Electric vehicle battery liquid cooling plate and hot melting connection mold thereof

Abstract

The utility model discloses an electric vehicle battery liquid cooling plate and a hot melting connection mold thereof. The battery liquid cooling plate comprises a runner plate and a flat plate, a roundabout and coiled groove is formed in the runner plate, and the runner plate is formed by compression molding of plastic or non-metal composite materials; the flat plate is provided with a liquid inlet and a liquid outlet, the liquid inlet and the liquid outlet are located at the two ends of the diagonal line of the flat plate respectively, and the flat plate is made of metal. The runner plate and the flat plate are integrated into a whole through a hot melting molding process, a cooling medium flow guide channel communicated with the liquid inlet and the liquid outlet is formed between the groove of the runner plate and the flat plate, and a plurality of groups of mounting holes for realizing the assembly of the battery liquid cooling plate and a battery shell are formed in a non-cooling medium flow guide channel area. Through the innovative design of the electric vehicle battery liquid cooling plate and the hot melting connection mold thereof, the purposes of ensuring the product quality of the liquid cooling plate, reducing the production cost, prolonging the service life of the battery and prolonging the endurance mileage of the electric vehicle are achieved.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle battery technology, specifically to an electric vehicle battery liquid cooling plate and its hot melt connection mold. Background Technology

[0002] The battery pack is a core component of the drive system of new energy electric vehicles. Based on considerations of electric vehicle range, OEMs are placing higher demands on battery power and fast-charging performance. In this context, quickly dissipating the heat generated by the battery, cooling the battery pack, and ensuring battery safety are particularly important. Currently, the mainstream cooling method for battery packs is liquid cooling, which dissipates heat from the battery pack through the flow of a cooling medium within the channels of a liquid cooling plate. Therefore, a reasonable flow channel design for the liquid cooling plate and the selection of suitable cooling plate materials are crucial for enhancing the battery's heat dissipation effect and extending the battery pack's lifespan.

[0003] Brazing is a process that uses a filler metal with a lower melting point than the workpiece as a filler metal. The workpiece and filler metal are heated to a temperature higher than the filler metal's melting point but lower than the workpiece's melting point. The liquid filler metal wets the workpiece, fills the interface gap, and achieves atomic diffusion with the workpiece, thus achieving welding. Traditional electric vehicle battery liquid cooling plates are composed of two stamped metal plates joined together by brazing. Due to limitations in processing technology and material properties, existing battery liquid cooling plates have the following two drawbacks: First, during brazing, the workpiece needs to be wetted by melting filler metal. Insufficient wetting can lead to localized weld gaps, increasing the risk of cooling medium leakage. Second, because the brazing heating temperature is lower than the workpiece's melting point, corrosive flux is added to improve the welding effect. Residual flux after brazing is difficult to completely remove, reducing the weld joint strength and causing corrosion defects at the weld joint, increasing the risk of cooling medium leakage. Third, brazing fumes contain harmful substances such as tin, lead, rosin, and acid dust, polluting the atmosphere. Secondly, the flow channel plates of liquid cooling plates are usually made of metals such as aluminum or copper. The stamping process limits the thickness range of the plates and the minimum width of the flow channels, which increases production costs and increases the weight of the liquid cooling plates, negatively impacting the vehicle's driving range. Utility Model Content

[0004] This utility model provides a liquid cooling plate for electric vehicle batteries and its hot-melt connection mold. It aims to optimize the design of the non-metallic material flow channel plate structure and its hot-melt connection mold to match the hot-melt molding process of the flow channel plate and the metal plate. This achieves rapid flow of the cooling medium in the flow channel of the liquid cooling plate, enhances the reliability of the connection between the flow channel plate and the metal plate, and reduces the weight of the liquid cooling plate. The goal is to ensure the quality of the liquid cooling plate product, reduce production costs, extend battery life and electric vehicle range.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A liquid cooling plate for an electric vehicle battery includes a flow channel plate and a flat plate. The flow channel plate has a meandering groove and is molded from plastic or non-metallic composite material. The flat plate has an inlet and an outlet, which are located at opposite ends of the diagonal of the flat plate. The flat plate is made of metal. The flow channel plate and the flat plate are integrated into one piece by a hot melt molding process. A cooling medium guide channel is formed between the groove of the flow channel plate and the flat plate, which communicates with the inlet and outlet. Several sets of mounting holes are provided in the non-cooling medium guide channel area for assembling the battery liquid cooling plate with the battery casing.

[0007] The aforementioned electric vehicle battery liquid cooling plate has a flow channel plate wall thickness δ=0.8~2.5mm, a transition radius R=1~10mm between the bottom surface of the groove and the side wall of the flow channel plate, and a minimum width Wmin=3mm for the cooling medium guide channel.

[0008] A hot-melt connection mold for an electric vehicle battery liquid cooling plate is used to realize the hot-melt molding operation of the flow channel plate and the flat plate in the above-mentioned battery liquid cooling plate. It includes an upper mold, a lower mold, an electric heating element, and a temperature control system. The upper mold is provided with a flow channel plate receiving cavity, and an avoidance groove that mates with the groove on the flow channel plate is provided on the bottom surface of the flow channel plate receiving cavity. The depth of the avoidance groove is not less than the depth of the groove on the flow channel plate. The lower mold is provided with a flat plate receiving cavity, and an electric heating element is provided in the lower mold. The working state of the electric heating element is controlled by the temperature control system of the mold. After the upper mold and the lower mold are engaged, a molding cavity is formed between the upper mold and the lower mold.

[0009] The aforementioned electric vehicle battery liquid cooling plate hot-melt connection mold has several sets of positioning pins in the flat plate receiving cavity of the lower mold and several sets of positioning holes at the bottom of the flow channel plate receiving cavity of the upper mold; the positioning pins and positioning holes match the mounting holes on the battery liquid cooling plate.

[0010] This invention provides a liquid cooling plate for electric vehicle batteries. The flow channel plate is made of plastic or composite material, while the flat plate is made of aluminum alloy or other metal. The two are combined into one unit through a heat-fusion connection. A rational layout of the cooling medium flow channels not only improves the heat exchange effect of the liquid cooling plate but also reduces heat transfer in areas where cooling is not required by utilizing the good insulation properties of composite or plastic materials. This invention also provides a heat-fusion connection mold for electric vehicle battery liquid cooling plates, enabling mass production. The dimensional accuracy of the liquid cooling plate is ensured by the matching of the positioning pins of the lower mold and the mounting holes on the workpiece with the positioning holes of the upper mold, improving work efficiency and product quality. This invention's compatible heat-fusion connection method for battery liquid cooling plates can achieve the connection of different types of materials, offering advantages such as high connection strength and simple process, while reducing production costs. In summary, this invention achieves the goals of ensuring the quality of electric vehicle battery liquid cooling plates, reducing production costs, extending battery life, and increasing the driving range of electric vehicles. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the battery liquid cooling plate structure described in this utility model;

[0012] Figure 2 yes Figure 1 Exploded view of the liquid cooling plate structure of the battery;

[0013] Figure 3 This is a top view of the battery liquid cooling plate described in this utility model;

[0014] Figure 4 yes Figure 3 Schematic diagram of the cross-sectional structure of AA (enlarged);

[0015] Figure 5 This is an exploded structural diagram of the battery liquid cooling plate hot-melt connection mold described in this utility model;

[0016] Figure 6 yes Figure 5 A schematic diagram of the upper mold structure of the hot-melt connection mold for the liquid cooling plate of the battery.

[0017] Figure 7 This is a schematic diagram of the working state of the battery liquid cooling plate hot-melt connection mold;

[0018] Figure 8 yes Figure 7 Enlarged view of the structure at point I.

[0019] Explanation of each label in the diagram:

[0020] 1 is the battery liquid cooling plate

[0021] 1-1 is the flow channel plate, and 1-1-1 is the groove.

[0022] 1-2 is a flat plate, 1-2-1 is the inlet, and 1-2-2 is the outlet.

[0023] 1-3 are mounting holes.

[0024] 1-4 are cooling medium flow channels;

[0025] 2 is a mold for hot-melt connection of battery liquid cooling plate.

[0026] 2-1 is the upper mold, 2-1-1 is the runner plate receiving cavity, 2-1-2 is the clearance groove, and 2-1-3 is the positioning hole.

[0027] 2-2 is the lower mold, 2-2-1 is the flat plate receiving cavity, and 2-2-2 is the positioning pin. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0029] See Figure 1. Figure 2 , Figure 3 , Figure 4 This utility model provides a liquid cooling plate for an electric vehicle battery. The liquid cooling plate 1 includes a flow channel plate 1-1 and a flat plate 1-2. The flow channel plate 1-1 is provided with a meandering groove 1-1-1 and is molded from plastic or non-metallic composite material. The flat plate 1-2 is provided with an inlet 1-2-1 and an outlet 1-2-2, which are located at opposite ends of the diagonal of the flat plate. The flat plate 1-2 is made of metal. The flow channel plate 1-1 and the flat plate 1-2 are integrated into one piece by a hot melt molding process. A cooling medium guide channel 1-4 is formed between the groove 1-1-1 of the flow channel plate 1-1 and the flat plate 1-2, which communicates with the inlet 1-2-1 and the outlet 1-2-2. Several sets of mounting holes 1-3 are provided in the non-cooling medium guide channel area for assembling the liquid cooling plate 1 with the battery shell.

[0030] See Figure 3 , Figure 4 The liquid cooling plate for electric vehicle batteries described in this utility model has a flow channel plate 1-1 with a wall thickness δ=0.8~2.5mm, and a transition radius R=1~10mm between the bottom surface of the groove 1-1-1 on the flow channel plate 1-1 and the side wall; the minimum width Wmin of the cooling medium guiding channel 1-4 is 3mm.

[0031] In a specific embodiment of the electric vehicle battery liquid cooling plate of this utility model, the flow channel plate 1-1 can be made of plastic or fiber-reinforced composite material, with the density of the plastic being 0.8 to 1 g / cm³. 3 The density of the composite material is between 1.1 and 1.6 g / cm³. 3The density is less than half that of aluminum alloy; the strength of both plastic and composite materials can reach 150MPa, comparable to that of commonly used 3003-O aluminum plates. In this utility model, the thickness of the flow channel plate 1-1 in the battery liquid cooling plate 1 can be controlled between 0.8 and 2.5 mm, and the radius of curvature between 1 and 10 mm. Various processes can be used to mold the plastic or composite materials, such as molding and vacuum forming. Compared to metal plates, plastic or composite materials have better formability, providing more flexibility in flow channel design. The flow channel width can be narrower, with a minimum width of 3 mm, while the minimum flow channel width for aluminum alloy or metal plates is 6 mm. Through reasonable flow channel arrangement, better heat exchange can be achieved. Simultaneously, composite material plates or plastic plates have excellent thermal insulation properties, with a very low thermal conductivity, which can provide insulation and reduce unnecessary heat transfer to areas that do not require cooling.

[0032] See Figure 5 , Figure 6 , Figure 7 , Figure 8 This utility model also provides a hot-melt connection mold for liquid cooling plates of electric vehicle batteries. The hot-melt connection mold 2 for liquid cooling plates includes an upper mold 2-1, a lower mold 2-2, an electric heating element, and a temperature control system. The lower mold 2-2 is provided with a flat plate receiving cavity 2-2-1. An electric heating element is set in the lower mold 2-2, and the working state of the electric heating element is controlled by the temperature control system of the mold. Several sets of positioning posts 2-2-2 are set in the flat plate receiving cavity 2-2-1 of the lower mold 2-2. The upper mold 2-1 is provided with a flow channel plate receiving cavity 2-1-1. A clearance groove 2-1-2 is provided on the surface to cooperate with the groove 1-1-1 on the flow channel plate 1-1. The depth of the clearance groove 2-1-2 is not less than the depth of the groove 1-1-1 on the flow channel plate 1-1. Several sets of positioning holes 2-1-3 are provided at the bottom of the flow channel plate receiving cavity 2-1-1 of the upper mold 2-1. After the upper mold 2-1 and the lower mold 2-2 are engaged, a molding cavity is formed between the upper mold 2-1 and the lower mold 2-2. The positioning post 2-2-2 in the flat receiving cavity 2-2-1 of the lower mold 2-2 passes through the positioning hole 2-1-3 at the corresponding position in the flow channel plate receiving cavity 2-1-1 of the upper mold 2-1.

[0033] The electric vehicle battery liquid cooling plate hot-melt connection mold 2 of this utility model realizes the mass production of battery liquid cooling plate 1, and the positioning structure ensures the reliable positioning of flow channel plate 1-1 and plate 1-2 in battery liquid cooling plate 1, thereby ensuring the dimensional accuracy of battery liquid cooling plate 1, improving work efficiency and product quality.

[0034] See Figures 1 to 8This utility model can be matched with the battery liquid cooling plate hot-melt connection method. The flow channel plate 1-1 and the flat plate 1-2 of the battery liquid cooling plate 1 are integrated into one piece through the above-mentioned battery liquid cooling plate hot-melt connection mold 2. The specific operation steps are as follows:

[0035] a. Remove impurities and coatings from the surface of plate 1-2. Use laser cleaning equipment to clean the surface of plate 1-2, and then dry the cleaned plate 1-2.

[0036] b. Workpiece placement: Place the dried plate 1-2 into the plate receiving cavity 2-2-1 of the lower mold 2-2 of the battery liquid cooling plate hot melt connection mold 2, and position it by the positioning pin 2-2-2 cooperating with the mounting hole opened on the plate 1-2. Then place the flow channel plate 1-1 on the plate 1-2, so that the positioning pin 2-2-2 passes through the mounting hole opened on the flow channel plate 1-1.

[0037] c. Close the mold. Engage the upper mold 2-1 of the battery liquid cooling plate hot melt connection mold 2 with the lower mold 2-2 of the battery liquid cooling plate hot melt connection mold 2, so that the positioning pin 2-2-2 of the lower mold 2-2 of the battery liquid cooling plate hot melt connection mold 2 passes into the positioning hole 2-1-3 of the upper mold 2-1 of the battery liquid cooling plate hot melt connection mold 2.

[0038] d. Heating: The temperature of the metal plate 1-2 is controlled between 155 and 250°C by the temperature control system of the battery liquid cooling plate hot-melt connection mold 2.

[0039] e. Apply pressure to the battery liquid cooling plate hot-melt connection mold 2. The pressure range is controlled between 8 and 12 MPa, and the pressure holding time is not less than 30 seconds.

[0040] f. Cooling: The temperature of the metal plate 1-2 is reduced to the set temperature by the temperature control system of the battery liquid cooling plate hot-melt connection mold 2 or by natural cooling process.

[0041] g. Remove the workpiece. After opening the mold, remove the workpiece to complete the hot melt molding operation of the battery liquid cooling plate.

[0042] This utility model integrates the flow channel plate 1-1 and the flat plate 1-2 of the battery liquid cooling plate 1 into one unit using a heat-fusion connection process. In step a, the aluminum plate or other metal flat plate 1-2 undergoes laser cleaning to remove surface impurities and coatings. The principle of laser cleaning is to use a high-energy laser beam to irradiate the surface of the workpiece, causing the surface dirt, rust, or coating to evaporate or peel off instantly, effectively and quickly removing the adhering substances or surface coatings from the object being cleaned, thereby achieving the purpose of cleaning. Laser cleaning technology is a new technology based on the interaction effect between laser and matter. Unlike traditional mechanical cleaning methods, chemical cleaning methods, and ultrasonic cleaning methods, laser cleaning does not require any CFC organic solvents that damage the ozone layer. It is pollution-free, noiseless, and harmless to the human body and the environment, making it a "green" cleaning technology. After laser cleaning the surface of the aluminum plate or other metal plate 1-2, a micro-uneven structure is formed on the surface of the aluminum plate or other metal plate 1-2. Then, the aluminum plate or other metal plate 1-2 is heated to above the melting point of the plastic or composite material substrate of the flow channel plate 1-1. At the same time, pressure is applied to the battery liquid cooling plate hot melt connection mold 2 and the pressure is held for 30 seconds. The composite material substrate melts and fuses with the aluminum plate or other metal plate 1-2 in the micro-structure, so that the flow channel plate 1-1 and the plate 1-2 are tightly connected together and have high connection strength.

Claims

1. A liquid cooling plate for an electric vehicle battery, characterized in that: The battery liquid cooling plate (1) includes a flow channel plate (1-1) and a flat plate (1-2); the flow channel plate (1-1) is provided with a meandering groove (1-1-1), and the flow channel plate (1-1) is molded from plastic or non-metallic composite material; the flat plate (1-2) is provided with an inlet (1-2-1) and an outlet (1-2-2), the inlet (1-2-1) and the outlet (1-2-2) are respectively located at the two ends of the diagonal of the flat plate, and the flat plate (1-2) The material is metal; the flow channel plate (1-1) and the plate (1-2) are integrated into one piece by hot melt molding process. A cooling medium guide channel (1-4) is formed between the groove (1-1-1) of the flow channel plate (1-1) and the plate (1-2) and communicates with the liquid inlet (1-2-1) and the liquid outlet (1-2-2). Several sets of mounting holes (1-3) are set in the non-cooling medium guide channel area to realize the assembly of the battery liquid cooling plate (1) and the battery shell.

2. The electric vehicle battery liquid cooling plate according to claim 1, characterized in that: The wall thickness of the flow channel plate (1-1) is δ=0.8~2.5mm, and the transition radius R between the bottom surface of the groove (1-1-1) and the side wall of the flow channel plate (1-1) is 1~10mm; the minimum width Wmin of the cooling medium guide channel (1-4) is 3mm.

3. A hot-melt connection mold for an electric vehicle battery liquid cooling plate, used to realize the hot-melt molding operation of the flow channel plate (1-1) and the flat plate (1-2) in the battery liquid cooling plate (1) as described in claim 1 or 2, characterized in that: The battery liquid cooling plate hot melt connection mold (2) includes an upper mold (2-1), a lower mold (2-2), an electric heating element, and a temperature control system; the upper mold (2-1) is provided with a flow channel plate receiving cavity (2-1-1), and a relief groove (2-1-2) that cooperates with the groove (1-1-1) on the flow channel plate (1-1) is provided on the bottom surface of the flow channel plate receiving cavity (2-1-1), and the depth of the relief groove (2-1-2) is not less than the depth of the groove (1-1-1) on the flow channel plate (1-1); the lower mold (2-2) is provided with a flat plate receiving cavity (2-2-1), and an electric heating element is provided in the lower mold (2-2), and the working state of the electric heating element is controlled by the temperature control system of the mold; after the upper mold (2-1) and the lower mold (2-2) are fastened together, a molding cavity is formed between the upper mold (2-1) and the lower mold (2-2).

4. The electric vehicle battery liquid cooling plate hot-melt connection mold according to claim 3, characterized in that: Several sets of positioning posts (2-2-2) are provided in the flat plate receiving cavity (2-2-1) of the lower mold (2-2), and several sets of positioning holes (2-1-3) are provided at the bottom of the flow channel plate receiving cavity (2-1-1) of the upper mold (2-1); the positioning posts (2-2-2) and positioning holes (2-1-3) are matched with the mounting holes (1-3) on the battery liquid cooling plate (1).

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