Battery box and household battery pack device

Abstract

The utility model relates to a battery box and household battery pack device relates to battery energy storage technical field, it includes the lower box body and installs the upper cover of lower box body top, the inner side of lower box body is equipped with connector support seat, the right top of connector support seat is equipped with male connector and female connector respectively, the right bottom of connector support seat is equipped with male connector and female connector. The bottom of the upper cover and the bottom of the lower box body are respectively provided with through holes corresponding to the male connector and the female connector. According to the utility model, the complexity of electrical connection is simplified, the stability of connection is enhanced, the problem that the battery box body of the household energy storage battery pack is overweight is solved, and the battery box body has stronger corrosion resistance, insulating property and heat conduction property, is superior to a metal box body sprayed with fireproof paint, and can meet the UL94 flame-retardant requirements at home and abroad.

Description

Technical Field

[0001] This utility model relates to the field of battery energy storage technology, and more specifically to a composite material housing and a household battery pack device. Background Technology

[0002] In the field of new energy storage, battery boxes play a crucial role, providing essential structural support for new energy battery packs. However, due to the limited capacity of individual batteries, a large number of batteries are needed to meet high-capacity requirements, resulting in excessively heavy battery boxes and consequently, overweight power station containers. Currently, the weight of the battery box accounts for 20% to 35% of the total weight of the energy storage battery pack, consuming a significant amount of transportation capacity. Therefore, reducing the weight of the battery box has become a key task in the development of new energy storage battery packs.

[0003] In the field of residential energy storage battery packs, battery boxes have always been manufactured using steel with excellent fatigue resistance, and the technology has become increasingly mature. Experts have conducted strength analysis of battery boxes under different operating conditions, and carried out local optimization design and improvements to reduce local stress concentration and improve structural strength. Despite these optimizations, the weight of the battery box in residential battery packs has not been effectively reduced. Metal battery boxes are relatively heavy, affecting transportation efficiency and installation difficulty, and their strength and sealing performance are also lower compared to lightweight materials such as carbon fiber composites, glass fiber reinforced composites, and PCM composites. In recent years, composite materials such as carbon fiber have been widely used in the automotive industry due to their lightweight, high specific strength, high specific stiffness, and ability to be integrated into designs.

[0004] Although the residential battery pack casing is made of metal and attempts are made to use thinner sheet metal as the production base to reduce weight, the weight of the battery casing made of thin sheet metal still accounts for 20%-35% of the total product weight, failing to significantly reduce the weight. While using thinner sheet metal can reduce the weight of the battery box, this results in insufficient structural strength and rigidity, uneven stress distribution, and thus fails to meet usage requirements, posing safety hazards. Utility Model Content

[0005] The purpose of this utility model is to provide a battery box and a household battery pack device that enhances the electrical connection reliability and stacking stability of the battery box, solves the problem of excessive weight of the household energy storage battery pack battery box, and makes it have stronger corrosion resistance, insulation performance and thermal conductivity, which is superior to metal box body sprayed with fireproof paint and can meet the UL94 flame retardant requirements at home and abroad.

[0006] To achieve the above objectives, the present invention provides a battery box, including a lower box body and an upper cover mounted on the top of the lower box body. A connector support seat is provided inside the lower box body. A male connector and a female connector are respectively provided above and below the connector support seat. The upper cover and the bottom of the lower box body are respectively provided with through holes corresponding to the male connector and the female connector.

[0007] Preferably, the male connector is located on the connector support and passes through the upper cover.

[0008] Preferably, the upper cover has a limiting protrusion in the middle, the lower box has a lower box groove limiting platform at the bottom that matches the upper cover limiting protrusion, and the male connector passes through the upper cover limiting protrusion.

[0009] Preferably, the lower housing is provided with housing reinforcing ribs.

[0010] Preferably, the reinforcing ribs of the box body are U-shaped.

[0011] Preferably, the lower housing is made of a composite material, which is one of the following: PCM composite material, a mixture of PCM composite material and ceramicized polyolefin, ceramicized phenolic resin material, and high-density woven glass fiber cloth reinforcement material.

[0012] The present invention also provides a household battery pack device, which includes the aforementioned battery box, wherein a battery module is installed in the lower box, and the battery module includes a plurality of cells arranged in sequence, long end plates disposed on both sides of the arranged cells, and plastic steel cable ties for binding or fitting into the long end plates on both sides.

[0013] Preferably, the long end plate is provided with long screws for connecting the lower housing.

[0014] Preferably, the top of the sequentially arranged battery cells is connected to an output aluminum bar and a battery cell connecting aluminum bar, and the long end plate is provided with an injection molding seat.

[0015] Preferably, the bottom of the battery module is provided with a thermally conductive adhesive layer.

[0016] In summary, this utility model has the following beneficial technical effects:

[0017] By employing a structure with male and female connectors and a layered bracket arrangement, the complexity of electrical connections is simplified, and the layered fixing method enhances connection stability. This structural design helps reduce the risk of poor contact and short circuits at electrical connections, thereby significantly improving the safety and reliability of the battery box in terms of electrical connections, meeting the high safety and high stability requirements of modern battery energy storage systems.

[0018] By using one of the following materials: PCM composite material, a mixture of PCM composite material and ceramicized polyolefin, ceramicized phenolic resin material, or high-density woven glass fiber cloth reinforcement material, and further using glass fiber with continuous glass fiber and epoxy vinyl ester resin as the matrix to enhance the composite material properties, the problem of excessive weight of household energy storage battery pack enclosures can be solved. These composite material enclosures are not only lightweight, but also have stronger corrosion resistance, insulation properties, and thermal conductivity, and are superior to metal enclosures coated with fire-retardant paint, meeting domestic and international UL94 flame retardant requirements.

[0019] The lower casing made of composite materials is easy to mold and process, more corrosion-resistant, and has excellent insulation and flame-retardant properties. It also has a low coefficient of thermal expansion and small heat capacity, and using composite material casings can effectively reduce product weight. In addition, applying thermally conductive adhesive to the bottom of the battery module allows the battery module to conduct heat through the lower casing and the outside. In particular, the use of thermally conductive adhesive on the contact surface with the battery can transfer more heat to the outside, keeping the internal temperature of the battery pack suitable for battery operation. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of a battery box and household battery pack device according to the present invention;

[0021] Figure 2 This is a schematic diagram of the battery box and household battery pack device after being separated according to the present invention;

[0022] Figure 3 This is a schematic diagram of the battery module in a battery box and household battery pack device according to the present invention;

[0023] Figure 4 This is a schematic diagram of the lower casing of a battery box and household battery pack device according to the present invention;

[0024] Figure 5 This is a schematic diagram showing the connection between two battery boxes in a battery box and household battery pack device according to this utility model.

[0025] Reference numerals: 1. Battery cell; 2. Long end plate; 3. Plastic cable tie; 4. Male connector; 5. Female connector; 6. Lower housing; 7. Top cover; 8. Long screw; 9. Injection molding base; 10. Output aluminum bar; 11. Battery cell connection aluminum bar; 12. Top cover limiting protrusion; 13. Connector support base; 14. Housing reinforcing rib; 15. Lower housing groove limiting platform; 16. Mounting holes for the top cover and lower housing. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] This utility model discloses a battery box and a household battery pack device, aiming to reduce product weight and enhance corrosion resistance and insulation performance, belonging to the field of lithium-ion battery energy storage. The battery pack device includes a battery cell 1, a long end plate 2, plastic steel cable ties 3, a male connector 4, a female connector 5, a lower housing 6, and a top cover 7. The lower housing 6 is molded from a composite material, which can be one of the following: PCM composite material, a mixture of PCM composite material and ceramicized polyolefin, ceramicized phenolic resin material, or high-density woven glass fiber cloth reinforcement material. Preferably, glass fiber with continuous glass fiber and epoxy vinyl ester resin as the matrix is ​​used to enhance the composite material's performance. The internal reinforcing ribs 14 of the lower housing 6 are molded together with the lower housing 6 in a single molding process, resulting in a simple molding structure and convenient processing, while also providing superior corrosion resistance, insulation, flame retardancy, and thermal conductivity. Using a composite material housing can effectively reduce product weight and improve product performance.

[0028] In this solution, the residential battery pack assembly comprises battery cells 1, long end plates 2, plastic cable ties 3, male connectors 4, female connectors 5, a lower housing 6, and a top cover 7. Multiple battery cells 1 form a battery module. Compared to traditional sheet metal fixing methods for residential battery pack modules, this solution uses a fixing method with long end plates 2, plastic cable ties 3, and long screws 8. This not only improves the compatibility with parts from similar products but also increases production and assembly efficiency. Compared to traditional sheet metal fixing module solutions for residential batteries, this solution reduces costs, and the use of long end plates 2 for fixing also improves product reliability.

[0029] In the process of assembling the battery module, the battery cells 1 first need to be arranged in the order of positive and negative terminals. Next, the long end plates 2 are placed on both sides of the arranged battery cells 1, ensuring that the injection molding base 9 and the long end plates 2 are firmly connected by the locking mechanism. Then, the long end plates 2 on both sides are pressed to secure the battery cells 1, and the long end plates 2 are bound or fitted with plastic steel cable ties 3 to form a battery module composed of multiple battery cells 1.

[0030] Subsequently, the output aluminum bar 10 and the cell connection aluminum bar 11 are placed on top of the cell 1, and they are welded together with the cell 1 using a welding machine to ensure the reliability of the electrical connection. After welding is completed, the battery module is placed into the lower housing 6 made of composite material, and it is fixed to the bottom of the lower housing 6 made of composite material using long screws 8.

[0031] The connector support base 13 is fixed to the inside of the lower housing 6 and close to the upper cover 7 by screws. The male connector 4 is installed on the connector support base 13 by screws, and the female connector 5 is installed on the bottom of the lower housing 6, which is made of composite material, and fixed with screws. The upper cover 7 and the lower housing 6 are respectively provided with through holes corresponding to the male connector 4 and the female connector 5. The upper cover 7 and the lower housing 6 are fixed by screws through the upper cover edge distributed on the outside of the upper cover limiting protrusion 12 and the lower housing mounting holes 16 (screw holes).

[0032] In a preferred embodiment, the connector support 13 extends upward inside the lower housing 6 so that the male connector 4 partially or completely passes through the upper cover limiting protrusion 12, while the female connector 5 is entirely located inside the lower housing 6. When multiple battery boxes need to be stacked, the lower battery box is limited by the upper cover limiting protrusion 12, and it fits tightly with the lower housing recess limiting platform 15 of the upper battery box to ensure the stability of the battery box. At the same time, the male connector 4, located at the top of the lower battery box and passing through the upper cover limiting protrusion 12, is inserted into the female connector 5 located inside the bottom of the lower housing 6 of the upper battery box.

[0033] In addition, the lower housing reinforcing rib 14 enhances the strength of the lower housing 6. Its U-shaped design provides additional support and protection. These steps ensure the structural stability of the battery module and the safety of its electrical connections.

[0034] PCM (phase change material) composites are a special type of material that can absorb or release latent heat through changes in its state of matter while maintaining a constant temperature. Boxes made from this material have the following characteristics: First, they possess a high latent heat of fusion, which helps in absorbing or releasing a large amount of heat during phase change; second, PCM composites exhibit minimal volume expansion and contraction during phase change, contributing to the stability and durability of the box; third, PCM composites have a high thermal conductivity, meaning they can rapidly conduct heat, improving thermal energy utilization efficiency; and finally, PCM composites have a high density and specific heat capacity, allowing them to store more heat per unit volume.

[0035] Ceramicized polyolefin is a novel type of flame-retardant and refractory material. It is made by adding ceramic fillers, fluxes, and flame retardants to a polyolefin matrix. It can rapidly form a ceramic body with a certain strength in flame and high-temperature environments, thus playing a role in flame retardancy and oxygen isolation. At high temperatures, the ceramic fillers and fluxes interact to form a ceramic body, enhancing the material's fire resistance.

[0036] Ceramizable phenolic resin is a special polymer that exhibits properties similar to ordinary polymers at low temperatures. However, at high temperatures, it undergoes a secondary chemical reaction to transform into ceramic, resulting in a ceramic product with superior temperature and impact resistance. Using phenolic resin as a matrix, heat-resistant fillers or other functional fillers are added to induce a ceramization reaction in the carbon layer produced during ablation, forming a dense ceramic layer and thus improving the ablation insulation performance of the composite material. The preparation method involves first uniformly mixing phenolic resin with a dispersant and ceramizable additives in a specific ratio (the solution is anhydrous ethanol), and then using a solution method to prepare a prepreg by blending it with an aromatic carbon-based woven fabric.

[0037] Fiberglass is a high-performance inorganic non-metallic material with many varieties, possessing advantages such as good insulation, strong heat resistance, good corrosion resistance, and high mechanical strength. It is manufactured from six minerals—pyrophyllite, quartz sand, limestone, dolomite, borocalcite, and boromagnesia—through high-temperature melting, drawing, winding, and weaving processes. Fiberglass is commonly used as a reinforcing material and electrical insulation material in composite materials.

[0038] By using one of the following materials: PCM composite material, a mixture of PCM composite material and ceramicized polyolefin, ceramicized phenolic resin material, or high-density woven glass fiber cloth reinforcement material, and preferably using glass fiber with continuous glass fiber and epoxy vinyl ester resin as the matrix to enhance the composite material properties, the problem of excessive weight of household energy storage battery pack enclosures can be solved. These composite material enclosures are not only lightweight, but also have stronger corrosion resistance, insulation properties, and thermal conductivity, and are superior to metal enclosures coated with fire-retardant paint, meeting domestic and international UL94 flame retardant requirements.

[0039] The lower housing 6, made of composite materials, is easy to mold and process, more corrosion-resistant, and has excellent insulation and flame-retardant properties. It also features a low coefficient of thermal expansion and small heat capacity, effectively reducing product weight. Furthermore, applying thermally conductive adhesive to the bottom of the battery module allows for heat conduction between the battery module and the external environment through the lower housing 6. In particular, the use of thermally conductive adhesive at the battery contact surface allows for greater heat transfer to the outside, maintaining a suitable internal temperature for battery operation.

[0040] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A battery box, characterized in that, It includes a lower housing (6) and an upper cover (7) installed on the top of the lower housing (6). A connector support seat (13) is provided inside the lower housing (6). A male connector (4) and a female connector (5) are provided directly above and below the connector support seat (13), respectively. The upper cover (7) and the bottom of the lower housing (6) are respectively provided with through holes corresponding to the male connector (4) and the female connector (5).

2. The battery box according to claim 1, characterized in that, The male connector (4) is located on the connector support (13) and passes through the upper cover (7).

3. A battery box according to claim 2, characterized in that, The upper cover (7) is provided with an upper cover limiting protrusion (12) in the middle, and the lower box (6) is provided with a lower box groove limiting platform (15) adapted to the upper cover limiting protrusion (12) at the bottom, and the male connector (4) passes through the upper cover limiting protrusion (12).

4. A battery box according to claim 3, characterized in that, The lower box (6) is provided with box reinforcement ribs (14).

5. A battery box according to claim 4, characterized in that, The box-shaped reinforcing rib (14) is U-shaped.

6. A battery box according to any one of claims 1 to 5, characterized in that, The lower housing (6) is made of composite material, which is one of PCM composite material, ceramizable phenolic resin material, and high-density woven glass fiber cloth reinforcement material.

7. A household battery pack device, characterized in that, The battery box includes any one of claims 1 to 6, wherein the lower box (6) is equipped with a battery module, the battery module including a plurality of sequentially arranged cells (1), long end plates (2) disposed on both sides of the arranged cells (1), and plastic steel cable ties (3) for binding or fitting into the long end plates (2) on both sides.

8. A household battery pack device according to claim 7, characterized in that, The long end plate (2) is fitted with long screws (8) for connecting the lower housing (6).

9. A household battery pack device according to claim 7, characterized in that, The top of the sequentially arranged battery cells (1) is connected to an output aluminum bar (10) and a battery cell connection aluminum bar (11), and an injection molding seat (9) is provided on the long end plate (2).

10. A household battery pack device according to claim 7, characterized in that, The bottom of the battery module is provided with a thermally conductive adhesive layer.

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