer 204 can directly contact the conductor portion 201.

[0055] By providing a mounting groove on the insulating portion 202, the thermally conductive layer 204 can be embedded within the mounting groove. The mounting groove serves to position the thermally conductive layer 204, thereby improving the structural stability of the thermally conductive layer 204 and preventing misalignment between the thermally conductive layer 204 and the insulating portion 202. Furthermore, the provision of the mounting groove allows the thermally conductive layer 204 to directly contact the conductor portion 201. The thermally conductive layer 204 is itself made of an insulating material and can replace the insulating portion 202 to provide insulation protection for this portion of the conductor portion 201. Furthermore, it can directly contact the conductor portion 201, resulting in higher heat dissipation efficiency and better heat dissipation.

[0056] Reference Figure 1 and Figure 2 In order to provide a stable support for the busbar body 2 and enable the busbar body 2 to fit on the surface of the battery pack cold plate, in this embodiment, the support assembly 1 includes a support beam 101 and a support member 102. The support beam 101 can be a sheet metal structural beam made of an aluminum alloy vertically arranged on the bottom surface inside the battery pack. The cross section of the support beam 101 is rectangular. The support beam 101 and the bottom surface inside the battery pack can be fixed by welding or bolting. The support member 102 is fixed to the upper surface of the support beam 101 by means of structural adhesive. The support member 102 is a block-shaped elastic member made of an elastic polymer material.

[0057] By configuring the support assembly 1 as a combination of support beams 101 and support members 102, the support beams 101 can limit the placement of the support members 102, while the support members 102 can support the busbar body 2, placing the busbar body 2 against the surface of the battery pack cold plate. By configuring the support members 102 as elastic members, the support members 102 provide elastic support for the busbar body 2. Compared to a rigid connection, this can reduce potential damage to the busbar body 2 during assembly and use.

[0058] Reference Figure 1 and Figure 2 To further enhance the stability of the support assembly 1 supporting the busbar body 2, in this embodiment, multiple support members 102 are provided. The support members 102 are arranged along the length of the support beam 101, with equal spacing between the multiple support members 102. Positioning slots 103 are defined in the support beam 101. These slots 103 can be horizontally extending rectangular through-slots.

[0059] By providing multiple support members 102 evenly spaced along the length of the support beam 101, the stability of the support members 102 supporting the busbar body 2 can be improved, and a stable support for the busbar body 2 can be formed at various positions along the length of the support beam 101. By providing positioning slots 103 on the support beam 101, the installation process of the support beam 101 is facilitated and the positioning of the support beam 101 is simplified. At the same time, it makes room for the internal parts of the battery pack to pass through the positioning slots 103 through the support beam 101, avoiding structural interference caused by the arrangement of the support beam 101.

[0060] Example 2

[0061] This embodiment relates to a battery pack, including the high-voltage busbar structure described in the first embodiment.

[0062] In this embodiment, by adopting the high-voltage busbar structure described in Example 1, the high-voltage busbar can be tightly attached to the surface of the battery pack cold plate under the limiting effect of the support structure. During operation, the battery pack cold plate can actively dissipate heat by transferring the heat generated by the high-voltage busbar to the outside of the battery pack through the heat transfer medium, thereby avoiding heat accumulation inside the high-voltage busbar. Compared with the technical solution in the prior art that increases the cross-sectional size of the high-voltage busbar conductor, it is possible to improve the heat dissipation efficiency of the high-voltage busbar without increasing the cross-sectional size of the high-voltage busbar, thereby maintaining the operating temperature of the high-voltage busbar within a suitable range, which is beneficial to extending the service life of the high-voltage busbar, and reducing the space occupied by the high-voltage busbar inside the battery pack, thereby improving the overall internal space utilization and energy density of the battery pack.

[0063] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, and all of these should be included in the scope of the claims of the present invention.

Claims

1. A high-voltage busbar structure, characterized by: It includes a support assembly, which is arranged in the battery pack; The busbar body is arranged on the support assembly and abuts against the surface of the battery pack cold plate due to the limitation of the support assembly; The support assembly includes a support beam vertically arranged in the battery pack along the vertical direction; The support member is arranged on the support beam and connected to the busbar body.

2. The high-voltage busbar structure according to claim 1, characterized in that: The busbar body includes a conductor portion; The insulating portion is covered on the outside of the conductor portion to form insulation protection for the conductor portion, and at least a portion of the conductor portion is exposed outside the insulating portion.

3. The high-voltage busbar structure according to claim 2, characterized in that: A mounting hole is formed in a portion of the conductor portion exposed outside the insulating portion.

4. The high-voltage busbar structure according to claim 2, characterized in that: A heat conducting layer is provided between the insulating portion and the surface of the battery pack cold plate.

5. The high-voltage busbar structure according to claim 4, characterized in that: The heat-conducting layer is a heat-conducting silicone pad; The insulating portion is provided with a mounting groove, the heat conducting layer is arranged in the mounting groove and is in contact with the conductor portion.

6. The high-voltage busbar structure according to claim 1, characterized in that: The supporting member is an elastic member.

7. The high-voltage busbar structure according to claim 1, characterized in that: The support members are constructed to be uniformly distributed at equal distances along the length direction of the support beam.

8. The high-voltage busbar structure according to claim 1, characterized in that: A positioning groove is provided on the support beam.

9. A battery pack, characterized in that: Comprising the high-voltage busbar structure according to any one of claims 1 to 8.

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