Special-shaped battery pack

Abstract

The utility model provides a special-shaped battery pack which is characterized in that the special-shaped battery pack is provided with a first battery pack (11), a second battery pack (12) and a special-shaped insulating plate (7), the first battery pack (11) comprises a first hard sleeve (8) and more than two batteries (10) which are accommodated in the first hard sleeve (8) and are connected end to end; the first battery pack (11) comprises a first hard sleeve (8) and more than one battery (10) accommodated in the first hard sleeve (8), the second battery pack (12) comprises a second hard sleeve (9) and more than one battery (10) arranged in parallel and accommodated in the second hard sleeve (9), the first battery pack (11) and the second battery pack (12) are arranged in an L shape in a manner that one ends are aligned, and the special-shaped insulating plate (7) is in an L-shaped plane plate shape and is attached to the side surfaces of the first hard sleeve (8) and the second hard sleeve (9).

Description

Technical Field

[0001] This utility model relates to an irregularly shaped battery pack. Background Technology

[0002] Irregularly shaped battery packs are commonly used in vehicle communication equipment. Due to space constraints, the battery compartments of communication equipment are often designed in various shapes. For special shapes such as stepped or trapezoidal structures, customized battery packs with appropriate dimensional tolerances are required. Even battery packs of the same shape will not be completely identical in terms of size and tolerance requirements. Therefore, the existing technology presents the following challenges: First, battery packs of different shapes cannot adapt to the varied design requirements of vehicle battery compartments; second, when the size of the vehicle battery compartment is adjusted for optimization, the battery pack needs to re-enter the development cycle, and its original structural dimensions and other requirements may not meet the needs of the new battery compartment.

[0003] Furthermore, heat shrink tubing plays a crucial role as a protective component for irregularly shaped battery packs. Heat shrink tubing possesses excellent insulation properties, effectively preventing internal short circuits and ensuring the safe operation of the battery pack. However, due to the complex and diverse shapes of irregularly shaped battery packs, traditional heat shrink tubing often fails to achieve a tight fit during the heat shrinking process, resulting in inconsistent dimensional accuracy. This not only affects the protective effect of the heat shrink tubing but may also lead to a series of safety hazards, such as battery overheating and fire. Therefore, improving the dimensional accuracy of the heat-shrinked battery pack is of great significance for ensuring battery performance and safety. Utility Model Content

[0004] This invention addresses the aforementioned problems and aims to provide an irregularly shaped battery pack that can adapt to battery compartments with different shapes and sizes, and has excellent dimensional accuracy after heat shrinking, ensuring reliable battery performance.

[0005] This utility model relates to an irregularly shaped battery pack (1), characterized in that it comprises a first battery pack (11), a second battery pack (12), and an irregularly shaped insulating plate (7).

[0006] The first battery pack (11) includes a first rigid sleeve (8) and two or more batteries (10) connected end to end therein;

[0007] The second battery pack (12) includes a second rigid sleeve (9) and one or more parallel-arranged batteries (10) housed therein.

[0008] The first battery pack (11) and the second battery pack (12) are arranged in an L-shape with one end aligned.

[0009] The irregularly shaped insulating plate (7) is an L-shaped flat plate that is attached to the side of the first rigid sleeve (8) and the second rigid sleeve (9).

[0010] Preferably, when the overall width of the irregularly shaped battery pack is set to W, the diameter of the battery is D1, the wall thickness of the first rigid sleeve is t1, and the wall thickness of the second rigid sleeve is t2, W = 2*(D1 + t1 + t2) is satisfied.

[0011] Preferably, when the thickness of the irregularly shaped battery pack is T, the diameter of the battery is D1, the wall thickness of the first rigid sleeve is t1, the wall thickness of the second rigid sleeve is t2, and the thickness of the irregularly shaped insulating plate is t3, t2≥t1 and T=D1+2*t2+t3 are satisfied.

[0012] Preferably, the irregularly shaped battery pack (1) includes a square main body (2) and an elongated extension (3), and is configured as an L-shape. A second heat-shrinkable sleeve (6) is covered on the outer surface of the main body (2), and a first heat-shrinkable sleeve (5) is covered on the lower half of the main body (2) and the outer surface of the extension (3).

[0013] Preferably, the irregularly shaped battery pack (1) further includes a wire harness (4) for electrically connecting the first battery pack (11) and the second battery pack (12) to an external device. The wire harness (4) is disposed between the first rigid sleeve (8) and the second rigid sleeve (9) and extends from the opening of the first heat shrink sleeve (5).

[0014] Preferably, the wire harness (4) further includes a PTC thermistor (15).

[0015] Preferably, the irregularly shaped insulating plate (7) includes a first portion (7a) that is attached to the side of the first rigid sleeve (8) and a second portion (7b) that is attached to the side of the second rigid sleeve (9) and covers the space between the first rigid sleeve (8) and the second rigid sleeve (9), wherein the thickness of the first portion (7a) is greater than or equal to the thickness of the second portion (7b).

[0016] Preferably, the irregularly shaped insulating board (7) is a PC insulating board, PET insulating board, or synthetic paper insulating board with low moisture absorption rate.

[0017] Preferably, the first rigid sleeve (8) and the second rigid sleeve (9) are rigid PI sleeves.

[0018] Preferably, the battery (10) is a cylindrical nickel-metal hydride secondary battery or a lithium secondary battery.

[0019] Utility Model Effect

[0020] This utility model discloses an L-shaped battery pack with a stepped structure, which can be adapted to battery compartments of special shapes. By using matching combinations of rigid sleeves of different sizes and irregularly shaped insulating plates, the thickness T and width W of the target battery pack can be achieved, exhibiting excellent dimensional accuracy after heat shrinking and ensuring reliable battery performance. Furthermore, the thickness T and width W of the battery pack can be easily adjusted through the pairing and adjustment of the rigid sleeves and insulating plates. When dealing with different customers, only the T and W dimensions need to be adjusted to meet various requirements, without the need for structural redesign, which greatly improves the structural flexibility and dimensional accuracy of the battery pack. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall appearance of the irregularly shaped battery pack of this utility model.

[0022] Figure 2 This is an exploded view of the irregularly shaped battery pack of this utility model.

[0023] Figure 3 This is a schematic diagram of the internal structure of the irregularly shaped battery pack of this utility model.

[0024] Figure 4 This is a schematic diagram showing the dimensional relationship of the irregularly shaped battery pack of this utility model.

[0025] Figure 5 This is a flowchart of the assembly process of the irregularly shaped battery pack of this utility model. Detailed Implementation

[0026] The specific embodiments of the irregularly shaped battery pack of this utility model will be described below with reference to the accompanying drawings.

[0027] Figure 1 This is a schematic diagram of the overall appearance of the irregularly shaped battery pack of this utility model. Figure 2 This is an exploded view of the irregularly shaped battery pack of this utility model. Figure 3 This is a schematic diagram of the internal structure of the irregularly shaped battery pack of this utility model.

[0028] like Figure 1 As shown, from the appearance, the irregular battery pack (1) of this utility model includes a square main body (2) and an elongated extension (3), and the whole is L-shaped. The lower half of the main body (2) (i.e. the part adjacent to the extension, the left side in the figure) and the outer surface of the extension (3) are covered with a first heat shrink tubing (5), and the outer surface of the main body (2) is covered with a second heat shrink tubing (6). The wire bundle (4) extends out from the opening of the first heat shrink tubing (5).

[0029] like Figure 2 and Figure 3 As shown, when the irregularly shaped battery pack (1) of this utility model is disassembled, that is, after removing the first heat-shrink tubing (5) and the second heat-shrink tubing (6) covering the battery pack, it is found that the irregularly shaped battery pack (1) also includes an insulating plate (7), a first rigid tubing (8), a second rigid tubing (9), and multiple batteries (10). Among them, the first rigid tubing (8) contains two or more batteries (10) connected end to end, forming a first battery pack (11); the second rigid tubing (9) contains one battery (10) or two or more batteries (10) arranged side by side, forming a second battery pack (12). The first battery pack (11) and the second battery pack (12) are electrically connected to an external device (not shown) through a wire harness (4). In addition, the second battery pack (12) and the portion of the first battery pack (11) that is parallel to the second battery pack (12) constitute the square main body (2) of the irregular battery pack (1), and the other portions of the first battery pack (11) constitute the elongated extension (3) of the irregular battery pack (1).

[0030] In other words, the shaped battery pack (1) of this utility model is characterized by having a first battery pack (11), a second battery pack (12) and a shaped insulating plate (7). The first battery pack (11) includes a first rigid sleeve (8) and two or more batteries (10) connected end to end therein. The second battery pack (12) includes a second rigid sleeve (9) and one or more batteries (10) arranged side by side therein. The first battery pack (11) and the second battery pack (12) are arranged in an L-shape with one end aligned. The shaped insulating plate (7) is an L-shaped flat plate that fits against the side of the first rigid sleeve (8) and the second rigid sleeve (9).

[0031] Among them, such as Figure 3 As shown, the L-shaped insulating plate (7) includes a first portion (7a) attached to the side of the first rigid sleeve (8) and a second portion (7b) attached to the side of the second rigid sleeve (9) and covering the space between the first rigid sleeve (8) and the second rigid sleeve (9), roughly corresponding to the elongated extension (3) and the square main body (2) of the irregular battery pack (1). The thicknesses of the first portion (7a) and the second portion (7b) can be the same or different. When the wall thickness of the first rigid sleeve (8) is less than the wall thickness of the second rigid sleeve (9), it is preferable that the thickness of the first portion (7a) is greater than the thickness of the second portion (7b). The different thicknesses of each component can be calculated based on the total thickness of the finished product and allocated according to the calculation results.

[0032] In this invention, since multiple batteries (10) can be arranged in various shapes and combinations using first rigid sleeves (8) and second rigid sleeves (9) of various sizes, it is easy to meet the design requirements of irregularly shaped battery packs for different shapes. For example, by changing the number of batteries contained in the first rigid sleeve (8) and the combination method of the second rigid sleeve (9), battery packs of different shapes, such as stepped battery packs or trapezoidal battery packs, can be constructed.

[0033] In this utility model, when the original battery compartment needs to be optimized by adjusting its size, the overall thickness and width of the irregular battery pack (1) can be adjusted by changing the thickness of the first rigid sleeve (8), the second rigid sleeve (9) and the irregular insulating plate (7), thereby achieving excellent dimensional accuracy.

[0034] Figure 4 This is a schematic diagram showing the dimensional relationship of the irregularly shaped battery pack of this utility model.

[0035] like Figure 4 As shown, when the overall width of the irregularly shaped battery pack is set to W, the battery diameter to D1, the wall thickness of the first rigid sleeve to t1, and the wall thickness of the second rigid sleeve to t2, it is preferable to satisfy W = 2*(D1 + t1 + t2).

[0036] Furthermore, when the thickness of the irregularly shaped battery pack is set to T, the battery diameter to D1, the wall thickness of the first rigid sleeve to t1, the wall thickness of the second rigid sleeve to t2, and the thickness of the irregularly shaped insulating plate to t3, it is preferable to satisfy t2≥t1 and T=D1+2*t2+t3. Where t1, t2, and t3 can all be adjusted according to requirements.

[0037] In this way, by selecting different pairs of rigid sleeves and irregularly shaped insulating plates, the overall thickness T and width W of the irregularly shaped battery pack can be flexibly adjusted.

[0038] The irregularly shaped battery pack of this utility model also includes a wire harness (4) for electrically connecting each battery pack to an external device, such as... Figure 3 As shown, the wire harness (4) is positioned between the first rigid sleeve (11) and the second rigid sleeve (12), and extends from the opening left during the heat shrinking of the first heat shrink sleeve 5. In addition, the wire harness (4) may also include a PTC thermistor (15) or the like.

[0039] Below, in conjunction with Figure 5 The assembly process of the irregularly shaped battery pack of this utility model will be described in more detail.

[0040] First, multiple batteries are placed into a first rigid sleeve and a second rigid sleeve of a set thickness. Specifically, two batteries (10) are placed end to end into the first rigid sleeve (8) to form a first battery pack (11), and one battery (10) is placed into the second rigid sleeve (9) to form a second battery pack (12). Next, the two battery packs (11, 12) with rigid sleeves and wire harness (4) are processed into a first semi-finished battery pack (13). Then, a special-shaped insulating plate (7) for adjusting the thickness is attached to the side of the semi-finished battery pack (13) to form a second semi-finished battery pack (14). Finally, the first heat-shrinkable sleeve (5) and the second heat-shrinkable sleeve (6) are used to heat-shrink the outer surface of the main body (2) and the extension (3) of the second semi-finished battery pack (14) step by step to complete the entire process and obtain the finished special-shaped battery pack (1).

[0041] Heat shrink tubing for battery packs offers advantages such as low cost and simple operation. However, irregularly shaped battery packs often experience uneven heating during the shrinking process, particularly at corners, edges, or protruding areas. This invention addresses this by employing a step-by-step heat shrinking method on different parts of the irregularly shaped battery pack, allowing the heat shrink tubing to better conform to the pack's surface, thus increasing the dimensional accuracy and safety of the battery pack's appearance.

[0042] In this invention, the irregularly shaped insulating board (7) can be a PC (polycarbonate) / PET (polyester) / synthetic paper insulating board with low moisture absorption, and the first rigid sleeve and the second rigid sleeve can be rigid PI (polyimide) sleeves. The first heat shrink sleeve and the second heat shrink sleeve can be PVC (polyvinyl chloride) heat shrink sleeves or PET (polyester) heat shrink sleeves. PVC heat shrink sleeves can be used for packaging battery cells or small battery packs with relatively low protection requirements and low operating temperatures. PET heat shrink sleeves greatly exceed PVC heat shrink sleeves in terms of heat resistance, electrical insulation performance, and mechanical properties, and are suitable for application scenarios with high environmental protection requirements and certain requirements for battery pack protection performance and appearance.

[0043] The battery used in the irregularly shaped battery pack of this invention can be a cylindrical battery or a prismatic battery, and the battery can be a nickel-metal hydride secondary battery or a lithium secondary battery. From the perspective of more effectively utilizing the advantages of this invention, a cylindrical nickel-metal hydride secondary battery or a lithium secondary battery is preferred.

[0044] This utility model's irregularly shaped battery pack utilizes rigid sleeves of varying sizes and irregularly shaped insulating plates in combination, along with step-by-step heat shrinking. This allows for precise matching of the battery pack's thickness (T) and width (W), flexibly adapting to battery compartments with unique shapes. Furthermore, it maintains excellent dimensional accuracy after heat shrinking, ensuring reliable battery performance. Additionally, by adjusting the dimensions of the rigid sleeves and insulating plates, the overall thickness (T) and width (W) of the battery pack can be adjusted. When catering to different customers, only the T and W dimensions need to be adjusted to meet various requirements, eliminating the need for structural redesign. This significantly improves the structural flexibility and dimensional accuracy of the battery pack.

[0045] The above description, with reference to the accompanying drawings and specific embodiments, illustrates several examples of the irregularly shaped battery pack of this utility model. However, this utility model is not limited to the specific embodiments described above. Various modifications or changes in elements can be made without departing from the spirit of this utility model, and these modifications or changes in elements are also included within the protection scope of this utility model.

Claims

1. An irregularly shaped battery pack (1), characterized in that: It includes a first battery pack (11), a second battery pack (12), and an irregularly shaped insulating plate (7). The first battery pack (11) includes a first rigid sleeve (8) and two or more batteries (10) connected end to end therein; The second battery pack (12) includes a second rigid sleeve (9) and one or more parallel-arranged batteries (10) housed therein. The first battery pack (11) and the second battery pack (12) are arranged in an L-shape with one end aligned. The irregularly shaped insulating plate (7) is an L-shaped flat plate that is attached to the side of the first rigid sleeve (8) and the second rigid sleeve (9).

2. The irregularly shaped battery pack according to claim 1, characterized in that, When the overall width of the irregularly shaped battery pack is set to W, the diameter of the battery is D1, the wall thickness of the first rigid sleeve is t1, and the wall thickness of the second rigid sleeve is t2, W = 2*(D1 + t1 + t2) is satisfied.

3. The irregularly shaped battery pack according to claim 1 or 2, characterized in that, When the thickness of the irregularly shaped battery pack is set to T, the diameter of the battery is D1, the wall thickness of the first rigid sleeve is t1, the wall thickness of the second rigid sleeve is t2, and the thickness of the irregularly shaped insulating plate is t3, the following conditions are met: t2≥t1, and T=D1+2*t2+t3.

4. The irregularly shaped battery pack according to claim 1 or 2, characterized in that, It includes a square main body (2) and a slender extension (3), and the overall structure is L-shaped. A first heat-shrinkable sleeve (5) covers the lower half of the main body (2) and the outer surface of the extension (3), and a second heat-shrinkable sleeve (6) covers the outer surface of the main body (2).

5. The irregularly shaped battery pack according to claim 4, characterized in that, It also includes a wire harness (4) for electrically connecting the first battery pack (11) and the second battery pack (12) to external devices. The wire bundle (4) is disposed between the first rigid sleeve (8) and the second rigid sleeve (9) and extends from the opening of the first heat shrink sleeve (5).

6. The irregularly shaped battery pack according to claim 5, characterized in that, The wire harness (4) also includes a PTC thermistor (15).

7. The irregularly shaped battery pack according to claim 3, characterized in that, The irregularly shaped insulating plate (7) includes a first portion (7a) attached to the side of the first rigid sleeve (8) and a second portion (7b) attached to the side of the second rigid sleeve (9) and covering the space between the first rigid sleeve (8) and the second rigid sleeve (9), wherein the thickness of the first portion (7a) is greater than or equal to the thickness of the second portion (7b).

8. The irregularly shaped battery pack according to claim 1 or 2, characterized in that, The irregularly shaped insulating board (7) is a PC insulating board, PET insulating board, or synthetic paper insulating board with low moisture absorption rate.

9. The irregularly shaped battery pack according to claim 1 or 2, characterized in that, The first rigid sleeve (8) and the second rigid sleeve (9) are rigid PI sleeves.

10. The irregularly shaped battery pack according to claim 9, characterized in that, The battery (10) is a cylindrical nickel-metal hydride secondary battery or a lithium secondary battery.

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