Battery pack

Abstract

The utility model relates to the technical field of batteries, and provides a battery pack which comprises a lower box body, and a liquid cooling plate and a distribution box assembly which are arranged in the lower box body, the distribution box assembly comprises a shell connected with the liquid cooling plate and a plurality of electrical parts arranged in the shell, the electrical parts are connected through connecting copper bars, and connecting points of at least part of the electrical parts and the connecting copper bars are arranged close to one side of the liquid cooling plate. According to the battery pack disclosed by the utility model, the cooling design can be carried out on a position which is seriously heated in the distribution box assembly, the cooling effect on the distribution box assembly can be better improved, the overcurrent capability of the distribution box assembly can be further improved in a limited space, and the requirement of rapid energy compensation of a high-power rapid charging vehicle can be met.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, and in particular to a battery pack. Background Technology

[0002] Currently, electric vehicles are the mainstream of new energy vehicles on the market, but their main problems include relatively low safety, long refueling time, and short driving range. To shorten refueling time, major manufacturers have proposed battery swapping and high-power fast charging solutions. High-power fast charging solutions require less investment than battery swapping solutions and are currently the mainstream solution on the market. High-power fast charging simultaneously increases both charging voltage and charging current to increase charging power, thereby shortening the refueling time of electric vehicles.

[0003] The power battery is one of the core components of an electric vehicle. It consists of modules, high-voltage copper busbars, low-voltage wiring harnesses, a battery management system, a battery distribution box assembly, and upper and lower housings. Among these, the battery distribution box assembly is the energy distribution unit of the power battery and plays a crucial role, especially with the current support of high-power fast charging solutions, making its design particularly important. However, most battery distribution box assemblies on the market are still based on low-voltage (400V) platforms. These assemblies use lower voltage platforms for their internal electrical components, resulting in larger specifications and higher costs, which cannot meet the rapid charging requirements of high-power fast-charging vehicles. Utility Model Content

[0004] In view of this, the present invention aims to provide a battery pack that is conducive to meeting the needs of high-power fast-charging vehicles for rapid energy replenishment.

[0005] To achieve the above objectives, the technical solution of this utility model is implemented as follows:

[0006] A battery pack includes a lower housing, and a liquid cooling plate and a power distribution box assembly disposed within the lower housing;

[0007] The power distribution box assembly includes a housing connected to the liquid cooling plate, and a plurality of electrical components disposed in the housing. The electrical components are connected to each other by connecting copper busbars, and at least some of the electrical components are disposed near the side of the liquid cooling plate at the connection points with the connecting copper busbars.

[0008] Furthermore, a heat-conducting element is provided between the housing and the liquid cooling plate.

[0009] Furthermore, an insulating element is provided between the housing and the heat-conducting component, and the insulating element is provided at least at the connection points of the connecting copper busbar and each of the electrical components.

[0010] Furthermore, the thickness t1 of the insulating component is between 0.1 and 0.3 mm; and / or the thickness t2 of the thermally conductive component is between 3 and 5 mm.

[0011] Furthermore, the housing includes a first sub-housing and a second sub-housing disposed on the first sub-housing, and each of the electrical components and the connecting copper busbars are disposed within the space enclosed by the first sub-housing and the second sub-housing; a flexible component is provided between the first sub-housing and each of the electrical components, or a flexible component is provided between the second sub-housing and each of the electrical components.

[0012] Furthermore, the plurality of electrical components include a main positive contactor, a main negative contactor, a fast-charging positive contactor, and a fast-charging negative contactor; the connection points of the main positive contactor, the main negative contactor, the fast-charging positive contactor, and the fast-charging negative contactor to the connecting copper busbar are all located near the side of the liquid cooling plate, and / or, the main positive contactor and the fast-charging positive contactor are connected in series through the connecting copper busbar, and the main negative contactor and the fast-charging negative contactor are connected in series through the connecting copper busbar.

[0013] Furthermore, the connecting copper busbars, which are at least partially connected to each of the electrical components, are injection molded into the housing; and / or, the connecting copper busbars are provided with a plurality of electrical interfaces.

[0014] Furthermore, the housing and the lower box are connected by a connector.

[0015] Furthermore, a gasket and a shock-absorbing bushing are provided between the housing and the lower box. The shock-absorbing bushing is sleeved on the connector, and the gasket is located between the shock-absorbing bushing and the head of the connector.

[0016] Furthermore, it also includes a BMS slave board disposed on the housing, and an electromagnetic shielding component disposed between the BMS slave board and the housing.

[0017] Compared with the prior art, this utility model has the following advantages:

[0018] The battery pack described in this utility model, by setting at least some of the electrical components and the connection points of the connecting copper busbars close to the side of the liquid cooling plate, can achieve a cooling design for the severely heated parts inside the power distribution box assembly, which is more conducive to improving the cooling effect of the power distribution box assembly. This improves the current carrying capacity of the power distribution box assembly within a limited space, thereby helping to meet the needs of high-power fast charging vehicles for rapid energy replenishment.

[0019] Furthermore, by incorporating heat-conducting components, heat exchange between the high-heat-generating areas inside the distribution box assembly and the liquid cooling plate is facilitated, resulting in better cooling of the distribution box assembly. Insulation components are installed at the connection points of the connecting copper busbars and various electrical components to enhance the electrical safety of the distribution box assembly and prevent risks such as short circuits and overheating. The thickness t1 of the insulation components is between 0.1-0.3 mm, and the thickness t2 of the heat-conducting components is between 3-5 mm, ensuring effective insulation and heat conduction, further improving the safety of the distribution box assembly.

[0020] Furthermore, the flexible components not only improve the installation stability of various electrical components but also simplify the assembly process, achieving cost reduction. The connection points of the main positive contactor, main negative contactor, fast-charging positive contactor, and fast-charging negative contactor to the connecting copper busbar are all located near the liquid cooling plate. This allows for better cooling of areas with high heat generation within the distribution box assembly, increasing the overcurrent capacity of the distribution box assembly. The main positive contactor and fast-charging positive contactor are connected in series via connecting copper busbars, as are the main negative contactor and fast-charging negative contactor, which enhances the overall vehicle functional safety level.

[0021] In addition, some connecting copper busbars are injection molded into the housing, which helps protect the connecting copper busbars, improves structural stability, and facilitates cooling of severely heat-generating areas inside the power distribution box assembly by the liquid cooling plate. The connecting copper busbars have multiple electrical interfaces to meet the electrical interface requirements of different vehicle models, enabling platform-based design of the power distribution box assembly and significantly reducing design and development costs. The housing and lower casing are connected by connectors for easy assembly and disassembly. Gaskets and shock-absorbing bushings are placed between the housing and lower casing to reduce vibration and noise. Electromagnetic shielding is installed between the BMS slave board and the housing to isolate high and low voltages, which is beneficial to the overall EMC (electromagnetic compatibility) of the battery pack. Attached Figure Description

[0022] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the utility model and do not constitute an undue limitation of the utility model. In the drawings:

[0023] Figure 1 This is a schematic diagram of the overall structure of the battery pack described in an embodiment of the present utility model;

[0024] Figure 2 for Figure 1 A schematic diagram of the structure shown in the image from another perspective;

[0025] Figure 3 This is a schematic diagram of the internal structure of the battery pack described in an embodiment of the present invention;

[0026] Figure 4This is a schematic diagram of the assembly of the power distribution box and the liquid cooling plate according to an embodiment of the present invention.

[0027] Figure 5 This is a partial structural schematic diagram of the power distribution box assembly described in an embodiment of the present utility model;

[0028] Figure 6 This is a schematic diagram of the internal structure of the power distribution box assembly described in an embodiment of the present utility model;

[0029] Figure 7 This is a schematic diagram of the assembly of the shock-absorbing bushing, gasket, and connector described in this embodiment of the utility model;

[0030] Explanation of reference numerals in the attached figures:

[0031] 11. Lower housing; 111. Frame; 112. Crossbeam; 113. Mounting beam;

[0032] 21. Liquid cooling plate;

[0033] 31. Housing; 311. First sub-housing; 3111. Connecting boss; 312. Second sub-housing; 313. Flexible component; 32. Electrical component; 33. Connecting copper busbar; 331. Electrical interface;

[0034] 41. Thermally conductive components; 42. Insulating components;

[0035] 51. Connecting parts; 52. Gaskets; 53. Shock-absorbing bushings;

[0036] 6. BMS slave board. Detailed Implementation

[0037] It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0038] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0039] In the description of this utility model, it should be noted that if terms such as "upper," "lower," "inner," or "outer" appear, indicating orientation or positional relationship, they are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model 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 this utility model. Furthermore, if terms such as "first" or "second" appear, they are also used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0040] In the embodiments, directional terms such as "up," "down," "left," "right," "front," and "back" are defined based on the vertical direction (also known as the height direction, or the Z-direction of the entire pack), the horizontal direction (also known as the width direction, or the Y-direction of the entire pack), and the front-back direction (also known as the length direction, or the X-direction of the entire pack) of the battery pack. "Inner" and "outer" are defined based on the outline of the corresponding components. For example, "inner" and "outer" are defined based on the outline of the battery pack housing. The side of the battery pack housing closer to the middle of the battery pack is "inner," and the opposite side is "outer."

[0041] Furthermore, in the description of this utility model, unless otherwise explicitly defined, the terms "installation," "connection," "joining," and "connector" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model in light of the specific circumstances.

[0042] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0043] This embodiment relates to a battery pack that addresses the problem that existing power distribution box assemblies cannot meet the rapid energy replenishment requirements of high-power fast-charging vehicles, thus offering better market competitiveness.

[0044] In terms of overall structure, such as Figures 1 to 7 As shown, the battery pack of this embodiment includes a lower housing 11, a liquid cooling plate 21 disposed within the lower housing 11, and a power distribution box assembly. The power distribution box assembly includes a housing 31 connected to the liquid cooling plate 21, and a plurality of electrical components 32 disposed within the housing 31. These electrical components 32 are connected to each other via connecting copper busbars 33, and at least some of the connection points between the electrical components 32 and the connecting copper busbars 33 are located near the side of the liquid cooling plate 21.

[0045] At this time, with the above configuration, by placing at least some of the electrical components 32 and the connection points of the connecting copper busbar 33 close to the side of the liquid cooling plate 21, it is possible to achieve a cooling design for the severely heated parts inside the power distribution box assembly, which is more conducive to improving the cooling effect of the power distribution box assembly, thereby increasing the current carrying capacity of the power distribution box assembly within a limited space, and thus helping to meet the needs of high-power fast charging vehicles for rapid energy replenishment.

[0046] Based on the above overview, in detail, in this embodiment, the liquid cooling plate 21 can be either installed on the top of the lower housing 11 as a top cover, or it can be directly installed inside the lower housing 11, with the power distribution box assembly located above the liquid cooling plate 21. This embodiment mainly uses the example of the liquid cooling plate 21 being installed on the top of the lower housing 11 for further explanation. Figure 2 As shown, an opening for assembling the power distribution box assembly is also provided at the bottom of the battery pack. Of course, the battery pack also includes a cover plate for sealing the opening if necessary.

[0047] In this embodiment, as a preferred implementation, such as Figures 3 to 6 As shown, the housing 31 includes a first sub-housing 311 and a second sub-housing 312 disposed on the first sub-housing 311. Each electrical component 32 and the connecting copper busbar 33 are disposed within the space enclosed by the first sub-housing 311 and the second sub-housing 312, and a flexible component 313 is provided between the second sub-housing 312 and each electrical component 32.

[0048] In specific implementation, the flexible component 313 in this embodiment can be compressed foam. The setting of the flexible component 313 can help improve the installation stability of each electrical component 32, while also simplifying the assembly process and achieving cost reduction design.

[0049] It should be mentioned again that the flexible member 312 is disposed between the second sub-shell 312 and each electrical component 32 in the vertical direction of the battery pack, where the second sub-shell 312 is located below the first sub-shell 311. In this case, the first sub-shell 311 is in contact with the liquid cooling plate 21. Of course, the flexible member 312 can also be disposed between the first sub-shell 311 and each electrical component 32. This arrangement is suitable for the case where the second sub-shell 312 is located above the first sub-shell 311 and is in contact with the liquid cooling plate 21.

[0050] In this embodiment, as a preferred implementation, the multiple electrical components 32 include a main positive contactor, a main negative contactor, a fast-charging positive contactor, and a fast-charging negative contactor. The connection points of the main positive contactor, the main negative contactor, the fast-charging positive contactor, and the fast-charging negative contactor to the connecting copper busbar 33 are all located close to the side of the liquid cooling plate 21. In this way, the liquid cooling plate 21 can better cool the areas with severe heat generation inside the distribution box assembly, thereby improving the overcurrent energy of the distribution box assembly.

[0051] It should be mentioned that in this embodiment, since the liquid cooling plate 21 is used to directly cool the parts of the power distribution box assembly that generate a lot of heat, that is, to cool the connection contact points of the large contactor, the power distribution box assembly can be adapted not only to low voltage (400V) platforms, but also to high voltage (e.g., 800V) platforms, thereby helping to meet the needs of high-power fast charging of battery packs and rapid energy replenishment of electric vehicles.

[0052] Furthermore, any structural components not mentioned in the power distribution box assembly of this embodiment can be referred to from the various structures in power distribution box products known to those skilled in the art. For example, the power distribution box assembly also includes electrical components 32 such as a pre-charge contactor, a pre-charge resistor, a current sensor, and a fuse.

[0053] Meanwhile, as a preferred implementation, the main positive contactor and the fast charging positive contactor are connected in series via connecting copper busbar 33, and the main negative contactor and the fast charging negative contactor are connected in series via connecting copper busbar 33, in order to improve the overall vehicle functional safety level.

[0054] Furthermore, in this embodiment, as a preferred implementation, reference is continued. Figures 3 to 6 As shown, at least some of the connecting copper busbars 33 connected to each electrical component 32 are injection molded in the housing 31. In particular, the connecting copper busbars 33 connected to the input and output contacts of large contactors (main positive contactor, main negative contactor, fast charging positive contactor and fast charging negative contactor) are injection molded in the housing 31. The main advantage of this arrangement is that it helps to protect the connecting copper busbars 33, improves structural stability, and facilitates the cooling of severely heated areas inside the distribution box assembly by the liquid cooling plate 21.

[0055] Furthermore, in this embodiment, the connecting copper busbar 33 is preferably provided with multiple electrical interfaces 331. This facilitates meeting the electrical interface 331 requirements of different vehicle models, enabling the platformization of the power distribution box assembly and significantly reducing the design and development costs of the power distribution box assembly.

[0056] In specific implementation, the electrical interface 331 of this embodiment may include interfaces such as battery+, battery-, front drive+, front drive-, rear drive+, rear drive-, fast charge+, fast charge-, PTC (thermistor)+, PTC (thermistor)-, OBC (on-board charger)+, OBC (on-board charger)-, and boost, in order to better adapt to the electrical interface 331 requirements of different vehicle models.

[0057] In addition, in this embodiment, as a preferred implementation, such as Figure 2 , Figure 5 and Figure 7As shown, the housing 31 and the lower box 11 are connected by a connector 51 to facilitate easy assembly and disassembly. In a specific implementation, the lower box 11 of this embodiment preferably includes a frame 111 and a crossbeam 112 disposed in the frame 111. The crossbeam 112 divides the lower box 11 into a battery compartment and an electrical compartment, and the power distribution box assembly is located in the electrical compartment.

[0058] Furthermore, to facilitate the installation of the power distribution box assembly, the electrical compartment is provided with mounting beams 113 at both ends of the corresponding length direction of the housing 31, and connecting bosses 3111 are provided at both ends of the length direction of the housing 31 (specifically, the first sub-housing 311). The connecting bosses 3111 and the corresponding mounting beams 113 are connected by connectors 51.

[0059] As for the quantity and arrangement of the connectors 51, they can be set and adjusted according to the installation requirements of the housing 31 in the lower box 11. For example, two connectors 51 are provided on the two connecting bosses 3111 respectively, and connectors 51 are also provided in the middle of the length direction of the housing 31.

[0060] In this embodiment, as a preferred implementation, combined with Figure 2 , Figure 5 and Figure 7 As shown, a gasket 52 and a shock-absorbing bushing 53 are provided between the housing 31 and the lower box 11. The shock-absorbing bushing 53 is fitted onto the connector 51, and the gasket 52 is located between the head of the shock-absorbing bushing 53 and the connector 51. In this way, it can play a role in shock absorption and noise reduction. At the same time, in the specific structure, the connector 51 can be a bolt or screw, the gasket 52 can be a steel gasket, and the shock-absorbing bushing 53 can preferably be made of rubber.

[0061] In addition, in this embodiment, as a preferred implementation, combined with Figures 4 to 6 As shown, a heat-conducting component 41 is provided between the housing 31 and the liquid cooling plate 21. By providing the heat-conducting component 41, heat exchange is facilitated between the severely heat-generating areas inside the power distribution box assembly and the liquid cooling plate 21, thereby achieving better cooling of the power distribution box assembly.

[0062] Secondly, as a preferred embodiment, in this example, an insulating member 42 is provided between the housing 31 and the heat-conducting component 41. The insulating member 42 is provided at least at the connection points corresponding to the copper busbar 33 and each electrical component 32. This improves the electrical safety of the distribution box assembly and avoids risks such as short circuits and overheating.

[0063] In this specific implementation, as a preferred embodiment, the thickness t1 of the insulating component 42 is between 0.1-0.3 mm, and the thickness t2 of the heat-conducting component 41 is between 3-5 mm. Specifically, the thickness t1 of the insulating component 42 can be set to 0.1 mm, 0.2 mm, or 0.3 mm, and the thickness t2 of the heat-conducting component 41 can be set to 3 mm, 4 mm, or 5 mm. The advantage of this setting is mainly to ensure insulation and heat conduction effects, further improving the safety of the distribution box assembly.

[0064] Furthermore, as a preferred implementation method, such as Figure 4 As shown, the battery pack in this embodiment also includes a BMS (Battery Management System) slave board disposed on the housing 31, and an electromagnetic shielding component disposed between the BMS slave board 6 and the housing 31. This not only improves the overall space utilization of the pack but also provides high and low voltage isolation, which is beneficial to the overall EMC (Electromagnetic Compatibility) of the battery pack.

[0065] It should be mentioned that the heat-conducting component 41 in this embodiment can be specifically made of thermally conductive adhesive or thermally conductive pad, the insulating component 42 in this embodiment can be specifically made of insulating sheet, and the electromagnetic shielding component can be specifically made of conductive cloth. At the same time, the BMS slave plate 6 can be located on the side of the housing 31 away from the liquid cooling plate 21 and connected to the housing 31 by bolts to facilitate disassembly and maintenance.

[0066] The battery pack in this embodiment features a cooling design for areas with severe heat generation within the power distribution box assembly. This improves the cooling effect of the power distribution box assembly, increasing its current-carrying capacity within a limited space. This, in turn, helps meet the rapid charging needs of high-power fast-charging vehicles. The above description is merely a preferred embodiment of this utility model and is not intended to limit its scope. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within its protection scope.

Claims

1. A battery pack, characterized in that: It includes a lower housing, and a liquid cooling plate and a power distribution box assembly disposed within the lower housing; The power distribution box assembly includes a housing connected to the liquid cooling plate, and a plurality of electrical components disposed in the housing. The electrical components are connected to each other by connecting copper busbars, and at least some of the electrical components are disposed near the side of the liquid cooling plate at the connection points with the connecting copper busbars.

2. The battery pack according to claim 1, characterized in that: A heat-conducting component is provided between the housing and the liquid cooling plate.

3. The battery pack according to claim 2, characterized in that: An insulating element is provided between the housing and the heat-conducting component, and the insulating element is provided at least at the connection points of the connecting copper busbar and each of the electrical components.

4. The battery pack according to claim 3, characterized in that: The thickness t1 of the insulating element is between 0.1 and 0.3 mm; and / or, The thickness t2 of the heat-conducting component is between 3 and 5 mm.

5. The battery pack according to claim 1, characterized in that: The housing includes a first sub-housing and a second sub-housing disposed on the first sub-housing, and each of the electrical components and the connecting copper busbars are disposed within the space enclosed by the first sub-housing and the second sub-housing; A flexible element is provided between the first sub-shell and each of the electrical components, or a flexible element is provided between the second sub-shell and each of the electrical components.

6. The battery pack according to claim 1, characterized in that: The plurality of electrical components include a main positive contactor, a main negative contactor, a fast charging positive contactor, and a fast charging negative contactor; The connection points of the main positive contactor, the main negative contactor, the fast charging positive contactor, and the fast charging negative contactor to the connecting copper busbar are all located near the side of the liquid cooling plate, and / or, the main positive contactor and the fast charging positive contactor are connected in series through the connecting copper busbar, and the main negative contactor and the fast charging negative contactor are connected in series through the connecting copper busbar.

7. The battery pack according to claim 1, characterized in that: The connecting copper busbars, at least partially connected to each of the aforementioned electrical components, are injection molded into the housing; and / or, The connecting copper busbar is equipped with multiple electrical interfaces.

8. The battery pack according to claim 1, characterized in that: The housing and the lower box are connected by a connector.

9. The battery pack according to claim 8, characterized in that: A gasket and a shock-absorbing bushing are provided between the housing and the lower box. The shock-absorbing bushing is sleeved on the connector, and the gasket is located between the shock-absorbing bushing and the head of the connector.

10. The battery pack according to any one of claims 1 to 9, characterized in that: It also includes a BMS slave board disposed on the housing, and an electromagnetic shielding component disposed between the BMS slave board and the housing.

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