Battery device and electric device

Abstract

The utility model provides a battery device and a power utilization device, and relates to the technical field of batteries, and the battery device comprises a battery pack which comprises at least one battery monomer; the bracket is arranged above the battery pack along the height direction of the battery device; the cooling piece is arranged on one side, deviating from the battery pack, of the bracket; the high-voltage box is arranged on the side, away from the support, of the cooling piece, makes contact with the cooling piece and can exchange heat with the cooling piece. The bracket, the cooling piece and the high-voltage box are arranged above the battery pack, so that the space utilization rate in the battery device is improved, and the problems of narrow cooling channel, low maintenance and replacement efficiency and the like caused by stacking and crowding of parts in the traditional layout of the battery device are effectively solved; and the maintainability, the heat dissipation efficiency and the overall service life of the battery device are remarkably improved.

Description

Technical Field

[0001] This application relates to the field of battery technology, and more specifically, to a battery device and an electrical device. Background Technology

[0002] In the relevant solutions, the components inside the power battery pack are arranged in a compact manner, resulting in poor heat dissipation efficiency, which seriously affects the service life and reliability of the power battery pack. At the same time, the crowded stacking of components inside the power battery pack means that the maintenance and replacement of any component requires the disassembly of a large number of other parts, which makes the maintenance efficiency of the power battery pack low.

[0003] Therefore, designing a battery device with good heat dissipation and easy maintenance has become an urgent problem to be solved. Utility Model Content

[0004] In view of this, this application provides a battery device with good heat dissipation and convenient maintenance.

[0005] Therefore, the first aspect of this application proposes a battery device.

[0006] The second aspect of this application proposes an electrical device.

[0007] In view of the above, the first aspect of this application provides a battery device for an electrical device, the battery device comprising: a battery pack including at least one battery cell; a support frame disposed above the battery pack along the height direction of the battery device; a cooling element disposed on the side of the support frame away from the battery pack; and a high-voltage box disposed on the side of the cooling element away from the support frame, in contact with the cooling element and capable of exchanging heat with the cooling element.

[0008] According to the battery device proposed in this application, by installing the bracket, cooling component, and high-voltage box as integrated components above the battery pack, the height (Z-axis) space of the battery device is fully utilized, freeing the high-voltage box from the traditional mode of competing with the battery pack for planar (XY-axis) layout. This significantly reduces the planar projection area of ​​the high-voltage box, thereby making it possible to increase the number of cells or use larger cells, directly improving the system energy density of the battery device. On the other hand, by installing the bracket, cooling component, and high-voltage box above the battery pack, the height space is rationally utilized, providing more space for the cooling component and high-voltage box. This allows for larger cooling channels within the cooling component, ensuring unobstructed cooling airflow paths. At the same time, the internal components of the high-voltage box do not need to be too compactly and stacked, allowing for a more loose arrangement. This results in larger gaps between the components inside the high-voltage box, which is more conducive to internal heat dissipation and solves the problem of difficult disassembly and assembly caused by overly crowded components inside the high-voltage box. Furthermore, by integrating the bracket, cooling components, and high-voltage box as a single unit above the battery pack, the maintenance efficiency of the battery device is significantly improved. This design allows for the individual disassembly and replacement of the entire module in case of any component failure, without disassembling other internal structures of the battery device, greatly reducing maintenance complexity and time costs. Simultaneously, the heat generated by the high-voltage box during operation can be directly and efficiently conducted and dissipated by the cooling components below, solving the heat dissipation problem caused by limited space in high-power high-voltage boxes and ensuring their reliability and lifespan.

[0009] In summary, the battery device of this embodiment, by mounting the bracket, cooling component, and high-voltage box as components on top of the battery pack, forms a modular unit that can be individually disassembled from the battery device. This effectively solves the problems of narrow cooling channels and low maintenance and replacement efficiency caused by the crowded stacking of components in traditional layouts, significantly improving the maintainability, heat dissipation efficiency, and overall service life of the battery device. It addresses the three core issues of "large footprint of the high-voltage box," "difficult heat dissipation," and "inconvenient maintenance," making a significant contribution to improving the driving range and reliability of electrical devices.

[0010] In any of the above technical solutions, optionally, the cooling component is mounted on the bracket, part of the high-voltage box is mounted on the bracket, and part of the high-voltage box is mounted on the cooling component.

[0011] In these technical solutions, the interconnection of the bracket, cooling components, and high-voltage box transforms them from isolated parts into a mechanically stable spatial frame structure. This frame structure greatly enhances the overall rigidity and deformation resistance of the battery device, enabling it to effectively resist vibrations and impacts from the device during operation and ensuring the reliability and safety of internal electrical connections.

[0012] Optionally, in any of the above technical solutions, the battery device further includes: at least two mounting bosses disposed on the bracket, with a first nut insert embedded in the mounting boss, and the bracket and the high voltage box are connected by the cooperation of the first threaded fastener and the first nut insert.

[0013] In these technical solutions, by providing mounting bosses on the bracket, a portion of the bracket structure can be set higher. This allows the cooling components to be positioned between the high-voltage box and the bracket, while the mounting bosses simultaneously support the high-voltage box, ensuring that the bracket can support both the water-cooled components and the high-voltage box. To achieve a fixed installation between the bracket and the high-voltage box, a first nut insert is embedded within the mounting boss. During installation, mounting holes can be provided on the high-voltage box, and a first threaded fastener can be inserted into the first nut insert through the mounting holes to achieve a fixed connection between the high-voltage box and the bracket.

[0014] Optionally, in any of the above technical solutions, the battery device further includes: at least two hole inserts, each with a mounting hole, and the bracket and cooling component are connected by a second threaded fastener engaging with the mounting hole.

[0015] In these technical solutions, by providing a pre-drilled insert in the bracket, mounting holes are provided for the bracket and cooling component to be installed using a second threaded fastener, thus enabling a quick connection between the bracket and the cooling component. Providing mounting holes through a pre-drilled insert, compared to directly creating mounting holes on the bracket, increases the strength of the mounting holes, resulting in a more stable and reliable fixation of the bracket and cooling component.

[0016] Optionally, in any of the above technical solutions, the battery device further includes: a lower housing assembly, on which the battery pack is mounted; at least two second nut inserts, embedded in the bracket, and the bracket and the lower housing assembly are connected by a third threaded fastener.

[0017] By setting a second nut insert in the bracket, the bracket and the lower housing assembly can be connected by a third threaded fastener. During installation, a through hole can be set on the lower housing assembly, and the third threaded fastener can be inserted into the second nut insert after passing through the through hole, so that the third threaded fastener can be locked and fixed by the second nut insert. In this way, the connection between the bracket and the lower housing assembly can be quickly achieved.

[0018] Optionally, the bracket may also include a hole insert, a second nut insert, and a first nut insert. By simultaneously incorporating these three inserts, the strength of the mounting holes and other components can be ensured, improving the reliability of the connection between the bracket and structures such as the high-voltage box and cooling components. Furthermore, multiple components and the bracket can be integrated together, achieving a high degree of component integration, reducing the number of parts, and lowering the weight and manufacturing cost of the battery device.

[0019] In any of the above technical solutions, optionally, the bracket is an injection-molded part. That is, the bracket is formed by injection molding. This processing method facilitates the placement of inserts in the bracket to improve its strength, thereby improving the reliability of the connection between the bracket and parts such as the high-pressure box and cooling components.

[0020] In any of the above technical solutions, optionally, the bracket is an insulating component, and / or the bracket is a non-metallic component.

[0021] In these technical solutions, by making the bracket a non-metallic component, the weight of the bracket itself is greatly reduced, achieving lightweighting of the battery device and even the entire vehicle, which helps to improve the driving range of the electrical device. The bracket is an insulating component, realizing the isolation between the battery and components such as the high-voltage box and cooling components, avoiding the risk of short circuits or leakage between live components and the battery pack through the bracket, and greatly improving the electrical safety and reliability of the battery device.

[0022] In any of the above technical solutions, optionally, the cooling component is a liquid cooling plate, the liquid cooling plate is provided with a cooling channel and an inlet and outlet water hole communicating with the cooling channel, and the battery device further includes: at least one water nozzle communicating with the inlet and outlet water hole, used to supply heat exchange medium to the cooling channel through the inlet and outlet water hole, or to discharge heat exchange medium in the cooling channel.

[0023] In these technical solutions, the core component of the cooling system is the liquid cooling plate. The liquid cooling plate has internal cooling channels and is connected to at least one external water nozzle through inlet and outlet water holes, forming a complete liquid cooling circulation loop. The liquid cooling plate contacts the high-voltage box, enabling heat exchange. Therefore, when the battery device is operating, the heat generated by the high-voltage box can be transferred to the liquid cooling plate through direct contact or a thermal pad. After a heat exchange medium is introduced into the cooling channels, the lower temperature of the heat exchange medium and the higher temperature of the liquid cooling plate allow for heat exchange, removing the heat transferred from the high-voltage box from the liquid cooling plate. This achieves heat dissipation for the high-voltage box through the liquid cooling plate. Based on the direct heat exchange method using a liquid medium, its heat exchange efficiency and heat capacity are far higher than traditional air cooling or indirect cooling modes, providing stable and efficient cooling for the high-voltage box operating at high power, ensuring that the operating temperature of the high-voltage box remains within a safe and reliable range, and improving the thermal management performance and operational stability of the entire battery device. Simultaneously, cooling the high-voltage box through a heat exchange medium simplifies the cooling structure. Furthermore, the high-voltage box and cooling components are cooled through contact, without altering the internal structure of the high-voltage box. This results in lower product modification costs, which is beneficial for the promotion of new products.

[0024] Optionally, in any of the above technical solutions, the battery device further includes: a water inlet / outlet connector communicating with a water inlet / outlet hole, the inner wall of the water inlet / outlet connector being provided with at least one sealing groove, the sealing groove being arranged circumferentially along the water inlet / outlet hole, and one end of the water nozzle being inserted into the water inlet / outlet connector; a sealing element being disposed in the sealing groove and located between the water nozzle and the water inlet / outlet connector, the depth of the sealing groove being less than the width of the sealing element along the radial direction of the water inlet / outlet hole, and the sealing element being used to seal the gap between the water nozzle and the water inlet / outlet connector.

[0025] In these technical solutions, a highly efficient and reliable sealing connection is achieved by setting inlet and outlet water connectors with dedicated sealing grooves. The sealing groove is circumferentially positioned around the inlet and outlet water holes, and its depth is specially designed to be less than the radial width of the seal. This key dimension ensures that the seal is in a pre-compressed state after installation, providing an initial and stable sealing force to the sealing interface. Through the cooperation of the sealing groove and the sealing ring, on the one hand, a more reliable and durable sealing performance is provided for the connection between the inlet and outlet water connectors and the water nozzle: the pre-compression design ensures immediate sealing under low pressure, while the reserved expansion space allows the seal to adaptively deform when the system pressure fluctuates, maintaining a stable sealing contact pressure, effectively compensating for long-term wear and aging of the seal, and significantly reducing the risk of heat exchange medium leakage. On the other hand, the cooperation of the sealing groove and the sealing ring optimizes assembly processability and error prevention performance: the sealing groove provides operators with a clear and unique installation position, thereby avoiding misinstallation, omission, or improper installation of the seal, improving assembly consistency and production yield. Finally, the combination of sealing grooves and sealing rings solved the new challenges brought about by raising the inlet and outlet water connectors and water nozzles above the bracket, ensuring the high sealing reliability of the inlet and outlet water connectors and water nozzles near key components such as the high-voltage box, and providing a basic guarantee for setting the high-voltage box and cooling components above the battery pack via the bracket.

[0026] In any of the above technical solutions, optionally, the inlet and outlet water connectors extend from the liquid cooling plate in a direction away from the support, and the water nozzle is located on the side of the liquid cooling plate away from the support; the inlet and outlet water connectors and the water nozzle are arranged on the periphery of the high-pressure box.

[0027] In these technical solutions, by centrally locating the inlet and outlet water connectors and nozzles above the support frame, operators can connect, disconnect, or maintain water pipes without disassembling the high-voltage box or other components, significantly reducing maintenance complexity. Furthermore, by centrally locating the inlet and outlet water connectors and nozzles above the support frame, unused vertical space around the high-voltage box is fully utilized for pipe interface placement, avoiding additional area occupation in the battery unit's planar direction and maintaining the overall structural compactness. Moreover, placing the inlet and outlet water connectors and / or at least one nozzle to the side of the electrical high-voltage box, rather than directly above it, effectively reduces the risk of heat exchange medium leaking and dripping directly onto the electrical components of the high-voltage box, providing additional safety redundancy for the battery unit. This layout not only optimizes assembly processability but also improves the overall system reliability and maintainability of the battery unit.

[0028] In any of the above technical solutions, optionally, the liquid cooling plate includes: an upper plate; a lower plate, the lower plate being mounted on the upper plate and forming a cooling channel with the upper plate; a first insulating member disposed on at least a portion of the surface of the upper plate on the side away from the lower plate; a second insulating member disposed on at least a portion of the surface of the lower plate on the side away from the upper plate; and water inlet and outlet holes penetrating the upper plate and the first insulating member and communicating with the cooling channel.

[0029] In these technical solutions, a double electrical insulation barrier is formed by the first and second insulating components, effectively isolating the liquid cooling plate from the conductive risks between the liquid cooling plate and live components such as the high-voltage box and battery pack, greatly improving the electrical safety of the battery device. The water inlet and outlet holes penetrate the upper plate and the first insulating component, ensuring the integrity of the heat exchange medium channel.

[0030] In any of the above technical solutions, the battery device may optionally include: a wiring channel disposed on the bracket for at least a portion of the wiring harness of the battery device to pass through; and / or a wiring harness fixing hole disposed on the bracket for at least a portion of the wiring harness of the battery device and / or a strap for fixing the wiring harness to pass through; and / or a wiring harness fixing buckle for fixing at least a portion of the wiring harness of the battery device.

[0031] In these technical solutions, by integrating wiring channels and / or wire harness fixing holes and / or wire harness fixing clips onto the bracket, the bracket not only fulfills its core function of supporting cooling components and high-voltage boxes but also simultaneously achieves efficient wire harness management. This design fully utilizes the three-dimensional structural space of the bracket, providing a regular routing path or fixing point for the wire harness. This not only avoids the need for additional wiring space and further optimizes the internal space utilization of the battery device but also significantly improves assembly efficiency and reliability. Clear wiring specifications effectively prevent interference and wear between the wire harness and moving parts or sharp edges, while ensuring a clear and orderly wire harness layout, greatly enhancing system maintainability. This bracket, which integrates support, installation, and wire harness management, significantly improves the integration, safety, and production yield of the battery device.

[0032] Optionally, in any of the above technical solutions, the battery device further includes: a reinforcing rib disposed on the bracket, wherein the reinforcing rib and the bracket are an integral structure.

[0033] In these technical solutions, reinforcing ribs can be added to strengthen localized areas of the support structure, such as the main stress-bearing areas, thereby improving the overall structural strength of the support. The support structure and the reinforcing ribs can be injection molded together, and the reinforcing ribs can be made of metal.

[0034] Optionally, the water inlet and outlet holes include at least two, at least one of which is connected to the inlet of the cooling channel, and at least one of which is connected to the outlet of the cooling channel. The water nozzle includes an inlet nozzle and an outlet nozzle, the inlet nozzle being used to supply heat exchange medium to the cooling channel through the water inlet and outlet holes, and the outlet nozzle being used to discharge heat exchange medium from the cooling channel through the water inlet and outlet holes.

[0035] At least two inlet and outlet ports are provided, including an inlet port communicating with the inlet of the cooling channel and an outlet port communicating with the outlet. Dedicated inlet and outlet nozzles are also provided, creating a complete and efficient liquid cooling circulation loop. This design achieves a unidirectional circulation of the heat exchange medium, from injection through the inlet nozzle, through the cooling channel where it undergoes sufficient heat exchange with the liquid cooling plate, to final discharge through the outlet nozzle. Continuous circulation of the heat exchange medium rapidly removes the heat generated by the high-pressure box, ensuring efficient heat dissipation.

[0036] Optionally, the inlet and outlet are connected by a connecting plate, which allows the inlet and outlet to be assembled into a single component, facilitating the overall installation of the inlet and outlet and improving the ease of installation.

[0037] Optionally, in any of the above technical solutions, the battery device further includes: a first mounting structure disposed on the bracket for connecting the bracket and the cooling component; and a second mounting structure disposed on the bracket for connecting the bracket and the high-voltage box; wherein the first mounting structure and / or the second mounting structure includes one or more combinations of mounting holes, mounting bosses, mounting grooves, first nut inserts, and pre-embedded hole components.

[0038] In these technical solutions, by integrating dedicated first and second mounting structures onto the bracket, modular and high-precision mounting interfaces are provided for the cooling components and the high-voltage box. The mounting structure can adopt one or more combinations of mounting holes, mounting bosses, mounting grooves, nut inserts, or pre-embedded holes, achieving a stable mechanical connection between the bracket and the cooling components, and between the bracket and the high-voltage box.

[0039] The second aspect of this application provides an electrical device including the battery device in any embodiment of the first aspect, the battery device being used to provide electrical energy.

[0040] The electrical device proposed in this application, since it includes the battery device in any embodiment of the first aspect, has all the beneficial effects of the battery device in any embodiment of the first aspect, which will not be repeated here.

[0041] Additional aspects and advantages of this application will become apparent in the following description or may be learned by practice of this application. Attached Figure Description

[0042] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0043] Figure 1 This is one of the structural schematic diagrams of the battery device in some embodiments of this application;

[0044] Figure 2 for Figure 1 A magnified view of the structure at point A in the diagram;

[0045] Figure 3 This is a schematic diagram of the structure of the support for the battery device in some embodiments of this application;

[0046] Figure 4 This is a schematic diagram of the structure of the liquid cooling plate of the battery device in some embodiments of this application;

[0047] Figure 5 This is a schematic diagram of the assembly structure of the water tap and inlet / outlet connector of the battery device in some embodiments of this application;

[0048] Figure 6 This is a second schematic diagram of the battery device in some embodiments of this application;

[0049] Figure 7 for Figure 6 A schematic diagram of the cross-sectional structure at point BB;

[0050] Figure 8 for Figure 7 A magnified schematic diagram of the local structure at point C;

[0051] Figure 9 This is the third of three schematic diagrams showing the structure of the battery device in some embodiments of this application;

[0052] Figure 10 This is a schematic diagram of the battery pack structure in some embodiments of this application;

[0053] Figure 11 This is a schematic diagram of the vehicle structure in some embodiments of this application.

[0054] in, Figures 1 to 11 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0055] 100 Battery Pack, 1 Battery Group, 12 Battery Cells, 2 Brackets, 20 Mounting Bosses, 21 First Nut Insert, 22 Hole Insert, 222 Mounting Hole, 23 Second Nut Insert, 3 Cooling Components, 32 Liquid Cooling Plate, 320 Water Inlet / Outlet Holes, 321 Plug, 322 Cooling Channel, 324 Upper Plate, 326 Lower Plate, 328 First Insulator, 329 Second Insulator, 4 High Voltage Box, 5 Water Nozzle, 6 Water Inlet / Outlet Connectors, 62 Sealing Groove, 7 Sealing Component, 8 Connecting Plate, 9 Lower Housing Assembly, 10 Battery Top Cover, 11 First Threaded Fastener, 13 Second Threaded Fastener, 15 Third Threaded Fastener, 200 Controller, 300 Motor. Detailed Implementation

[0056] To better understand the above-mentioned objectives, features, and advantages of this application, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0057] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0058] Current new energy passenger vehicles place extremely high demands on the energy density, space utilization, and reliability of power battery systems. Internal space within the battery pack is extremely valuable. Traditional high-voltage boxes employ a single-layer, flat layout, placing all high-voltage components, connectors, and cooling pipes on the same plane, which inherently has the following drawbacks:

[0059] 1. Low space utilization: It seriously occupies the horizontal projection area of ​​the battery device, squeezes the space for cell arrangement, and restricts the improvement of the energy density of the battery device.

[0060] 2. Poor integration and reliability: To achieve the function, multiple independent metal brackets are often required to fix different components, resulting in a large number of parts, heavy system weight, complex assembly process, and poor vibration resistance of the dispersed fixing points.

[0061] 3. Poor thermal management and maintainability: The components inside the existing high-voltage box are often arranged in a compact manner, which leads to limited heat dissipation channels and poor heat dissipation efficiency, seriously affecting the service life and reliability of the high-voltage box. At the same time, the crowded stacking of components makes it necessary to disassemble a lot of parts for maintenance and replacement, resulting in low efficiency.

[0062] 4. The compact and non-modular layout also brings many inconveniences to the installation, wiring, and subsequent maintenance and repair of components.

[0063] Therefore, there is an urgent need for a compact battery device that can efficiently integrate high-voltage components and a cooling system within a limited space, while also ensuring good heat dissipation, structural reliability, and ease of assembly, disassembly, and maintenance.

[0064] In view of the above problems, this application provides a battery device for use in electrical devices, such as... Figures 1 to 10As shown, the battery device includes a battery pack 1, a bracket 2, a cooling component 3, and a high-voltage box 4. The bracket 2, cooling component 3, and high-voltage box 4 are arranged sequentially from bottom to top. Both the cooling component 3 and the high-voltage box 4 are mounted on top of the bracket 2, forming a module that can be individually detached from the battery device. The bracket 2 integrates nut inserts, hole inserts, and metal reinforcing members for connecting with the cooling component 3 and the high-voltage box 4. Furthermore, the core component of the cooling component 3 is a liquid-cooled plate 32. The liquid-cooled plate 32 is a water-cooled structure; by circulating water into the liquid-cooled plate 32, heat exchange occurs between the water and the liquid-cooled plate 32, thus removing the heat generated by the high-voltage box 4. To improve the seal when the liquid-cooled plate 32 is connected to the water supply nozzle 5, a sealing groove 62 is provided in the inlet / outlet water connector 6 of the liquid-cooled plate 32, and a sealing component 7 is installed between the sealing groove 62, the inlet / outlet water connector 6, and the water nozzle 5.

[0065] In this embodiment, the battery device, by mounting the bracket 2, cooling component 3, and high-voltage box 4 as components on top of the battery pack 1, forms a module that can be individually disassembled from the battery device. This effectively solves the problems of narrow and obstructed cooling channels and low maintenance and replacement efficiency caused by the crowded stacking of components in traditional layouts, significantly improving the maintainability, heat dissipation efficiency, and overall service life of the battery device. It solves the three core problems of "large footprint of the high-voltage box," "difficult heat dissipation," and "inconvenient maintenance," making a significant contribution to improving the range and reliability of electrical devices. The sealing design of the sealing groove 62 and the sealing component 7 improves the seal when the liquid cooling plate 32 is connected to the water supply nozzle 5, providing a basic guarantee for mounting the high-voltage box 4 and cooling component 3 on top of the battery pack 1 via the bracket 2.

[0066] In this embodiment, the battery device can be a battery module or a battery pack. Specifically, the battery device can be a power battery device, which can be used in new energy vehicles or hybrid electric vehicles.

[0067] Battery devices can be used in electrical devices that use batteries as a power source. They can also be used in various energy storage devices that use batteries as energy storage elements. These electrical devices include, but are not limited to, mobile phones, tablets, laptops, electric toys, power tools, electric vehicles, electric cars, ships, spacecraft, etc. Electric toys can include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc., while spacecraft can include airplanes, rockets, space shuttles, and spacecraft, etc.

[0068] like Figure 1 , Figure 2 , Figure 9 and Figure 10 As shown, the first aspect of this application discloses a battery device for use in an electrical device. The battery device includes a battery pack 1, a support 2, a cooling element 3, and a high-voltage box 4. The battery pack 1 includes at least one battery cell 12, and the support 2, cooling element 3, and high-voltage box 4 are arranged sequentially from bottom to top. Both the cooling element 3 and the high-voltage box 4 are mounted above the support 2, forming a module that can be individually detached from the battery device. The cooling element 3 is thermally connected to the high-voltage box 4, allowing the high-voltage box 4 to be cooled by the cooling element 3.

[0069] Battery pack 1 serves as an energy source, providing electrical energy to power electric vehicles and other applications. Battery pack 1 consists of one or more individual battery cells 12. A bracket 2 supports the battery pack 1, providing a stable mounting platform for the cooling unit 3 and the high-voltage box 4. The cooling unit 3, located on the bracket 2, dissipates heat from the high-voltage box 4, removing the heat generated by it. The cooling unit 3 can be part of the housing of the high-voltage box 4 or a separate structure. The high-voltage box 4 serves as a key interface between the battery pack and the vehicle's high-voltage system. Internally, it integrates core electrical components such as a main positive relay, main negative relay, pre-charge relay, fuse, and current sensor. Externally, it has a high-voltage connector interface for connecting the internal modules of the battery pack to external loads (such as motor controllers) and charging equipment. The key function of the high-voltage box 4 is to centrally manage the high-voltage power distribution and safety control of the battery device. For example, it controls the opening and closing of the high-voltage circuit through the on and off of the internal relay, uses the pre-charging circuit to suppress the inrush current at the moment of power-on, provides overcurrent protection with the help of fuses, and monitors the system's working status in real time through current sensors.

[0070] By integrating the bracket 2, cooling component 3, and high-voltage box 4 onto the battery pack 1, the height (Z-axis) space of the battery device is fully utilized. This frees the high-voltage box 4 from the traditional layout that competes with the battery pack 1 for planar (XY-axis) space, significantly reducing its planar projection area. This allows for an increase in the number of cells or the use of larger cells, directly improving the system energy density of the battery device. Furthermore, by placing the bracket 2, cooling component 3, and high-voltage box 4 above the battery pack 1, the height space is rationally utilized, providing more room for the cooling component 3 and high-voltage box 4. This allows for larger cooling channels within the cooling component, ensuring smooth airflow. Simultaneously, the internal components of the high-voltage box 4 do not need to be overly compact or stacked, allowing for a more loose arrangement. This results in larger gaps between the components, facilitating heat dissipation and solving the problem of difficult assembly and disassembly caused by overly crowded components within the high-voltage box 4. Furthermore, by integrating the bracket 2, cooling component 3, and high-voltage box 4 onto the battery pack 1, the maintenance efficiency of the battery unit is significantly improved. This design allows for individual disassembly and replacement of the entire module in case of any component failure, eliminating the need to disassemble other internal structures of the battery unit and greatly reducing maintenance complexity and time costs. Simultaneously, the heat generated by the high-voltage box 4 during operation can be directly and efficiently conducted and dissipated by the cooling component 3 below it, solving the heat dissipation problem caused by limited space in the high-power high-voltage box 4 and ensuring its reliability and lifespan.

[0071] In any of the above embodiments, optionally, the cooling component 3 is mounted on the bracket 2, part of the high-voltage box 4 is mounted on the bracket 2, and part of the high-voltage box 4 is mounted on the cooling component 3, that is, the bracket 2 is fixedly connected to both the cooling component 3 and the high-voltage box 4.

[0072] In these embodiments, the bracket 2 serves as the structural foundation and is fixedly connected to the cooling component 3 and the high-voltage box 4 above it. The cooling component 3 is connected to both the bracket 2 and the high-voltage box 4. The high-voltage box 4 is directly fixed to the cooling component 3.

[0073] When connecting the bracket 2, cooling component 3, and high-voltage box 4, fasteners such as screws or bolts can be used, or snap-fit ​​structures can be used. Alternatively, welding or adhesive bonding can also be used to connect the two parts.

[0074] The interconnection of the bracket 2, cooling component 3 and high-voltage box 4 transforms them from isolated components into a stable spatial frame structure. This frame structure greatly enhances the overall rigidity and deformation resistance of the battery device, enabling it to effectively resist vibrations and impacts from the device during operation and ensuring the reliability and safety of the internal electrical connections.

[0075] In any of the above embodiments, optionally, as Figure 1 , Figure 2 and Figure 3 As shown, the battery device also includes at least two mounting bosses 20, which are disposed on the bracket 2. A first nut insert 21 is disposed in the mounting boss 20. The first nut insert 21, the mounting bosses 20 and the bracket 2 are an integral structure. The bracket 2 and the high voltage box 4 are connected by the cooperation of the first threaded fastener 11 and the first nut insert 21.

[0076] In these embodiments, the bracket 2 is integrally provided with a first nut insert 21 and a mounting boss 20. The bracket 2 and the high-voltage box 4 can be connected by the engagement of the first threaded fastener 11 with the first nut insert 21. The mounting boss 20 can raise a local position of the bracket 2, thereby facilitating direct connection between the bracket 2 and the high-voltage box 4. Furthermore, the mounting boss 20 can support the high-voltage box 4, improving the installation stability of the high-voltage box 4.

[0077] Optionally, such as Figure 3 As shown, the battery device also includes at least two hole-shaped inserts 22, each with a mounting hole 222. The hole-shaped inserts 22 and the bracket 2 are an integral structure. Figure 2 As shown, the bracket 2 and the cooling component 3 are connected by the engagement of the second threaded fastener 13 with the mounting hole 222. The mounting hole 222 is provided by the hole insert 22 to facilitate the connection between the bracket 2 and the cooling component 3 via the second threaded fastener 13.

[0078] Optionally, a second nut insert 23 is integrally provided on the bracket 2. The second nut insert 23 is used to cooperate with the third threaded fastener 15 to realize the connection between the bracket 2 and the lower housing assembly 9. The battery device also includes the lower housing assembly 9, which is used to support the battery pack 1 and the bracket 2, etc. By directly fixing the bracket 2 to the lower housing assembly 9, it can be ensured that the bracket 2 does not shift, which improves the installation stability of the bracket 2 within the battery device.

[0079] The lower housing assembly 9 is used to support and install the battery pack 1 and the bracket 2, among other structures. The lower housing assembly 9 includes a protective frame, within which the battery pack 1 is housed. It also includes multiple reinforcing beams located inside the protective frame to enhance its strength. The lower housing assembly 9 further includes a base plate and a protective plate located below the protective frame; the base plate seals the bottom of the protective frame. To dissipate heat or cool the battery pack 1, the lower housing assembly 9 also includes heat exchange components (such as water-cooled heat exchangers) that exchange heat with the battery pack, achieving cooling or heating of the battery pack.

[0080] The first nut insert 21, the second nut insert 23, and the hole insert 22 can be pre-installed as inserts in the mold during the injection molding of the bracket 2, so that they can be integrally injection molded with the bracket 2. Alternatively, the first nut insert 21, the second nut insert 23, and the hole insert 22 can also be integrally molded with the bracket 2 after its manufacturing process, using methods such as adhesive bonding.

[0081] By providing a hole insert 22, a second nut insert 23, and a first nut insert 21 within the bracket 2, the strength of the mounting hole 222 and other components can be ensured, improving the reliability of the connection between the bracket 2 and structures such as the high-voltage box 4 and the cooling component 3. Furthermore, multiple components can be integrated with the bracket 2, achieving a high degree of component integration, reducing the number of parts, and lowering the weight and processing cost of the battery device.

[0082] In any of the above embodiments, the bracket 2 may optionally be an injection molded part, and / or an insulating part, and / or a non-metallic part.

[0083] In these embodiments, the bracket 2 may satisfy one or more of the following three conditions: injection molding, insulation, and non-metallic component. For example, the bracket 2 is configured as an insulating injection molded component made of a non-metallic material.

[0084] The bracket 2 is an injection-molded part, meaning it is formed through injection molding. This process allows for the inclusion of inserts within the bracket 2 to enhance its strength and improve the reliability of the connection between it and components such as the high-voltage box 4 and the cooling unit 3. By making the bracket 2 a non-metallic component, its weight is significantly reduced, contributing to weight reduction for the battery pack and the entire vehicle, and ultimately improving the driving range of the electrical system. The bracket 2 also serves as an insulator, isolating the battery from components such as the high-voltage box 4 and the cooling unit 3. This prevents short circuits or leakage between live components and the battery pack 1 via the bracket 2, significantly enhancing the electrical safety and reliability of the battery pack.

[0085] In any of the above embodiments, optionally, as Figure 1 , Figure 2 and Figure 4 As shown, the cooling component 3 is a liquid cooling plate 32, which has cooling channels 322 and inlet / outlet water holes 320 communicating with the cooling channels 322. Figure 1 , Figures 5 to 8 As shown, the battery device also includes at least one water nozzle 5, which is connected to the water inlet / outlet hole 320, for supplying heat exchange medium to the cooling channel 322 through the water inlet / outlet hole 320, or discharging heat exchange medium from the cooling channel 322.

[0086] In these embodiments, the core component of the cooling element 3 is the liquid cooling plate 32. The liquid cooling plate 32 has internal cooling channels 322 and is connected to at least one external water nozzle 5 via water inlet / outlet holes 320, forming a complete liquid cooling circulation loop. The liquid cooling plate 32 is in contact with the high-voltage box 4 and can exchange heat with it. Therefore, when the battery device is operating, the heat generated by the high-voltage box 4 can be transferred to the liquid cooling plate 32 through direct contact or a thermal pad. After the heat exchange medium is introduced into the cooling channels 322, the temperature of the heat exchange medium is lower, while the temperature of the liquid cooling plate 32 is higher, allowing the heat exchange medium to exchange heat with the liquid cooling plate 32 to remove the heat transferred from the high-voltage box 4 from the liquid cooling plate 32. This achieves heat dissipation for the high-voltage box 4 through the liquid cooling plate 32.

[0087] The heat exchange medium can be water or a mixture of water and other substances. However, water is more common and cheaper, so using it as a heat exchange medium can reduce the cost of the product.

[0088] The direct heat exchange method based on a liquid medium offers significantly higher heat exchange efficiency and heat capacity than traditional air cooling or indirect cooling methods. This provides stable and efficient cooling for the high-voltage box 4 operating at high power, ensuring its operating temperature remains within a safe and reliable range, thus improving the overall thermal management performance and operational stability of the battery device. Furthermore, cooling the high-voltage box 4 through the heat exchange medium simplifies its cooling structure. Since the high-voltage box 4 and the cooling component 3 are cooled through contact, the internal structure of the high-voltage box 4 does not need to be altered, resulting in lower modification costs and facilitating the promotion of new products.

[0089] In any of the above embodiments, optionally, as Figure 1 , Figure 2 , Figure 5 , Figure 6 , Figure 7 and Figure 8As shown, the battery device also includes a water inlet / outlet connector 6. The water inlet / outlet connector 6 communicates with the water inlet / outlet hole 320. At least one sealing groove 62 is provided on the inner wall of the water inlet / outlet connector 6, and the sealing groove 62 is arranged circumferentially along the water inlet / outlet hole 320. One end of the water nozzle 5 is inserted into the water inlet / outlet connector 6. The battery device also includes a sealing element 7. The sealing element 7 is disposed within the sealing groove 62 and located between the water nozzle 5 and the water inlet / outlet connector 6. The depth of the sealing groove 62 is less than the radial width of the sealing element 7 along the water inlet / outlet hole 320. The sealing element 7 is used to seal the gap between the water nozzle 5 and the water inlet / outlet connector 6.

[0090] In these embodiments, the battery device includes an inlet / outlet water connector 6, the interior of which is provided with a liquid passage for the flow of heat exchange medium, the liquid passage communicating with the inlet / outlet water hole 320. At least one sealing groove 62 (annular or non-annular) is machined on the inner wall of the inlet / outlet water connector 6. The battery device also includes a water nozzle 5, one end of which is inserted into the inlet / outlet water connector 6. A sealing element 7 (e.g., a sealing ring) is installed between the water nozzle 5 and the inlet / outlet water connector 6 at the location of the sealing groove 62, the sealing element 7 sealing the gap between the water nozzle 5 and the inlet / outlet water connector 6. Simultaneously, the depth of the sealing groove 62 is shallower than the lateral width (thickness) of the sealing ring itself. When the sealing ring is pressed into the sealing groove 62, it is compressed (pre-compressed), thereby tightly filling the gap between the water nozzle 5 and the connector, achieving a reliable seal.

[0091] By incorporating a water inlet / outlet connector 6 with a dedicated sealing groove 62, a highly efficient and reliable sealing connection is achieved. The sealing groove 62 is circumferentially positioned along the water inlet / outlet holes 320°, and its depth is specially designed to be less than the radial width of the seal 7. This critical dimension ensures that the seal 7 is in a pre-compressed state upon installation, providing an initial and stable sealing force to the sealing interface.

[0092] The combination of the sealing groove 62 and the sealing ring provides a more reliable and durable sealing performance for the connection between the inlet / outlet water connector 6 and the water nozzle 5. The pre-compression design ensures immediate sealing under low pressure, while the reserved expansion space allows the seal 7 to adapt to deformation during system pressure fluctuations, maintaining a stable sealing contact pressure, effectively compensating for long-term wear and aging of the seal 7, and significantly reducing the risk of heat exchange medium leakage. Furthermore, the combination of the sealing groove 62 and the sealing ring optimizes assembly processability and error prevention. The sealing groove 62 provides operators with a clear and unique installation position, thus avoiding misinstallation, omission, or improper installation of the seal 7, improving assembly consistency and production yield. Finally, the combination of the sealing groove 62 and the sealing ring solves the new challenges brought about by raising the inlet / outlet water connector 6 and the water nozzle 5 above the bracket 2, ensuring high sealing reliability of the inlet / outlet water connector 6 and the water nozzle 5 near key components such as the high-pressure box 4, providing a fundamental guarantee for placing the high-pressure box 4 and the cooling component 3 above the battery pack 1 via the bracket 2.

[0093] In any of the above embodiments, optionally, as Figure 2 and Figure 6 As shown, the inlet / outlet water connector 6 extends from the liquid cooling plate 32 toward the direction away from the bracket 2, and the water nozzle 5 is located on the side of the liquid cooling plate 32 away from the bracket 2; the inlet / outlet water connector 6 and the water nozzle 5 are arranged on the periphery of the high-pressure box 4.

[0094] In these embodiments, the water inlet / outlet connector 6 extends upward from the liquid cooling plate 32. The water nozzle 5 is also located above the liquid cooling plate 32. Furthermore, the water inlet / outlet connector 6 and the water nozzle 5 are located on the periphery of the high-pressure box 4, meaning they are not located at the top or bottom of the high-pressure box 4.

[0095] To facilitate the upward extension of the inlet / outlet water connector 6, the inlet / outlet water connector 6 can be positioned on the upper side of the cold plate.

[0096] By centrally locating the inlet / outlet water connectors 6 and / or water nozzles 5 above the bracket 2, operators can connect, disconnect, or maintain water pipes without disassembling the high-pressure box 4 or other components, significantly reducing maintenance complexity. Furthermore, by centrally locating the inlet / outlet water connectors 6 and water nozzles 5 above the bracket 2, the unused three-dimensional space around the high-pressure box 4 is fully utilized for arranging pipe interfaces, avoiding additional area occupation in the battery unit's planar direction and maintaining the overall structural compactness. Moreover, placing the inlet / outlet water connectors 6 and / or water nozzles 5 to the side of the electrical high-pressure box 4, rather than directly above it, effectively reduces the risk of heat exchange medium leaking directly onto the electrical components of the high-pressure box 4, providing additional safety redundancy for the battery unit. This layout not only optimizes assembly processability but also improves the overall system reliability and maintainability of the battery unit.

[0097] In any of the above embodiments, optionally, as Figure 4 As shown, the liquid cooling plate 32 includes an upper plate 324 and a lower plate 326, which are joined together to form a cooling channel 322. A first insulating member 328 is provided on the outside of the upper plate 324, and a second insulating member 329 is provided on the outside of the lower plate 326, forming a double insulating barrier; the water inlet and outlet holes 320 penetrate the upper plate 324 and the first insulating member 328 and communicate with the cooling channel 322.

[0098] In this embodiment, a double electrical insulation barrier is formed by the first insulating member 328 and the second insulating member 329, effectively isolating the liquid cooling plate 32 from the conductive risks between it and live components such as the high-voltage box 4 and the battery pack 1, greatly improving the electrical safety of the battery device. The water inlet / outlet hole 320 penetrates the upper plate 324 and the first insulating member 328, ensuring the integrity of the heat exchange medium channel.

[0099] The liquid cooling plate 32 also includes a removable plug 321. The plug 321 is used to open the water inlet and outlet holes 320. Before the liquid cooling plate 32 is installed, the water inlet and outlet holes 320 can be sealed by the removable plug 321 to prevent impurities from entering the water inlet and outlet holes 320. When the liquid cooling plate 32 is installed on the battery device, the plug 321 can be removed to connect the water inlet and outlet holes 320 to the water nozzle 5.

[0100] In any of the above embodiments, the battery device may optionally include: a wiring channel disposed on the bracket 2 for at least a portion of the wiring harness of the battery device to pass through; and / or a wiring harness fixing hole disposed on the bracket 2 for at least a portion of the wiring harness of the battery device and / or a strap for fixing the wiring harness to pass through; and / or a wiring harness fixing buckle for fixing at least a portion of the wiring harness of the battery device.

[0101] In these embodiments, the bracket 2 is provided with a wiring channel and / or a wiring harness fixing hole and / or a wiring harness fixing buckle, through which the wiring channel, wiring harness fixing hole or wiring harness fixing buckle can be fixed and guided.

[0102] The wiring harness here includes wires inside the battery device, such as wires connected to battery pack 1 or high-voltage box 4. Wiring channels, wiring harness fixing holes, and wiring harness fixing clips can be provided as needed; all can be provided, or only one type can be provided. The straps can be ropes, rubber rings, metal wires, or cable ties, etc.

[0103] By integrating wiring channels and / or wire harness fixing holes and / or wire harness fixing clips on the bracket 2, the bracket 2, in addition to fulfilling its core function of supporting the cooling component 3 and the high-voltage box 4, simultaneously achieves efficient wire harness management. This design fully utilizes the three-dimensional structural space of the bracket 2, providing a regular routing path or fixing point for the wire harness. This not only avoids the need for additional wiring space and further optimizes the internal space utilization of the battery device, but also significantly improves assembly efficiency and reliability. Clear wiring specifications effectively prevent interference and wear between the wire harness and moving parts or sharp edges, while ensuring a clear and orderly wire harness layout, greatly enhancing the maintainability of the system. This bracket 2, which integrates support, installation, and wire harness management, significantly improves the integration, safety, and production yield of the battery device.

[0104] In any of the above embodiments, the battery device may optionally include a reinforcing rib disposed on the bracket 2, wherein the reinforcing rib and the bracket 2 are an integral structure.

[0105] In these embodiments, by providing reinforcing ribs, local areas of the support 2 can be strengthened, such as the main stress-bearing areas of the support 2, thereby improving the overall structural strength of the support 2. The support 2 can be injection molded together with the reinforcing member, which can be a metal component.

[0106] Optionally, the inlet and outlet water holes 320 include at least two, at least one of which communicates with the inlet of the cooling channel 322, and at least one of which communicates with the outlet of the cooling channel 322. The water nozzle 5 includes an inlet nozzle and an outlet nozzle. The inlet nozzle is used to supply heat exchange medium to the cooling channel 322 through the inlet and outlet water holes 320, and the outlet nozzle is used to discharge the heat exchange medium in the cooling channel 322 through the inlet and outlet water holes 320.

[0107] At least two inlet and outlet water holes 320 include an inlet water hole communicating with the inlet of the cooling channel 322 and an outlet water hole communicating with the outlet. Dedicated inlet and outlet nozzles are also provided, constructing a complete and efficient liquid cooling circulation loop. This design achieves a unidirectional circulation of the heat exchange medium, which is injected through the inlet nozzle, flows through the cooling channel 322 to fully exchange heat with the liquid cooling plate 32, and finally exits through the outlet nozzle. Continuous circulation of the heat exchange medium rapidly removes the heat generated by the high-pressure box 4, ensuring efficient heat dissipation.

[0108] Optionally, such as Figure 5 As shown, the inlet and outlet are connected by the connecting plate 8, which allows the inlet and outlet to be assembled into a single component, thus facilitating the overall installation of the inlet and outlet and improving the ease of installation.

[0109] In any of the above embodiments, the battery device may optionally include: a first mounting structure disposed on the bracket 2 for connecting the bracket 2 and the cooling component 3; and a second mounting structure disposed on the bracket 2 for connecting the bracket 2 and the high-voltage box 4; wherein the first mounting structure and / or the second mounting structure includes one or more combinations of mounting holes 222, mounting bosses 20, mounting grooves, first nut inserts 21, and pre-embedded holes.

[0110] In these embodiments, by integrating dedicated first and second mounting structures on the bracket 2, modular and high-precision mounting interfaces are provided for the cooling component 3 and the high-voltage box 4. The mounting structure can adopt one or more combinations of mounting holes 222, mounting bosses 20, mounting grooves, nut inserts, or pre-embedded holes, achieving a stable mechanical connection between the bracket 2 and the cooling component 3, and between the bracket 2 and the high-voltage box 4.

[0111] The second aspect of this application provides an electrical device including the battery device in any embodiment of the first aspect, the battery device being used to provide electrical energy.

[0112] The electrical device proposed in this application, since it includes the battery device in any embodiment of the first aspect, has all the beneficial effects of the battery device in any embodiment of the first aspect, which will not be repeated here.

[0113] Alternatively, the electrical device can be a vehicle (the vehicle's structure is as follows) Figure 11 As shown, the vehicle can be a gasoline-powered vehicle, a natural gas-powered vehicle, or a new energy vehicle. New energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. The vehicle's interior includes a battery pack 100, which may include the aforementioned battery device or may be the battery device itself. In addition to the battery pack 1, bracket 2, high-voltage box 4, and lower housing assembly 9, the battery pack 100 also includes a battery cover 10. The battery cover 10 and the lower housing assembly 9 form a closed cavity to house the battery pack 1, bracket 2, high-voltage box 4, and other components. The battery pack 100 can be located at the bottom, front, or rear of the vehicle. The battery pack 100 can be used to power the vehicle; for example, it can serve as the vehicle's operating power source. The vehicle may also include a controller 200 and a motor 300. The controller 200 may be used, for example, to control the battery pack 100 to supply power to the motor 300, so that the vehicle can start and drive. The controller 200 may also be used, for example, to control the battery pack 100 for other working power needs of the vehicle. Here, working power needs may refer to the battery pack 100 providing power to electrical components of the vehicle such as the lighting system.

[0114] The following is combined Figures 1 to 8 This paper introduces a power battery device.

[0115] This embodiment provides a new battery device that can achieve high-density, modular integration of high-voltage components and cooling systems without significantly increasing system weight and number of parts. It also has excellent heat dissipation performance and structural reliability, while facilitating the installation and maintenance of internal components. This solves the problems of large planar space occupation and low integration caused by traditional single-layer layout.

[0116] The battery device provided in this application, such as Figures 1 to 8 As shown, a dedicated injection molding bracket is used as the core support and connection platform, and the high-pressure box 4 and the cooling system (including cooling components 3 and other structures) are set above the injection molding bracket, thereby achieving a high-density, reliable and easy-to-maintain layout of the high-pressure components and the cooling system in terms of height space.

[0117] The high-voltage box 4 includes a box body and a box cover. The box body is directly locked to the water-cooling plate by bolts at its four corners, and the water-cooling plate is connected to the high-voltage components by injection-molded brackets, forming a relatively stable overall structure. For example, the box body, water-cooling plate (i.e., cooling component 3), and injection-molded brackets are interconnected by fasteners, together forming a stable and deformation-resistant overall frame structure.

[0118] At the same time, such as Figures 5 to 8As shown, a special double-layer sealing structure or an easily replaceable sealing groove 62 is designed for the inlet and outlet ports located on the upper layer of the injection molding bracket: an integrated sealing groove 62 is provided at the interface of the inlet and outlet ports. The sealing groove 62 is used to accommodate and compress a sealing ring (i.e., sealing element 7) with a rectangular cross section, and the depth of the sealing groove 62 is less than the width of the sealing ring.

[0119] Specifically, this embodiment provides a battery device including a double-layer high-voltage box assembly. The double-layer high-voltage box assembly includes, from top to bottom, a box body, a water-cooling plate, and an injection-molded bracket serving as a core load-bearing platform. The box body, water-cooling plate, and injection-molded bracket are interconnected by fasteners, forming a deformation-resistant overall frame structure.

[0120] The double-layer high-voltage box assembly adopts a layered layout in the vertical direction (Z-axis):

[0121] The bottom layer is an injection-molded support;

[0122] The middle layer is a water-cooled plate, which is fixedly connected to the injection-molded bracket by a first fastener (e.g., an internal hex bolt).

[0123] Upper layer: Multiple high-voltage components (such as high-voltage connectors, fuses, and contactors) are secured to the water-cooled plate using second fasteners (e.g., pan head screws). Finally, the housing is connected to the injection-molded bracket via mounting ears around its perimeter using third fasteners (e.g., bolts).

[0124] The key structure in this embodiment lies in the injection-molded bracket. The injection-molded bracket is integrally injection molded from engineering plastic (PA66-GF30) using an injection molding process, and it has the following key design features:

[0125] Integrated design: Its structure integrates bottom mounting holes 222 for connecting water-cooled plates, multiple dedicated mounting bosses / slots for fixing various high-voltage devices, and wiring channels and strapping holes reserved for wire harness arrangement.

[0126] Structural reinforcement: Nut inserts or reinforcing ribs are embedded inside the areas bearing the main loads and fasteners to ensure that the connection strength meets vibration requirements.

[0127] Lightweight and Insulation: Compared with the traditional metal bracket 2, its weight is reduced by more than 50%, and it has excellent electrical insulation properties, which improves the safety of the system.

[0128] For example, the water-cooled plate is made of aluminum alloy and is connected to the injection-molded bracket by four hexagonal bolts.

[0129] For example, the box body and / or lid are made of PPE (Polyphenylene Ether) plastic. Mounting ears are provided at the four corners of the box body, and the mounting ears have through holes. The box body is connected to the threaded holes on the injection-molded bracket by bolts.

[0130] In this embodiment of the battery device, the housing, water-cooling plate, and injection-molded bracket are not isolated components, but are interconnected via fasteners, working together to form a stable spatial frame structure. Specifically, the housing is securely connected to the water-cooling plate; the water-cooling plate is securely connected to the injection-molded bracket; and the side walls or internal stiffeners of the housing may form auxiliary contact or interlocking relationships with the injection-molded bracket to further constrain displacement. This connection method makes the housing, water-cooling plate, and injection-molded bracket mechanically a unified whole, greatly improving the overall rigidity and deformation resistance of the battery device, effectively resisting vibrations and impacts from the direction of travel of the electrical device.

[0131] The battery device in this embodiment also includes a cooling and sealing system. A water-cooled plate, located in the center of the assembly, forms the cooling system. Cooling channels 322 are cast inside the water-cooled plate. Heat generated by the high-voltage components is conducted (through direct contact or via a thermal pad) to the water-cooled plate and carried away by the heat exchange medium. Simultaneously, the inlet and outlet of the water-cooled plate extend to the second layer and are located within the housing. The interface of the water nozzle 5 on the water-cooled plate is provided with a machined sealing groove 62. The depth of the sealing groove 62 is greater than its width, used to accommodate a rectangular cross-section silicone sealing ring. This deep groove design ensures that the sealing ring receives uniform and sufficient compression, maintaining excellent sealing performance even under long-term vibration and pressure fluctuations, effectively preventing the heat exchange medium from leaking into the upper high-voltage area.

[0132] In this embodiment of the battery device, each high-voltage component can be pre-installed on an injection-molded bracket to form a high-voltage module sub-assembly. Then, the high-voltage module sub-assembly is fixed to a water-cooling plate with bolts. Next, the water-cooling piping is connected. Finally, the casing is closed and tightened to complete the final assembly. This process achieves modular assembly, greatly improving production efficiency.

[0133] The Pack high-voltage box 4 layout scheme provided according to the embodiments of this application achieves the following beneficial effects:

[0134] 1. High space utilization: Fully utilizes the Z-axis space, greatly reduces the plane occupation, and improves the energy density of the Pack. This greatly improves the space utilization and solves the problem of the high voltage box 4 occupying too much space in the plane of the battery device, thus contributing to the improvement of the energy density of the battery device.

[0135] 2. Integration and lightweighting: By replacing multiple metal parts with an integrated injection-molded bracket, a high degree of integration of parts is achieved, reducing the number of parts and lowering the system weight and cost;

[0136] 3. Excellent maintainability: The injection-molded bracket, cooling plate, and high-voltage box 4 are installed as components within the battery device, realizing a modular design that greatly simplifies the assembly process and facilitates manufacturing. For future maintenance, the box can be disassembled to directly operate the modules integrated on the injection-molded bracket, making it simple, efficient, and convenient for subsequent maintenance.

[0137] 4. The structure is compact and reasonable, with reliable connections. The three core components are fastened together by bolts, transforming a simple "stacked relationship" into a "mechanically integrated whole." This means that any force or vibration experienced by any part can be shared and resisted by all three components, greatly suppressing the deformation and displacement of individual components. This results in a highly rigid overall frame consisting of the plastic support 2, cooling plate, and high-voltage box 4. Vibration during operation of the electrical device is one of the main causes of electrical connection failures. This overall frame structure has a higher natural frequency and stronger damping characteristics, which can more effectively resist the vibration transmission from the battery device housing, prevent bolt loosening and interface wear, thereby greatly enhancing the battery device's vibration and impact resistance, and improving the battery device's service life and safety.

[0138] 5. The short thermal management path and high heat dissipation efficiency ensure that high-voltage devices operate stably at suitable temperatures.

[0139] 6. Eliminates installation stress and improves the lifespan of components: Traditional decentralized fixing methods may cause installation stress on components due to slight deformation of the enclosure or water-cooling plate. The overall frame forms a stable internal support structure, reducing dependence on deformation of the downstream enclosure mounting surface, allowing high-voltage devices to operate in a more stable mechanical environment.

[0140] 7. A more reliable and durable sealing effect is achieved through the design of the dedicated sealing groove 62. By setting the width of the sealing ring to be greater than the depth of the sealing groove 62, the sealing ring is placed in a pre-compressed state after being placed in the sealing groove 62, and has greater expansion space. This design provides a more stable sealing force under system pressure fluctuations, compensates for the wear and aging of the sealing ring, and significantly reduces the risk of heat exchange medium leakage.

[0141] 8. The design of the special sealing groove 62 optimizes the assembly process and realizes the error prevention design for sealing ring installation: the specific groove shape processed in one piece provides operators with a clear and unique sealing ring installation position, avoiding misinstallation, omission or improper installation, and improving the consistency of assembly and the yield rate.

[0142] 9. The dedicated sealing groove 62 design effectively addresses the new challenges brought about by the two-layer layout. By raising the inlet and outlet from their traditional base position to above the injection molding bracket, the sealing reliability of the inlet and outlet becomes more critical, as leakage would directly affect surrounding high-pressure components. The dedicated sealing groove 62 design directly addresses the new risks arising from the innovative layout, ensuring the feasibility of the core utility model.

[0143] In this application, the term "multiple" refers to two or more unless otherwise expressly defined. The terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0144] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. The above are merely some embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A battery device, characterized in that, include: A battery pack includes at least one battery cell; A bracket is disposed above the battery pack along the height direction of the battery device; A cooling element is disposed on the side of the bracket opposite to the battery pack; The high-pressure box is located on the side of the cooling component away from the support, and is in contact with the cooling component and can exchange heat with the cooling component.

2. The battery device according to claim 1, characterized in that, The cooling component is mounted on the bracket, a portion of the high-voltage box is mounted on the bracket, and a portion of the high-voltage box is mounted on the cooling component.

3. The battery device according to claim 1, characterized in that, Also includes: At least two mounting bosses are provided on the bracket, and a first nut insert is embedded in the mounting boss. The bracket and the high-voltage box are connected by the cooperation of a first threaded fastener and the first nut insert.

4. The battery device according to claim 1, characterized in that, Also includes: At least two hole inserts are provided with mounting holes, and the bracket and the cooling component are connected by a second threaded fastener engaging with the mounting holes.

5. The battery device according to claim 1, characterized in that, Also includes: The lower housing assembly, on which the battery pack is mounted; At least two second nut inserts are embedded in the bracket, and the bracket and the lower housing assembly are connected by a third threaded fastener.

6. The battery device according to claim 1, characterized in that, The bracket is an insulating component, and / or the bracket is a non-metallic component.

7. The battery device according to claim 1, characterized in that, The cooling component is a liquid cooling plate, which is provided with cooling channels and inlet / outlet water holes communicating with the cooling channels. The battery device further includes: At least one water nozzle, connected to the inlet and outlet water holes, is used to supply heat exchange medium to the cooling channel through the inlet and outlet water holes, or to discharge heat exchange medium from the cooling channel.

8. The battery device according to claim 7, characterized in that, Also includes: A water inlet / outlet connector is connected to the water inlet / outlet hole. At least one sealing groove is provided on the inner wall of the water inlet / outlet connector. The sealing groove is arranged around the circumference of the water inlet / outlet hole. One end of the water nozzle is inserted into the water inlet / outlet connector. A sealing element is disposed within the sealing groove and located between the water nozzle and the inlet / outlet water connector. The depth of the sealing groove is less than the radial width of the sealing element along the inlet / outlet water hole. The sealing element is used to seal the gap between the water nozzle and the inlet / outlet water connector.

9. The battery device according to claim 8, characterized in that, The inlet and outlet water connectors extend from the liquid cooling plate in a direction away from the support, and the water nozzle is located on the side of the liquid cooling plate away from the support; The inlet and outlet water connectors and the water nozzle are located on the periphery of the high-pressure box.

10. The battery device according to claim 7, characterized in that, The liquid cooling plate includes: upper plate; The lower plate is installed on the upper plate and together with the upper plate form the cooling channel; A first insulating element is disposed on at least a portion of the surface of the upper plate on the side away from the lower plate; The second insulating element is disposed on at least a portion of the surface of the lower plate on the side away from the upper plate, and the water inlet and outlet holes penetrate the upper plate and the first insulating element and communicate with the cooling channel.

11. The battery device according to any one of claims 1 to 10, characterized in that, Also includes: A wiring channel is provided on the bracket for at least a portion of the wiring harness of the battery device to pass through; and / or A wire harness fixing hole, provided on the bracket, is for at least a portion of the battery device's wire harness and / or the securing strap for the wire harness to pass through; and / or A wiring harness securing clip is used to secure at least a portion of the wiring harness of the battery device.

12. An electrical appliance, characterized in that, include: The battery device according to any one of claims 1 to 11, wherein the battery device is used to provide electrical energy.

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