Pole adapter, single battery assembly and battery module

Abstract

The utility model belongs to the field of batteries, and particularly relates to a pole adapter, a single battery assembly and a battery module. The problem of thermal runaway possibly caused by over-high heat at the pole position of the single battery in the existing battery module is solved. The terminal post adapter comprises a terminal post adapter main body, a connecting structure is arranged on the terminal post adapter main body, and the connecting structure is used for being connected with a terminal post; the pole adapter main body comprises a first main body and a second main body; a cavity is arranged between the first main body and the second main body, the cavity penetrates through the pole adapter main body along the first direction, and the cross section of the cavity is an open section; a heat transfer pipe with the cross section matched with the cavity is inserted into the cavity, and a heat transfer medium flow sub-cavity is formed between the second body and the inner wall of the heat transfer pipe. The pole adapter is in direct contact with the heat transfer medium, so that heat exchange of the pole adapter is realized, a short heat exchange path is provided, and the heat exchange efficiency of the battery module is improved.

Description

Technical Field

[0001] This utility model belongs to the field of batteries, specifically a terminal adapter, a single battery assembly, and a battery module. Background Technology

[0002] Currently, common battery modules (also known as battery packs) are composed of multiple individual cells (which are generally cylindrical or square) connected together in series, parallel, or a combination of series and parallel connections.

[0003] Temperature control of battery modules has always been a hot topic in this field. Most existing battery modules use air cooling or liquid cooling to control the temperature of the entire battery module. However, since the terminals of individual cells in the battery module are the parts with the most concentrated heat, if the local heat of the terminals is too high, it is very likely to cause thermal runaway of the individual cells in the battery module. Summary of the Invention

[0004] To address the issue of excessive heat at the terminal position of individual cells in existing battery modules, which could lead to thermal runaway, this invention provides a terminal adapter, a single-cell battery assembly, and a battery module.

[0005] The first aspect of this utility model provides a pole adapter, which is characterized in that: it includes a pole adapter body, and the pole adapter body is provided with a connecting structure for connecting with the pole.

[0006] The main body of the pole adapter includes a first body and a second body;

[0007] A cavity is provided between the first body and the second body, and the cavity extends through the pole adapter body in the first direction. The cross-section of the cavity is an open cross-section. The cavity is used to insert a heat transfer tube with a cross-section that is compatible with it, and a heat transfer medium flow sub-cavity is formed between the second body and the inner wall of the heat transfer tube.

[0008] This invention forms a heat transfer medium flow cavity between the second main body and the inner wall of the heat transfer tube, and at least a portion of the structure of the electrode adapter (second main body) is in direct contact with the heat transfer medium. After the battery module is constructed, a heat transfer tube can be inserted into the cavity of the electrode adapter on the same side of each individual battery cell, forming a heat transfer channel at the top of the battery module for heat exchange. The heat generated by the battery electrode is first conducted to the electrode adapter in close contact with it. A portion of the electrode adapter is placed directly within the heat transfer medium flow cavity, allowing the electrode adapter to directly contact the heat transfer medium, thus achieving heat exchange through the electrode adapter. This provides a shorter heat exchange path, and the heat transfer medium acts directly on the electrode adapter, improving the utilization efficiency of the heat transfer medium and enhancing the heat exchange efficiency of the battery module.

[0009] Furthermore, the connection structure includes a first through hole and a blind hole; the first through hole is formed on the first body and extends along the second direction; the blind hole is formed on the second body and extends along the second direction, and the blind hole communicates with the first through hole; the bottom of the blind hole is used for fixed connection with the pole post; wherein the second direction is perpendicular to the first direction.

[0010] By creating blind holes, the inner cavity of these holes serves as a dedicated connection operation space, making connection operations more convenient. Welding or bolting can typically be used for fixing. Furthermore, the shape of the bottom of the blind hole matches the shape of the corresponding terminal post top, allowing for a larger contact surface during connection. This effectively increases the effective contact area during welding or bolting. This not only ensures uniform stress distribution at the connection interface, reducing the risk of connection failure due to stress concentration, but also improves the stability and reliability of the connection. From a process perspective, the height-matched shape of the bottom of the blind hole and the top of the terminal post ensures tight contact, facilitating the connection process. Especially during laser welding, it ensures a continuous and dense weld, greatly improving electrical conductivity and mechanical connection strength, meeting the requirements of battery modules under complex operating conditions. In terms of heat conduction, the larger contact surface enhances the heat transfer efficiency of the heat transfer interface, further optimizing the heat transfer path from the terminal post to the adapter. This allows heat to be conducted more efficiently from the terminal post to the adapter, laying a solid foundation for subsequent heat dissipation through the heat transfer medium and effectively ensuring the thermal stability of the battery module.

[0011] Furthermore, the projected area of ​​the first main body on the plane of the single cell cover is larger than that of the second main body, and the second main body protrudes from the first main body toward the single cell cover.

[0012] This design offers significant advantages when the pole adapter is located outside the housing. When it is necessary to connect the pole adapter to a pole located inside the housing, the second body can extend into the clearance hole on the top plate of the housing via its protrusion to complete the connection with the corresponding pole.

[0013] Furthermore, functional structures for increasing the heat exchange area are provided on at least one of the inner walls of the heat transfer tube and the second main body. A larger heat exchange area means that more heat can be transferred under the same time and conditions. This is crucial for the stable operation of the battery module, effectively preventing problems such as performance degradation and shortened lifespan caused by overheating. At the same time, efficient heat exchange also makes the temperature distribution of each individual cell in the battery module more uniform, reducing inconsistencies in battery performance caused by temperature differences, further improving the stability and reliability of the entire battery module, and ensuring that it can work efficiently and stably under different operating conditions.

[0014] Furthermore, the functional structure is at least one second through hole formed on the second body, the second through hole penetrating the second body along the first direction.

[0015] When the heat transfer medium flows through the second body, the second through hole allows the heat transfer medium to more fully surround the second body. Originally, it could only contact the surface of the second body for heat exchange, but now it can achieve internal through heat exchange through the second through hole, which greatly improves the amount of heat transferred per unit time and accelerates the heat dissipation speed on the pole adapter.

[0016] The second aspect of this utility model provides a single-cell battery assembly, which is characterized in that it includes a single-cell battery and a terminal adapter fixedly connected to the terminal post of the single-cell battery, wherein the terminal adapter is the aforementioned terminal adapter.

[0017] The third aspect of this utility model provides a battery module, which is characterized in that it includes a first shell, a heat transfer pipe with an open cross-section, and n of the above-mentioned single battery cells; wherein n is an integer greater than 1.

[0018] The first housing contains n individual battery modules arranged along a first direction;

[0019] The heat transfer tubes are inserted into the cavities of the various pole-end adapters located on the same side along the first direction.

[0020] The first housing has a first insulating sealant layer inside, and in the second direction, the height of the first insulating sealant layer is higher than the open port of the heat transfer tube.

[0021] This invention inserts heat transfer tubes with cross-sections adapted to the cavity cross-sections into the cavities of each electrode adapter located on the same side, and cooperates with the first insulating sealant layer to form a sealed heat transfer channel. The heat generated by the individual battery during operation is conducted to the heat transfer medium through the electrode adapters, achieving efficient heat dissipation and effectively reducing the overall temperature of the battery module. This reduces battery performance degradation and shortened lifespan caused by high temperatures, ensuring that the battery module maintains good performance and stability under different operating conditions.

[0022] Furthermore, the aforementioned battery module also includes a second insulating sealant layer; the second insulating sealant layer is laid on the first insulating sealant layer, covering at least a portion of the structure of the heat transfer tube and the electrode adapter, with the electrical connection portion of the electrode adapter exposed by the second insulating sealant layer.

[0023] During battery module operation, internal temperature changes can cause moisture condensation. The second insulating sealant layer isolates external moisture, reduces internal humidity fluctuations, and prevents water droplets from forming on the surfaces of the heat transfer pipes and terminal connectors. This prevents short circuits and component corrosion caused by condensation. Furthermore, encasing the heat transfer pipes and terminal connectors within the sealant layer ensures tighter connections between components, reducing relative displacement under vibration and impact conditions and enhancing the overall structural stability of the battery module.

[0024] The fourth aspect of this utility model provides another battery module, which is characterized in that it includes a second shell, a heat transfer pipe with an open cross section, and n of the above-mentioned single battery cells; wherein n is an integer greater than 1.

[0025] Inside the second housing, n individual battery modules are arranged along the first direction; the top plate of the second housing has clearance holes corresponding to the terminal adapters of each individual battery module; each terminal adapter extends out of the corresponding clearance hole; the clearance hole is fixedly sealed to the individual battery housing in the area corresponding to the top plate of the second housing.

[0026] The heat transfer tubes are inserted into the cavities of the various pole-end adapters located on the same side along the first direction.

[0027] The top plate of the second housing is provided with a first insulating sealant layer, and in the second direction, the height of the first insulating sealant layer is higher than the open port of the heat transfer tube.

[0028] Unlike the battery modules mentioned above, in this design, the terminal connectors of each individual battery cell extend beyond the second housing, increasing their contact area with the outside air and facilitating direct heat dissipation to the surrounding environment. This further aids the heat dissipation process, effectively reducing the overall temperature of the battery module, improving heat dissipation efficiency, and mitigating performance degradation caused by high temperatures. Simultaneously, it makes wiring connections easier during battery module assembly. Wiring can be directly connected to the extended terminal connectors externally, significantly reducing installation difficulty. When the battery module requires maintenance or repair, the extended terminal connectors allow technicians to quickly inspect and test them. The connection status and electrical performance of the terminal connectors can be checked without opening the housing, allowing for timely detection and resolution of problems.

[0029] Furthermore, the electrolyte and / or gas are shared among the individual cells in the aforementioned battery module. This reduces the differences between individual cells and improves the cycle life of such battery modules. The extension of the terminal adapter beyond the second housing also isolates the electrolyte from external electrical connections, enhancing safety. Because the terminal adapter extends beyond the second housing, its electrical connection points are outside the housing, preventing direct contact with the internal electrolyte and avoiding potential short circuits, corrosion, and other problems caused by the electrolyte. Contact between the electrolyte and electrical connections can lead to circuit corrosion, increased resistance, and even short circuits and fires, seriously threatening the safety of the battery module. The extended terminal adapter design physically eliminates this potential hazard, effectively improving the safety and reliability of the battery module under complex operating conditions and ensuring its stable operation.

[0030] Furthermore, the aforementioned battery module also includes a second insulating sealant layer. This second insulating sealant layer is laid on top of the first insulating sealant layer, encasing at least a portion of the structure of the heat transfer pipe and the terminal connector, with the electrical connection points of the terminal connector exposed within the second insulating sealant layer. During battery module operation, internal temperature changes may cause moisture condensation. The second insulating sealant layer isolates external moisture, reduces internal humidity changes, and prevents water droplets from forming on the surfaces of the heat transfer pipe and the terminal connector, thus preventing short circuits and component corrosion caused by condensation. Additionally, encasing a portion of the heat transfer pipe and the terminal connector within this layer ensures tighter connections between components, reducing relative displacement between components under vibration and impact conditions, and enhancing the overall structural stability of the battery module.

[0031] The fifth aspect of this utility model provides a method for assembling a battery module, characterized by the following steps:

[0032] Each individual battery cell assembly is placed inside a first housing having at least one open end;

[0033] A heat transfer tube with an open cross-section is inserted into the cavity of each pole adapter located on the same side along the first direction.

[0034] A first insulating sealant layer is laid inside the first outer casing with an open end, and in a second direction, the height of the first insulating sealant layer is higher than the open port of the heat transfer tube.

[0035] Seal the open end of the first outer casing.

[0036] Furthermore, the process of laying a first insulating sealant layer inside the first housing with the open end also includes the following steps:

[0037] After the first insulating sealant layer has solidified, a second insulating sealant layer is laid on top of the first insulating sealant layer. The second insulating sealant layer covers at least part of the structure of the heat transfer tube and the pole adapter, and the electrical connection part of the pole adapter is exposed by the second insulating sealant layer.

[0038] The sixth aspect of this utility model provides another method for assembling a battery module, characterized by the following steps:

[0039] Each individual battery cell assembly is placed inside the second housing, with each terminal connector extending out of the corresponding clearance hole; the clearance holes are fixed and sealed to correspond to the top plate area of ​​the second housing and the individual battery cell housing.

[0040] A heat transfer tube with an open cross-section is inserted into the cavity of each pole adapter located on the same side along the first direction.

[0041] A first insulating sealant layer is laid on the top plate of the second outer shell, and in the second direction, the height of the first insulating sealant layer is higher than the open port of the heat transfer tube.

[0042] Furthermore, each individual battery cell assembly is placed inside the second housing, so that each terminal connector extends out of the corresponding clearance hole; specifically:

[0043] Each individual battery cell is placed inside the second housing, so that each terminal post corresponds to a clearance hole. At the clearance hole position, each terminal post adapter is fixed to the corresponding terminal post through a connecting structure.

[0044] Furthermore, the above assembly method also includes the following steps:

[0045] After the first insulating sealant layer has solidified, a second insulating sealant layer is laid on top of the first insulating sealant layer. The second insulating sealant layer covers at least part of the structure of the heat transfer tube and the pole adapter, and the electrical connection part of the pole adapter is exposed by the second insulating sealant layer.

[0046] The beneficial effects of this utility model are:

[0047] This invention forms a heat transfer medium flow cavity between the second main body and the inner wall of the heat transfer tube, and at least a portion of the structure of the electrode adapter (second main body) is in direct contact with the heat transfer medium. After the battery module is constructed, a heat transfer tube can be inserted into the cavity of the electrode adapter on the same side of each individual battery cell, forming a heat transfer channel at the top of the battery module for heat exchange. The heat generated by the battery electrode is first conducted to the electrode adapter in close contact with it. A portion of the electrode adapter is placed directly within the heat transfer medium flow cavity, allowing the electrode adapter to directly contact the heat transfer medium, thus achieving heat exchange through the electrode adapter. This provides a shorter heat exchange path, and the heat transfer medium acts directly on the electrode adapter, improving the utilization efficiency of the heat transfer medium and enhancing the heat exchange efficiency of the battery module. Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the structure of a pole adapter in Example 1;

[0049] Figure 2 This is a cross-sectional view of a pole adapter in Example 1;

[0050] Figure 3 This is a schematic diagram of another type of pole adapter in Example 1;

[0051] Figure 4 This is a cross-sectional view of another pole adapter in Example 1;

[0052] Figure 5 This is a cross-sectional view of a single battery module in Example 1;

[0053] Figure 6 This is a schematic diagram of the battery module structure in Example 2;

[0054] Figure 7 This is an exploded view of the battery module in Example 2;

[0055] Figure 8 This is a schematic diagram of the heat transfer tube in Example 2;

[0056] Figure 9 This is a three-dimensional cross-sectional view of the battery module in Example 2;

[0057] Figure 10 This is a schematic diagram of the battery module structure in Example 3;

[0058] Figure 11 This is a cross-sectional view of the battery module in Example 3;

[0059] Figure 12 This is a partial enlarged cross-sectional view of the battery module in Example 3;

[0060] Figure 13 This is a cross-sectional view of the battery module with the second insulating sealant layer laid in Example 3;

[0061] Figure 14 The explosion of the battery module in Example 3 Figure 1 ;

[0062] Figure 15 The explosion of the battery module in Example 3 Figure 2 ;

[0063] Figure 16 The explosion of the battery module in Example 3 Figure 3 .

[0064] The attached figures are labeled as follows:

[0065] 1. First main body; 2. Second main body; 3. Cavity; 4. Second through hole; 51. Terminal post; 52. First through hole; 53. Blind hole; 54. Single cell battery assembly; 55. Single cell battery cover plate; 56. Fourth through hole; 6. First outer shell; 7. Heat transfer pipe; 71. Open port of heat transfer pipe; 8. Second outer shell; 81. Top plate of second outer shell; 82. Clearance hole; 9. First insulating sealant layer; 10. Second insulating sealant layer; 11. Explosion venting channel. Detailed Implementation

[0066] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.

[0067] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0068] In the description of this utility model, it should be noted that the terms "top," "bottom," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," "third," "fourth," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0069] This utility model provides a pole adapter, including a pole adapter body, a connecting structure on the pole adapter body for connecting with a pole; the connecting structure can be a folded edge structure provided on the pole adapter body, which is welded or bolted to the pole through the folded edge structure; the connecting structure can also be a blind hole opened on the pole adapter, which is welded or bolted to the pole through the bottom of the blind hole.

[0070] Simultaneously, a cavity for installing the heat transfer tube is formed in the main body of the pole adapter, and this cavity extends through the main body of the pole adapter in the first direction. The cross-section of the cavity (the cross-section perpendicular to the first direction) of this utility model is a non-closed cross-section such as U-shaped, C-shaped, or Ω-shaped. In this utility model, a cavity with a non-closed cross-section is defined as an open cross-section cavity. That is, this utility model forms a cavity with an open cross-section in the main body of the pole adapter for inserting a heat transfer tube with a cross-section adapted to it, forming a heat transfer medium flow sub-cavity. The heat transfer medium in the heat transfer medium flow sub-cavity directly acts on the main body of the pole adapter, improving the utilization efficiency of the heat transfer medium.

[0071] For ease of description, in this utility model, the main body of the pole adapter is divided into two parts, which are defined as the first main body and the second main body respectively. The cavity is located between the first main body and the second main body. After the heat transfer tube is inserted, a heat transfer medium flow sub-cavity is formed between the second main body and the inner wall of the heat transfer tube.

[0072] This utility model also provides a single-cell battery assembly with the aforementioned terminal adapter and a battery module with such a single-cell battery assembly. In the battery module, heat transfer tubes are inserted into the cavities of the terminal adapters on the same side of each single-cell battery assembly. The open ports of the heat transfer tubes are sealed by laying a first insulating sealant layer, forming a heat exchange channel. A heat transfer medium is injected into the heat exchange channel to exchange heat with the battery module. A portion of the main body of the battery terminal adapter is directly placed within the heat transfer medium flow sub-cavity, allowing direct contact between the main body of the terminal adapter and the heat transfer medium. This achieves heat exchange through the terminal adapter, resulting in a shorter heat exchange path. The heat transfer medium acts directly on the terminal adapter, improving the utilization efficiency of the heat transfer medium and enhancing the heat exchange efficiency of the battery module.

[0073] The open-section cavity on the electrode adapter matches the open-section heat transfer tube (which can be prepared by aluminum extrusion process), which has low requirements for the machining accuracy of the parts themselves, reducing the assembly difficulty and complexity when assembling the battery module, thereby reducing the machining cost and assembly cost of the battery module parts.

[0074] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0075] Example 1

[0076] like Figure 1 and Figure 2 The figures show a schematic diagram and a cross-sectional view of the electrode adapter in this embodiment. As can be seen from the figures, the electrode adapter in this embodiment is a columnar structure. It can be made of a metal material with good electrical and thermal conductivity, such as silver, copper, aluminum, etc. However, considering the cost and the electrical and thermal conductivity, aluminum is generally chosen as the material for the electrode adapter.

[0077] The pole adapter includes a pole adapter body, which is mainly composed of a first body 1 and a second body 2. A cavity 3 is formed between the first body 1 and the second body 2, and the cavity 3 penetrates the pole adapter body in a first direction.

[0078] The shape of the cross-section of the cavity 3 mainly conforms to the shape of the heat transfer tube 7 that it is adapted to. It should be noted that the cross-section described here is the cross-section obtained by cutting the cavity 3 along a plane perpendicular to the first direction. For example, as can be seen from the figure, the cross-section of the cavity 3 in this embodiment is U-shaped, and the cross-section of the heat transfer tube 7 adapted to it is also U-shaped. In some other embodiments, a cavity 3 with a C-shaped cross-section can be formed between the first body 1 and the second body 2, and the cross-section of the heat transfer tube 7 adapted to it is correspondingly C-shaped. In some other embodiments, a cavity 3 with an Ω-shaped cross-section can be formed between the first body 1 and the second body 2, and the cross-section of the heat transfer tube 7 adapted to it is correspondingly Ω-shaped.

[0079] The dimensions of the cavity 3 must ensure that the corresponding heat transfer tube 7 can be inserted along the first direction, and that there is a certain gap between the inner wall of the heat transfer tube 7 and the second body 2 to allow for the flow of the heat transfer medium. The end face of the open port of the heat transfer tube 7 should have a small gap with the inner wall of the cavity 3 or remain sealed.

[0080] To further improve the heat transfer performance of the aforementioned pole adapter, such as Figure 3 and Figure 4 As shown, in this embodiment, two second through holes 4 can also be formed on the second body 2, with the second through holes 4 penetrating the second body 2 along the first direction. In practical applications, the size and number of the second through holes 4 can be flexibly adjusted according to specific needs, provided that the conductivity of the electrode adapter is not affected. The second through holes 4 increase the contact area between the second body 2 and the heat transfer medium, thereby significantly improving heat transfer efficiency. When the heat transfer medium flows through the second body 2, it can more fully surround the second body 2 through the second through holes 4. Previously, the heat transfer medium could only exchange heat with the surface of the second body 2; now, internal heat exchange can be achieved through the second through holes 4, which greatly increases the amount of heat transferred per unit time and accelerates the heat dissipation speed of the electrode adapter.

[0081] In other embodiments, other structures may be processed on the inner wall of the second body 2 and / or the heat transfer tube 7 to increase the heat exchange area. For ease of description, in this utility model, the structures that can increase the heat exchange area are collectively referred to as functional structures. Such functional structures may include dot-shaped pits and protrusions located on the outer wall of the second body 2, and may also include annular grooves located on the outer wall of the second body 2; and may also include heat dissipation teeth provided on the inner wall of the heat transfer tube 7.

[0082] Combination Figures 1 to 4As can be seen, in this embodiment, a first through hole 52 extending along the second direction is also provided on the first body 1; a blind hole 53 extending along the second direction is provided on the second body 2, the blind hole 53 communicates with the first through hole 52, and the bottom shape of the blind hole 53 is adapted to the top shape of the corresponding pole post 51; the bottom of the blind hole 53 is used to fix it to the pole post 51; wherein the second direction is perpendicular to the first direction.

[0083] By creating a blind hole 53, the inner cavity of the blind hole 53 is used as a dedicated connection operation space, making the connection operation more convenient. Generally, welding or bolting can be used for fixing. Furthermore, the bottom shape of the blind hole 53 matches the top shape of the corresponding terminal post 51. During connection, the bottom of the blind hole 53 and the top of the terminal post 51 can form a large contact surface, effectively increasing the effective contact area during welding or bolting. This not only ensures uniform stress distribution at the connection interface, reducing the risk of connection failure due to stress concentration, but also improves the stability and reliability of the connection. From a process perspective, the height-matched shape of the bottom of the blind hole 53 and the top of the terminal post 51 ensures tight contact between the two, facilitating the implementation of the connection process. Especially during laser welding, it ensures a continuous and dense weld, greatly improving conductivity reliability and mechanical connection strength, meeting the requirements of battery modules under complex operating conditions. In terms of heat conduction, the larger contact surface enhances the heat conduction efficiency of the heat transfer interface and further optimizes the heat transfer path from the electrode 51 to the adapter, enabling heat to be conducted more efficiently from the electrode 51 to the electrode adapter. This lays a good foundation for subsequent heat dissipation through the heat transfer medium and effectively ensures the thermal stability of the battery module.

[0084] like Figure 2 and Figure 3 As shown, in this embodiment, the bottom of the blind hole 53 is used for welding connection with the pole post 51; a fourth through hole 56 is opened at the bottom of the blind hole 53, and the diameter of the fourth through hole 56 is smaller than the diameter of the blind hole 53.

[0085] Compared to other connection methods, such as bolted connections, welding offers higher strength and stability. During battery module operation, regardless of factors such as vibration, impact, or temperature changes, welded connections effectively resist external forces, ensuring that the terminal adapter and terminal 51 do not easily loosen or separate, thus guaranteeing the reliability and stability of the battery module's electrical connection. Simultaneously, welding ensures minimal contact resistance between the terminal adapter and terminal 51, facilitating smooth current transmission. During battery charging and discharging, current can efficiently pass through the terminal adapter, reducing energy loss and heat generation, and improving the overall performance and efficiency of the battery module. During welding, significant stress is generated at the weld joint due to localized high-temperature heating and subsequent rapid cooling. The fourth through-hole 56 provides a channel for releasing this stress. When welding stress occurs, minor deformation and displacement can occur through the fourth through-hole 56, thereby dispersing the stress and preventing stress concentration at the weld joint, which could lead to weld cracking or reduced connection strength.

[0086] In addition, as can be seen from the above figure, the projected area of ​​the first main body on the plane where the single cell cover plate is located is larger than that of the second main body, and the second main body protrudes from the first main body toward the single cell cover plate.

[0087] This design offers significant advantages when the pole adapter is located outside the housing. When it is necessary to connect the pole adapter to the pole 51 located inside the housing, the second body 2 can extend into the clearance hole 82 on the top plate of the housing via its protrusion (see...). Figure 14 (As shown), complete the connection with the corresponding pole 51.

[0088] like Figure 5 As shown, a single-cell battery assembly 54 with the terminal adapter of this embodiment is electrically connected to the single-cell battery terminal 51.

[0089] Example 2

[0090] This embodiment is a battery module, such as Figure 6 and Figure 7 The figures show a schematic diagram and an exploded view of a battery module constructed from the single battery assembly 54 in Embodiment 1. As can be seen from the figures, the battery module includes a first outer shell 6, a heat transfer pipe 7 located inside the first outer shell 6, and 12 of the aforementioned single battery assemblies 54 arranged along a first direction inside the first outer shell 6. In some other embodiments, the number of single battery assemblies 54 can be adjusted according to actual needs.

[0091] This embodiment does not specifically limit the structure of the first outer shell 6, but at least the following two structures can be adopted:

[0092] The first structure includes a cylindrical body with open ends (i.e., the port parallel to the yz plane is the open end) and end plates fixed to the two open ends of the cylindrical body (i.e., the end plates are parallel to the yz plane); in the spatial coordinate system of this device, the first direction is the x-axis direction in the xyz coordinate system, the second direction is the z-axis direction, and the third direction is the y-axis direction.

[0093] The second type of structure includes a cylindrical body with open ends at the top and bottom (i.e., the port parallel to the xy plane is the open end) and a top plate and a bottom plate fixed to the open ends at the top and bottom of the cylindrical body respectively (i.e., the top plate and the bottom plate are both parallel to the xy plane, and the top plate or the bottom plate can be an integral structure with the cylindrical body).

[0094] The first outer shell 6 in this embodiment mainly has the following two functions:

[0095] Firstly, improve the safety performance of the entire battery module;

[0096] 1. When the single battery assembly 54 located in the inner cavity of the first outer shell 6 explodes due to thermal runaway, the flying debris will not pose a threat to the personal safety of people around the battery module due to the obstruction of the first outer shell 6;

[0097] 2. The first outer shell 6 also provides a certain degree of protection for each individual battery module 54, which can prevent damage caused by direct exposure of each individual battery module 54.

[0098] Secondly, it facilitates the storage and transportation of the entire battery module;

[0099] Multiple individual battery modules 54 are placed inside a relatively regular housing, making the battery module easy to store and transport.

[0100] from Figure 8 As can be seen, in this embodiment, the heat transfer tube 7 has a U-shaped cross-section that matches the cross-section of the cavity 3. The heat transfer tube 7 is inserted into the cavity 3 of each pole adapter located on the same side along the first direction; combined with Figure 7 and Figure 9As can be seen, at this time, there may be a small gap between the end face of the open port of the heat transfer pipe 7 inserted into the cavity 3 of the electrode adapter (it should be noted that the open port of the heat transfer pipe 7 refers to the port parallel to the xy plane) and the inner wall of the cavity 3. There is also a certain gap between the end face of the open port of the heat transfer pipe 7 not inserted into the cavity 3 of the electrode adapter and the top cover plate 55 of the single battery. In order to ensure that the heat transfer medium does not overflow from the above gaps, in this embodiment, the first insulating sealant is injected into the first outer shell 6, and after solidification, a first insulating sealant layer is formed (the first insulating sealant layer is not shown in the figure). In the second direction, the height of the first insulating sealant layer is higher than the end face of the open port of the heat transfer pipe 7, thereby sealing the above gaps, effectively preventing the leakage of the heat transfer medium, ensuring the integrity and efficiency of the heat transfer channel, and enabling heat to be continuously and stably dissipated through the heat transfer pipe 7 and the heat transfer medium, further improving the heat dissipation performance of the battery module.

[0101] In this battery module, the first insulating sealant layer disposed inside the first outer casing 6 plays multiple key roles in addition to the sealing function mentioned above.

[0102] From an insulation perspective, it effectively avoids the risk of short circuits between components within the battery module, ensuring the electrical safety and stability of the battery module, especially in humid or high-voltage environments, reliably preventing abnormal current conduction. Furthermore, the first insulating sealant layer plays a crucial role in enhancing the stability of the individual battery assembly 54 within the first housing. It fills the gap between the individual battery assembly 54 and the first housing, acting as a buffer and fixation agent, reducing displacement and shaking of the individual battery assembly 54 under vibration or impact, ensuring stable operation of the battery module under complex operating conditions.

[0103] In this embodiment, efficient heat exchange of the battery module is achieved through ingenious structural design. Specifically, heat transfer tubes 7 are inserted into the cavities 3 of the terminal adapters on the same side of each individual battery assembly 54, and the open ports of the heat transfer tubes 7 are sealed using a first insulating sealant layer, thereby constructing two heat exchange channels. A heat transfer medium is injected into the heat exchange channels to facilitate heat exchange within the battery module.

[0104] It is worth mentioning that part of the battery terminal adapter structure is directly placed inside the heat exchange channel. The terminal adapter and the heat transfer medium are in direct contact. In previous heat exchange methods, heat needs to pass through multiple levels of transfer to achieve exchange. However, in this embodiment, the terminal adapter and the heat transfer medium are directly connected, and the heat transfer medium can directly act on the terminal adapter without losing energy in other intermediate links. The utilization efficiency of the heat transfer medium is significantly improved. This means that the same amount of heat transfer medium can play a greater role in heat transfer, greatly improving the efficiency of heat transfer. While improving the utilization efficiency of the heat transfer medium, the heat exchange efficiency of the entire battery module is also greatly improved. The problem that might have led to a decline in battery performance due to untimely heat exchange is solved with this efficient heat exchange design, thereby ensuring that the battery module is always in good working condition, extending the service life of the battery module, and improving its operational stability.

[0105] In this embodiment, a second insulating sealant layer can also be laid on the first insulating sealant layer; the second insulating sealant layer covers at least part of the structure of the heat transfer tube and the pole adapter, and the electrical connection part of the pole adapter is exposed to the second insulating sealant layer.

[0106] During battery module operation, internal temperature changes may cause moisture condensation. The second insulating sealant layer can isolate external moisture, reduce internal humidity changes, and prevent water droplets from forming on the surfaces of the heat transfer pipe 7 and the terminal adapter, thus preventing short circuits and component corrosion caused by condensation. In addition, encasing the heat transfer pipe 7 and the terminal adapter partially within the sealant makes the connections between components tighter, reducing relative displacement between components under vibration, impact, and other conditions, and enhancing the structural stability of the entire battery module.

[0107] In addition, such as Figure 7 As shown, in this embodiment, a venting channel 11 can also be provided between each individual battery assembly 54 and the first housing 6, and a venting part communicating with the venting channel 11 can be provided on the first housing 6. During the thermal runaway stage, the thermal runaway smoke can be discharged in an orderly manner through the venting channel 11, effectively preventing it from spreading into the first housing 6, thereby preventing further deterioration of the thermal runaway situation.

[0108] It should be noted that no first insulating sealant layer and a second insulating sealant layer are installed in the explosion venting channel 11.

[0109] The assembly process of the battery module described above will be explained below, taking the first outer casing 6, which includes a cylindrical body with an open top and a top plate structure, as an example:

[0110] Arrangement of individual battery modules 54: Arrange each individual battery module 54 along the first direction in the top-opening cylinder.

[0111] Insert heat transfer tube 7: Select a heat transfer tube 7 that is compatible with the cavity 3 of the pole adapter and insert it into the cavity 3 of each pole adapter located on the same side along the first direction; then the heat transfer tubes 7 on both sides can be connected based on the outer tube section.

[0112] Laying the first insulating sealant layer: Lay the first insulating sealant layer inside the top-open cylinder. During the laying process, monitor the thickness of the first insulating sealant layer in real time to ensure that its height in the second direction is higher than the open port of the heat transfer tube 7. This process requires strict control of the thickness of the sealant layer to avoid it being too thick or too thin, which would affect the sealing effect of the heat transfer channel.

[0113] Laying the second insulating sealant layer: After the first insulating sealant layer is laid, let it stand for a period of time until the first insulating sealant layer is completely solidified. Then lay the second insulating sealant layer on the first insulating sealant layer. The second insulating sealant layer needs to cover at least part of the structure of the heat transfer tube 7 and the pole adapter, while ensuring that the electrical connection part of the pole adapter is exposed in the second insulating sealant layer to ensure the normal operation of the electrical connection.

[0114] Fixed Top Plate: Check the curing of the second insulating sealant layer and the installation position of each component. After confirming that everything is correct, seal and fix the top plate of the first outer casing 6 to the open end of the top of the cylinder to ensure the structural stability of the entire battery module.

[0115] Example 3

[0116] This embodiment is another type of battery module. Unlike embodiment 2, in this embodiment, each terminal adapter in the single battery assembly 54 extends out of the outer shell. In order to distinguish it from the outer shell in embodiment 2, this embodiment defines the outer shell as the second outer shell 8.

[0117] The specific structure is as follows: Figure 10 and Figure 11 The figures show a schematic diagram and a cross-sectional view of a battery module constructed from the single battery assembly 54 in Embodiment 1. As can be seen from the figures, the battery module includes a second housing 8, a heat transfer pipe 7 located outside the second housing 8, and 12 of the aforementioned single battery assemblies 54 arranged in the second housing 8 along the first direction. In some other embodiments, the number of single battery assemblies 54 can be adjusted according to actual needs.

[0118] This embodiment does not specifically limit the structure of the second outer shell 8, but at least the following two structures can be adopted:

[0119] The first structure includes a cylindrical body with open ends (i.e., the port parallel to the yz plane is the open end) and end plates fixed to the two open ends of the cylindrical body (i.e., the end plates are parallel to the yz plane); in the spatial coordinate system of this device, the first direction is the x-axis direction in the xyz coordinate system, the second direction is the z-axis direction, and the third direction is the y-axis direction.

[0120] The second type of structure includes a cylindrical body with open ends at the top and bottom (i.e., the port parallel to the xy plane is the open end) and a top plate and a bottom plate fixed to the open ends at the top and bottom of the cylindrical body respectively (i.e., the top plate and the bottom plate are both parallel to the xy plane, and the top plate or the bottom plate can be an integral structure with the cylindrical body).

[0121] The top plate 81 of the second outer casing (here, the top plate is the plate parallel to the xy plane and close to the terminal adapter) has clearance holes 82 corresponding to the terminal adapters of each individual battery assembly 54 (see... Figure 14 Each terminal adapter extends out of the corresponding clearance hole 82; the clearance hole 82 corresponds to the top plate 81 area of ​​the second outer casing and is fixedly sealed with the housing of the single battery assembly 54.

[0122] Combination Figure 8 It can be seen that in this embodiment, the cross-section of the heat transfer tube 7 is U-shaped and adapted to the cross-section of the cavity 3. The heat transfer tube 7 is inserted into the cavity 3 of each pole adapter located on the same side along the first direction; combined with Figure 10 , Figure 11 and Figure 12 As can be seen, at this time, there may be a small gap between the end face of the open port of the heat transfer tube 7 inserted into the cavity 3 of the electrode adapter (it should be noted that the open port of the heat transfer tube 7 refers to the port parallel to the xy plane) and the inner wall of the cavity 3. There is also a certain gap between the end face of the open port of the heat transfer tube 7 not inserted into the cavity 3 of the electrode adapter and the top plate 81 of the second shell. In order to ensure that the heat transfer medium does not overflow from the above gaps, in this embodiment, a first insulating sealant layer 9 is laid on the top plate 81 of the second shell. In the second direction, the height of the first insulating sealant layer 9 is higher than the end face of the open port of the heat transfer tube 7, thereby sealing the above gaps, effectively preventing the leakage of the heat transfer medium, ensuring the integrity and efficiency of the heat transfer channel, and enabling heat to be continuously and stably dissipated through the heat transfer tube 7 and the heat transfer medium, further improving the heat dissipation performance of the battery module.

[0123] Unlike the battery module in Embodiment 2, in this embodiment, the terminal adapters of each individual battery module 54 extend beyond the second housing 8, increasing their contact area with the outside air and facilitating direct heat dissipation to the surrounding environment. This further aids the heat dissipation process, effectively reducing the overall temperature of the battery module, improving heat dissipation efficiency, and mitigating performance degradation caused by high temperatures. Simultaneously, it makes wiring connections easier during battery module assembly. Wiring can be directly connected externally to the extended terminal adapters, significantly reducing installation difficulty. When the battery module requires maintenance or repair, the extended terminal adapters allow technicians to quickly inspect and test them. The connection status and electrical performance of the terminal adapters can be checked without opening the housing, allowing for timely detection and resolution of problems.

[0124] Furthermore, this embodiment can also provide through holes in the housing of each individual battery module 54, allowing for electrolyte and / or gas sharing among the individual battery modules 54. During the charging and discharging process of the battery module, the distribution of electrolyte and gas has a crucial impact on battery performance. When there are differences between individual battery modules 54, such as different electrolyte concentrations or gas contents, inconsistent battery performance will result, thus affecting the stability and lifespan of the entire battery module. The electrolyte and gas sharing achieved through through holes allows for a more uniform internal environment in each individual battery module 54, effectively reducing the differences between them. This improved uniformity makes the performance of each individual battery module 54 more consistent during charging and discharging, greatly improving the stability, reliability, and overall performance of this type of battery module, ensuring stable and efficient operation under various operating conditions.

[0125] When the electrolyte between the individual battery modules 54 inside the second housing 8 is connected and shared, there is free electrolyte inside the second housing 8. At this time, the design advantage of the extended terminal adapter becomes apparent. The electrical connection part of the terminal adapter is located outside the second housing 8. This layout physically avoids direct contact between it and the internal electrolyte. In practical applications, once the electrolyte comes into contact with the electrical connection parts, the chemical components in the electrolyte may react with the metal parts, leading to circuit corrosion, increased resistance, and reduced power transmission efficiency. More seriously, it may cause a short circuit, instantly generating a large amount of heat, or even igniting a fire, seriously threatening the safety of the battery module. The design of the terminal adapter extending out of the second housing 8 effectively eliminates these hidden dangers. Under complex operating conditions, whether in high-temperature, humid environments or subjected to external vibration and impact, it can ensure the safety and reliability of the battery module, guarantee its stable operation, and provide a solid safety guarantee for the application of the battery module in various scenarios.

[0126] like Figure 13As shown, in this embodiment, a second insulating sealant layer 10 can also be laid on the first insulating sealant layer 9; the second insulating sealant layer 10 covers at least part of the structure of the heat transfer tube 7 and the pole adapter, and the electrical connection part of the pole adapter is exposed to the second insulating sealant layer 10.

[0127] During the operation of the battery module, internal temperature changes may cause moisture condensation. The second insulating sealant layer 10 can isolate external moisture, reduce internal humidity changes, and prevent water droplets from forming on the surfaces of the heat transfer pipe 7 and the terminal adapter, thus preventing short circuits and component corrosion caused by condensation. In addition, encasing the heat transfer pipe 7 and the terminal adapter partially within the layer makes the connections between components tighter, reducing relative displacement between components under vibration, impact, and other conditions, and enhancing the structural stability of the entire battery module.

[0128] The following embodiment uses the second outer shell 8, which includes a cylindrical body with open ends and end plates fixed to the two open ends of the cylindrical body, as an example to illustrate the assembly process of the battery module:

[0129] Arrange the individual battery modules 54 and seal the second outer casing 8: Arrange each individual battery module 54 along a first direction in a cylindrical body with open ends; make the terminal adapter of each individual battery module 54 extend out of the corresponding clearance hole 82; seal the second outer casing 8, and seal and fix the end plate to the two open ends of the cylindrical body; at the same time, seal the area of ​​the top plate 81 of the second outer casing corresponding to the clearance hole 82 and the housing of the individual battery module 54. The area of ​​the top plate 81 of the second outer casing corresponding to the clearance hole 82 mentioned here can be the area of ​​the top plate 81 of the second outer casing around the clearance hole 82, or it can be the wall of the clearance hole 82.

[0130] Specifically, each individual battery assembly 54 can be raised by setting a pad at the bottom of each individual battery assembly 54, so that its terminal adapter extends out of the corresponding clearance hole 82; then the second outer shell 8 is sealed.

[0131] Alternatively, individual battery cells (finished individual battery cells) without terminal adapters can be arranged inside the casing, with the terminals corresponding one-to-one with the clearance holes, sealing the second outer casing 8; then, the terminal adapter of this invention can be fixed to the corresponding terminal 51 through the clearance hole 82, so that the terminal adapter extends out of the second outer casing 8, as shown. Figure 14 As shown. In this embodiment, the bottom of the blind hole 53 of the pole adapter is welded to the corresponding pole 51 to fix the pole adapter to the pole 51.

[0132] Insert heat transfer tube 7: Reference Figure 15 and Figure 16 Select a heat transfer tube 7 that is compatible with the cavity 3 of the pole adapter and insert it into the cavity 3 of each pole adapter located on the same side along the first direction; then the heat transfer tubes 7 on both sides can be connected based on the outer pipe section.

[0133] Laying the first insulating sealant layer 9: Laying the first insulating sealant layer 9 on the top plate 81 of the second shell. During the laying process, the thickness of the first insulating sealant layer 9 is monitored in real time to ensure that its height in the second direction is higher than the open port of the heat transfer tube 7. The thickness of the sealant layer must be strictly controlled in this process to avoid it being too thick or too thin, which would affect the sealing effect of the heat transfer channel.

[0134] Laying the second insulating sealant layer 10: After the first insulating sealant layer 9 is laid, let it stand for a period of time until the first insulating sealant layer 9 is completely solidified. Then, lay the second insulating sealant layer 10 on the first insulating sealant layer 9. The second insulating sealant layer 10 needs to cover at least part of the structure of the heat transfer tube 7 and the pole adapter. At the same time, it is necessary to ensure that the electrical connection part of the pole adapter is exposed in the second insulating sealant layer 10 to ensure the normal operation of the electrical connection.

Claims

1. A pole adapter, characterized by: The pole post adapter body is provided with a connecting structure for connecting with the pole post; The pole post adapter body comprises a first body and a second body; A cavity is arranged between the first body and the second body, the cavity penetrates the pole post adapter body along a first direction, and the cross section of the cavity is an open section; the cavity is used for inserting a heat transfer pipe with a cross section adapted thereto to form a heat transfer medium flow sub-cavity between the second body and the inner wall of the heat transfer pipe.

2. The pole lug adapter of claim 1, wherein: The connecting structure comprises a first through hole and a blind hole; The first through hole is arranged on the first body and extends along a second direction; the blind hole is arranged on the second body and extends along the second direction, and the blind hole penetrates the first through hole; the bottom of the blind hole is used for fixedly connecting with the pole post; wherein the second direction is perpendicular to the first direction.

3. The pole post adapter according to claim 2, characterized in that: The projection area of the first body on the plane of the single cell battery upper cover plate is larger than that of the second body, and the second body protrudes from the first body towards the single cell battery upper cover plate.

4. The pole lug adapter of claim 1, wherein: Functional structures for increasing the heat exchange area are arranged on at least one of the inner wall of the heat transfer pipe and the second body.

5. The pole lug adapter of claim 4, wherein: The functional structure is at least one second through hole arranged on the second body, and the second through hole penetrates the second body along the first direction.

6. A monobloc battery assembly characterized by: The single cell battery assembly comprises a single cell battery and a pole post adapter fixedly connected to the pole post of the single cell battery, and the pole post adapter is the pole post adapter according to any one of claims 1 to 5.

7. A battery module, characterized by: The single cell battery assembly comprises a first housing, a heat transfer pipe with an open section, and n single cell battery assemblies according to claim 6; wherein n is an integer greater than 1; The n single cell battery assemblies are arranged in the first housing along a first direction; The heat transfer pipe is inserted into the cavity of each pole post adapter on the same side along the first direction; The first housing is provided with a first insulating sealing layer, and the height of the first insulating sealing layer in the second direction is higher than the open port of the heat transfer pipe.

8. The battery module of claim 7, wherein: Further comprising a second insulating sealing layer; the second insulating sealing layer is laid on the first insulating sealing layer, and at least part of the structure of the heat transfer pipe and the pole post adapter is wrapped, and the electrical connection part of the pole post adapter is exposed to the second insulating sealing layer.

9. A battery module, characterized by: The single cell battery assembly comprises a second housing, a heat transfer pipe with an open section, and n single cell battery assemblies according to claim 6; wherein n is an integer greater than 1; The n single cell battery assemblies are arranged in the second housing along a first direction; the top plate of the second housing is provided with a plurality of avoiding holes corresponding to the pole post adapters of the single cell battery assemblies; each pole post adapter protrudes out of the corresponding avoiding hole; the avoiding hole corresponding to the top plate area of the second housing is fixedly sealed with the single cell battery shell; The heat transfer pipe is inserted into the cavity of each pole post adapter on the same side along the first direction; The top plate of the second housing is provided with a first insulating sealing layer, and the height of the first insulating sealing layer in the second direction is higher than the open port of the heat transfer pipe.

10. The battery module of claim 9, wherein: The electrolyte and / or gas between each single cell battery is shared.

11. The battery module of claim 9, wherein: Further comprising a second insulating sealing layer; the second insulating sealing layer is laid on the first insulating sealing layer, and at least part of the structure of the heat transfer pipe and the pole post adapter is wrapped, and the electrical connection part of the pole post adapter is exposed to the second insulating sealing layer.

Images