Integrated relay module and battery pack

Abstract

The utility model relates to the technical field of power batteries, and provides an integrated relay module and a battery pack, the integrated relay module comprises a heat conduction shell and at least one relay, the heat conduction shell comprises an upper shell and a lower shell, and the upper shell and the lower shell are mutually covered to form a mounting cavity; the relay is arranged in the mounting cavity, an output terminal of the relay penetrates out of the upper shell, a heat dissipation part is arranged on the output terminal, and the heat dissipation part is in heat conduction contact with the upper shell. The heat conduction shell is arranged, the heat dissipation part is arranged on the output terminal, and heat conduction contact is formed between the heat dissipation part and the upper shell; therefore, when the relay is in use, heat at the output terminal can be transmitted and dissipated through the heat conduction shell, and compared with the traditional technology, the relay can be conveniently installed in an upright mode, the space layout is optimized, and the application cost is reduced.

Description

Technical Field

[0001] This application relates to the field of power battery technology, and more specifically, to an integrated relay module and battery pack. Background Technology

[0002] Currently, the high-voltage connection of a battery pack is generally a hierarchical relationship of battery module - BDU - high-voltage output. The BDU (Battery Disconnect Unit) is a module controlled by the BMS (Battery Management System) to control high-voltage switching and active / passive safety protection. It typically contains a main relay, pre-charge relay, pre-charge resistor, and fuse. During battery charging and discharging, the large current in the BDU causes significant heat generation due to the inherent resistance and contact resistance of the electrical components, especially the relays and fuses. To reduce the heat generated by these components, current practices involve inverting the relays inside the BDU and installing the busbar at the bottom of the BDU, connecting it to the battery liquid cooling plate via thermal conductivity to cool the relays.

[0003] However, the inverted relay cooling method requires the busbar and relay to be installed in advance, and the external high-voltage connection of the BDU needs to be installed from the top. Therefore, the busbar needs to be guided from the bottom to the top of the BDU, which increases the integration space of the BDU and significantly increases the cost of the busbar. In addition, the inverted relay design is prone to insulation risks when condensation occurs during battery pack temperature shocks. Therefore, insulation protection design is required at the bottom of the BDU, which further increases the cooling thermal resistance and cost. Utility Model Content

[0004] In order to overcome at least one of the disadvantages of the prior art, the purpose of this application is to provide an integrated relay module and battery pack.

[0005] The technical means adopted in this application to solve the above-mentioned technical problems are:

[0006] On one hand, this application provides an integrated relay module, including:

[0007] A heat-conducting housing, comprising an upper housing and a lower housing, wherein the upper housing and the lower housing are fitted together to form a mounting cavity;

[0008] At least one relay is disposed within the mounting cavity, and the output terminal of the relay extends through the upper housing. A heat dissipation part is provided on the output terminal, and the heat dissipation part is in thermal contact with the upper housing.

[0009] In this embodiment, the heat-conducting outer shell and the heat dissipation part on the output terminal are arranged to form a heat-conducting contact between the heat dissipation part and the upper shell. Therefore, during use, the heat at the output terminal can be transferred and dissipated through the heat-conducting outer shell. Compared with traditional technology, this facilitates the upright installation of the relay, optimizes the space layout, and reduces application costs.

[0010] In some embodiments, the heat dissipation part has a sheet-like structure, and the projected shape of the heat dissipation part is any one of a circle, an ellipse, and a polygon.

[0011] In this embodiment, by setting the heat dissipation part in the form of a sheet structure, the contact area between the heat dissipation part and the upper housing can be increased, thereby improving the heat dissipation effect.

[0012] In some embodiments, a first thermally conductive adhesive layer is provided between the heat dissipation part and the upper housing.

[0013] In this embodiment, the first thermally conductive adhesive layer facilitates the connection between the heat dissipation part and the upper housing, and facilitates the transfer of heat from the heat dissipation part to the upper housing.

[0014] In some embodiments, the heat dissipation section is provided with a plurality of glue overflow grooves.

[0015] In this embodiment, the provided overflow groove can improve the reliability of the heat dissipation part and the upper housing after bonding.

[0016] In some embodiments, the thickness of the first thermally conductive adhesive layer is no more than 2 mm, the thickness of the heat dissipation part is set between 0.5 and 2 mm, and the depth of the adhesive overflow groove is set between 0.1 and 0.8 mm.

[0017] In some embodiments, the bottom of the lower housing is provided with a plurality of limiting protrusions, and a reserved gap is formed between the end of the limiting protrusions and the bottom end face of the lower housing.

[0018] A second thermally conductive adhesive layer is provided within the reserved gap.

[0019] In this embodiment, the second thermally conductive adhesive layer facilitates the installation and connection between the lower housing and external components, thereby achieving further heat dissipation.

[0020] In some embodiments, the length of the limiting protrusion is set between 0.2 and 1.5 mm.

[0021] In some embodiments, the outer side of the heat-conducting housing is provided with a plurality of mounting ears, and a threaded sleeve is embedded in the mounting ears.

[0022] In this embodiment, the threaded sleeve can be used to improve the structural strength of the heat-conducting outer shell at the installation and fixing point.

[0023] In some embodiments, the upper housing includes a first cover and a second cover, the first cover and the second cover being respectively connected to the lower housing;

[0024] The mounting cavity includes a first inner cavity formed after the first cover and the lower cover are closed, and a second inner cavity formed after the second cover and the lower cover are closed, wherein the first inner cavity and the second inner cavity are independent of each other.

[0025] In this embodiment, the first and second inner cavities facilitate the installation and configuration of relays according to actual application requirements, thereby improving application safety.

[0026] On the other hand, the present application also provides a battery pack in which an integrated relay module as described above is provided.

[0027] In this embodiment, by applying the integrated relay module as described above within the battery pack, it is easy to achieve upright installation of the relay within the battery pack. Compared to the traditional method where the relay needs to be installed upside down within the battery pack, this method can improve the space utilization within the battery pack, and the heat dissipation method of the relay is optimized, which can help reduce the actual application cost and improve safety performance. Attached Figure Description

[0028] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the structure of an integrated relay module as an example of this application.

[0030] Figure 2 This is a schematic diagram of the structure of the output terminal in one example of this application.

[0031] Figure 3 This is a schematic diagram of the lower shell structure as an example of this application.

[0032] Figure 4 This is a schematic diagram of the bottom structure of the lower shell, as shown in one example of this application.

[0033] Figure 5 This is a schematic diagram of the structure of the first shell cover in one example of this application.

[0034] Marker explanation:

[0035] 1-Heat-conducting outer shell, 11-Upper shell, 111-First shell cover, 112-Second shell cover, 12-Lower shell, 121-Limiting protrusion, 13-Mounting cavity, 131-First inner cavity, 132-Second inner cavity, 14-Mounting ear, 141-Threaded sleeve;

[0036] 2-Output terminal, 21-Heat dissipation unit, 211-Glue overflow groove. Detailed Implementation

[0037] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be 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 this application can be combined with each other. Many specific details are set forth in the following description to provide a thorough understanding of the present invention; the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0038] It should be noted that, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. Similar reference numerals and letters denote similar items in the following figures; therefore, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.

[0039] Furthermore, in the description of this application, the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance, or requiring or implying any actual relationship or order between entities or operations. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0040] like Figures 1 to 5As shown, this embodiment provides an integrated relay module, including a heat-conducting housing 1 and at least one relay; the heat-conducting housing 1 includes an upper housing 11 and a lower housing 12, the upper housing 11 and the lower housing 12 are mutually covered to form a mounting cavity 13; the relay is disposed in the mounting cavity 13, the output terminal 2 of the relay extends out of the upper housing 11, the output terminal 2 is provided with a heat dissipation part 21, and the heat dissipation part 21 is in thermal contact with the upper housing 11.

[0041] In some embodiments, both the upper housing 11 and the lower housing 12 are made of insulating materials with good thermal conductivity, such as silicone, polyurethane, etc.

[0042] In some embodiments, the thermal conductivity of the upper housing 11 and the lower housing 12 is greater than or equal to 3 W / (m·K).

[0043] In some embodiments, the relay may be configured as a high-voltage relay, such as a main positive relay and / or a fast-charging relay used in the control circuit within the battery pack. Additionally, a main negative relay may be included, depending on the specific application requirements.

[0044] In some embodiments, the relay is configured to include both the high-voltage relay described above and the low-voltage relay, such as a pre-charge relay used in the control circuit within the battery pack.

[0045] In some embodiments, the upper housing 11 and the lower housing 12 are detachably connected; for example, the upper housing 11 and the lower housing 12 are connected by a snap-fit ​​mechanism to achieve installation and fixation. Figure 3 , Figure 5 As shown; for example, the upper housing 11 and the lower housing 12 are installed and fixed together by fasteners such as bolts. No specific restrictions are placed on the installation method between the upper housing 11 and the lower housing 12 here.

[0046] By providing the heat-conducting outer shell 1 and the heat dissipation part 21 on the output terminal 2, and by ensuring that the relay is installed in the mounting cavity 13, the heat dissipation part 21 and the upper shell 11 can form a thermally conductive contact. Therefore, during use, the heat generated at the output terminal 2 due to electrical operating conditions can be dissipated through the upper shell 11 and the lower shell 12, or transferred through the upper shell 11 to the lower shell 12, and then transferred from the lower shell 12 to external components (such as a cooling plate in a liquid cooling system), thereby achieving effective cooling and heat exchange.

[0047] Compared to the traditional installation method, the solution in this embodiment can achieve upright installation of each relay, and the relay can still maintain good heat dissipation and cooling effect after upright installation. The upright installation method eliminates the need for a complex busbar structure, so the spatial layout of the entire module is more reasonable and can improve space utilization. At the same time, there is no need to set an insulation protection design at the bottom of the module, which can effectively reduce the overall application cost and improve safety performance.

[0048] As one application example, see reference Figure 2 As shown, the heat dissipation part 21 has a sheet-like structure, and the projected shape of the heat dissipation part 21 is any one of a circle, an ellipse, or a polygon.

[0049] In some embodiments, the heat dissipation part 21 is provided as a complete sheet structure, in which case the heat dissipation part 21 is arranged around the outer periphery of the output terminal 2.

[0050] In some embodiments, the heat dissipation part 21 is configured as a plurality of sheet-like structures, wherein the plurality of sheet-like structures are arranged in a radial pattern with the output terminal 2 as the center.

[0051] By setting the heat dissipation part 21 in the form of a sheet structure, the contact area between the heat dissipation part 21 and the upper housing 11 can be increased, and the heat dissipation effect can be improved.

[0052] As one application example, a first thermally conductive adhesive layer is provided between the heat dissipation part 21 and the upper housing 11.

[0053] In some embodiments, the first thermally conductive adhesive layer is formed by coating with thermally conductive adhesive and then solidifying it.

[0054] The first thermally conductive adhesive layer facilitates the connection between the heat dissipation part 21 and the upper housing 11, and facilitates the transfer of heat from the heat dissipation part 21 to the upper housing 11.

[0055] As one application example, the heat dissipation part 21 is provided with a plurality of glue overflow grooves 211.

[0056] In some embodiments, the glue overflow groove 211 is uniformly arranged around the axis of the output terminal 2.

[0057] In this embodiment, the number and shape of the overflow groove 211 are not limited.

[0058] The overflow groove 211 provided can improve the reliability of the heat dissipation part 21 and the upper housing 11 after bonding. It allows some of the overflowing glue to enter the overflow groove 211, so as to control the relative distance between the heat dissipation part 21 and the upper housing 11, and to increase the effective contact area between the heat dissipation part 21 and the glue, so that the bonded state can be more reliable.

[0059] As one application example, the thickness of the first thermally conductive adhesive layer is no more than 2 mm, the thickness of the heat dissipation part 21 is set between 0.5-2 mm, and the depth of the adhesive overflow groove 211 is set between 0.1-0.8 mm.

[0060] In some embodiments, the thickness of the first thermally conductive adhesive layer is set between 0.8 and 1.2 mm.

[0061] In some embodiments, the thickness of the heat dissipation portion 21 is set between 0.5 and 1.5 mm.

[0062] In some embodiments, the depth of the glue overflow groove 211 is set between 0.2 and 0.5 mm.

[0063] As one application example, see reference Figure 4 As shown, the bottom of the lower housing 12 is provided with a plurality of limiting protrusions 121, and a reserved gap is formed between the end of the limiting protrusions 121 and the bottom end face of the lower housing 12.

[0064] A second thermally conductive adhesive layer is provided within the reserved gap.

[0065] In some embodiments, the limiting protrusion 121 is disposed at the edge of the bottom end face of the lower housing 12.

[0066] In some embodiments, the length of the limiting protrusion 121 is set between 0.2 and 1.5 mm.

[0067] In some embodiments, the second thermally conductive adhesive layer can be configured as a thermally conductive pad, or it can be formed by coating with thermally conductive adhesive and then solidifying it.

[0068] By using the second thermally conductive adhesive layer, after the lower housing 12 is installed on the external component, the bottom end face of the lower housing 12 can form a better thermally conductive contact with the end face of the external component through the second thermally conductive adhesive layer, thereby facilitating further improvement in heat exchange and heat dissipation.

[0069] As one example of its application, such as Figure 1 , Figure 3 , Figure 4As shown, the outer side of the heat-conducting outer shell 1 is provided with a plurality of mounting ears 14, and a threaded sleeve 141 is embedded in the mounting ears 14.

[0070] In some embodiments, the threaded sleeve 141 is made of metal, such as a threaded steel sleeve.

[0071] By inserting fasteners such as bolts into the threaded sleeve 141, the heat-conducting outer shell 1 can be easily installed and fixed. Moreover, the threaded sleeve 141 can improve the structural strength and durability of the heat-conducting outer shell 1 at the installation and fixing point.

[0072] As one application example, see reference Figure 1 , Figure 3 As shown, the upper housing 11 includes a first housing cover 111 and a second housing cover 112, which are respectively connected to the lower housing 12. The mounting cavity 13 includes a first inner cavity 131 formed by the first housing cover 111 and the lower housing 12, and a second inner cavity 132 formed by the second housing cover 112 and the lower housing 12. The first inner cavity 131 and the second inner cavity 132 are independent of each other.

[0073] In some embodiments, the first inner cavity 131 is used for mounting a high-voltage relay, and the second inner cavity 132 is used for mounting a low-voltage relay.

[0074] In some embodiments, the number of relays in the first inner cavity 131 is two, and the number of relays in the second inner cavity 132 is one.

[0075] The first inner cavity 131 and the second inner cavity 132 formed facilitate the installation and setting of relays according to actual application requirements. For example, high-voltage relays and low-voltage relays can be separated to improve application safety.

[0076] In addition, this embodiment also provides a battery pack, which contains the integrated relay module as described above.

[0077] By applying the integrated relay module described above within the battery pack, it is easy to achieve upright installation of the relay within the battery pack. Compared to the traditional method where the relay needs to be installed upside down within the battery pack, this improves the space utilization within the battery pack and optimizes the heat dissipation of the relay, thereby reducing practical application costs and improving safety performance.

[0078] The above description is merely a specific embodiment of this application and is not intended to limit the scope of protection of 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 scope of protection of this application. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should also be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An integrated relay module, comprising: The utility model relates to a battery pack integrated relay module, which comprises: a heat-conducting shell comprising an upper shell and a lower shell, the upper shell and the lower shell being mutually covered to form a mounting cavity; at least one relay arranged in the mounting cavity, an output terminal of the relay being arranged to pass through the upper shell, and a heat-dissipating part being arranged on the output terminal and being in heat-conducting contact with the upper shell.

2. The integrated relay module of claim 1, wherein, The heat-dissipating part is in the form of a sheet, and the projection shape of the heat-dissipating part is any one of a circle, an ellipse, and a polygon.

3. The integrated relay module of claim 1 or 2, wherein, A first heat-conducting glue layer is arranged between the heat-dissipating part and the upper shell.

4. The integrated relay module of claim 3, wherein, A plurality of glue overflow grooves are arranged on the heat-dissipating part.

5. The integrated relay module of claim 4, wherein, The thickness of the first heat-conducting glue layer is not greater than 2 mm, the thickness of the heat-dissipating part is arranged to be between 0.5 mm and 2 mm, and the depth of the glue overflow grooves is arranged to be between 0.1 mm and 0.8 mm.

6. The integrated relay module of claim 1, wherein, A plurality of limiting protrusions are arranged at the bottom of the lower shell, and a reserved gap is formed between the end of the limiting protrusion and the bottom end face of the lower shell. A second heat-conducting glue layer is arranged in the reserved gap.

7. The integrated relay module of claim 6, wherein, The length of the limiting protrusion is arranged to be between 0.2 mm and 1.5 mm.

8. The integrated relay module of claim 1, wherein, A plurality of mounting lugs are arranged on the outer side of the heat-conducting shell, and a threaded sleeve is embedded on the mounting lug.

9. The integrated relay module of claim 1 or 8, wherein, The upper shell comprises a first shell cover and a second shell cover, and the first shell cover and the second shell cover are respectively connected to the lower shell in a covering manner. The mounting cavity comprises a first inner cavity formed after the first shell cover is covered to the lower shell and a second inner cavity formed after the second shell cover is covered to the lower shell, and the first inner cavity and the second inner cavity are independent of each other.

10. A battery pack, characterized by, The battery pack is internally provided with the integrated relay module as claimed in any one of claims 1-9.

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