Battery pack structure with relatively good heat dissipation performance

Abstract

The utility model discloses a battery pack structure which comprises a heat dissipation upper cover, a cylinder body, a BDC module and a battery module, the heat dissipation upper cover comprises a charging port, a discharging port, a handle, a fan cover plate and a fan, and the battery module is provided with one or more battery cells which are connected in series and in parallel and is fixedly arranged in the cylinder body; the heat dissipation upper cover is detachably connected with the cylinder body through screws, the fan is arranged on the surface of the heat dissipation upper cover, a fan cover plate with heat dissipation holes is arranged above the fan, the heat dissipation upper cover is made of aluminum alloy, and heat dissipation fins are arranged on the outer surface of the heat dissipation upper cover; and the BDC module is electrically connected with the battery module through a copper bar. According to the utility model, an air-cooling heat dissipation design is adopted, and the aluminum alloy fins and the embedded fan are cooperated for heat dissipation, so that a sufficient heat dissipation condition is provided for the battery pack, and the internal temperature of the battery is improved; and meanwhile, the BDC module and the battery module are connected by adopting the copper bars instead of connecting wire harnesses, so that faults caused by line aging or vibration are reduced, and the internal space of the battery pack is saved.

Description

Technical Field

[0001] This utility model belongs to the field of battery technology, specifically relating to a battery pack structure with better heat dissipation performance. Background Technology

[0002] Existing battery pack structures have the following significant drawbacks in terms of heat dissipation design, safety, and ease of assembly:

[0003] (1) Traditional air-cooled heat dissipation structures are costly and bulky: For example, the intelligent lithium battery pack with heat dissipation structure for new energy electric vehicles described in Chinese patent application CN209249523U adopts a complex fan system and hollow sandwich design. Although it can improve the heat dissipation uniformity, it leads to the expansion of the battery pack volume and the increase in manufacturing cost, making it difficult to meet the lightweight requirements of low-power scenarios such as electric two-wheeled vehicles.

[0004] (2) Insufficient natural heat dissipation efficiency: As described in the Chinese patent application CN205790087U, the air-cooled battery pack relies on the natural heat dissipation solution of aluminum alloy shell. This is difficult to cope with the concentrated heat generated by the high-power BDC (Bidirectional DC / DC Converter) module, which can easily cause uneven temperature inside the battery, accelerate cell aging, and even cause the risk of thermal runaway.

[0005] (3) Overheating of the handle: In traditional designs, the handle is in direct contact with the heat dissipation area (such as the top cover). Heat is conducted to the surface of the handle through the heat dissipation top cover. Users need to wait for the handle to cool down when moving it, which seriously affects the efficiency of use.

[0006] (4) Low reliability of wiring harness connection: The battery module and the BDC module are connected by traditional wiring harness, which is prone to breakage or short circuit due to vibration and aging, increasing maintenance costs and safety hazards.

[0007] (5) Difficult to maintain: The integrated battery pack design requires the BDC module and battery module to be disassembled as a whole during maintenance, which is complicated and easily exposes the electrodes, increasing the risk of short circuit. Summary of the Invention

[0008] In view of the above, the present invention provides a battery pack structure that has good heat dissipation performance, high safety and is easy to assemble.

[0009] A battery pack structure with better heat dissipation performance includes a heat dissipation cover, a cylindrical body, a battery module, and a BDC module. The heat dissipation cover is fixed to the top of the cylindrical body, and the battery module and the BDC module are installed in a box formed by the heat dissipation cover and the cylindrical body. The BDC module is connected to the battery module and is used to convert the output voltage of the battery module or the external input voltage and monitor the working status of the battery module.

[0010] The heat dissipation cover includes a fan, a fan cover, a handle, and heat dissipation fins (made of aluminum alloy). The fan is embedded and fixed to the heat dissipation cover. The heat dissipation fins around the fan are radially distributed and fixed to the outer surface of the heat dissipation cover. The fan cover covers the heat dissipation fins and the fan and is fixedly connected to the heat dissipation cover via connectors. The handle is fixedly connected to the fan cover via positioning holes. The fan cover has ventilation holes in the corresponding area covering the fan. The fan dissipates heat and distributes it fully to the heat dissipation fins, reducing the risk of the handle becoming too hot due to heat dissipation.

[0011] Furthermore, the handle houses a 4G module connected to the BDC module. This 4G module wirelessly transmits relevant electrical information from the BDC module and battery module to a host computer, enabling remote monitoring of the entire battery pack's operation. A sealing gasket is installed at the contact surface between the 4G module and the fan cover to achieve an IP65 waterproof rating. The 4G module's location on the outside of the housing saves internal space within the battery pack.

[0012] Furthermore, the heat dissipation cover is made of aluminum alloy heat dissipation material, and its side is provided with a charging port for an external charger and a discharging port for an external electric vehicle. Both the charging port and the discharging port are waterproof.

[0013] Furthermore, the heat dissipation holes are mesh structures that match the size of the fan. The height of the heat dissipation fins around the fan is higher than the fan embedding depth, and the fan cover and heat dissipation fins form a convection channel. This helps to increase the heat radiation area of ​​the heat dissipation cover to the surrounding air, thereby improving the heat dissipation effect and quickly dissipating the heat generated by the BDC module, reducing the heat accumulation of heat-generating components.

[0014] Furthermore, the heat dissipation cover is detachably connected to the edge of the cylinder by screws, and the connection is sealed with sealant, so that the battery pack structure achieves an IP65 waterproof rating; the bottom of the cylinder is provided with anti-slip ridges for anti-slip, shock absorption and protection of the battery pack.

[0015] Furthermore, the BDC module includes a PCBA (Printed Circuit Assembly) board and a heat sink aluminum block. The PCBA board is fixed to the inner side of the heat sink cover by copper pillars. The heat sink aluminum block is placed above the power device and fixed to the PCBA board by connectors to provide heat dissipation for the power device on the PCBA board. Thermal pads are attached to the power device to assist in heat dissipation.

[0016] Furthermore, the BDC module adopts a battery management system with intelligent bidirectional DC-DC conversion function, which has charge and discharge control function, voltage, current and temperature detection and protection function, short circuit protection function, SOC (state of charge) calculation function and charging equalization function.

[0017] Furthermore, the battery module is fixed inside the cylinder by pressure strips, and includes one or more battery cells. The battery cells are connected by aluminum busbars, and the battery cells are connected to the BDC module by copper busbars. The battery module is wrapped with insulating plates around its perimeter and bottom, and shock-absorbing foam is filled between the insulating plates and the cylinder to provide shock absorption and protection for the battery module.

[0018] Furthermore, an epoxy board is installed on top of the battery module for protection and insulation, preventing the battery module's tabs from being exposed during maintenance and assembly; Mylar sheets are fixed to the back of the BDC module with rivets for insulation.

[0019] The core innovations of this utility model include the following:

[0020] (1) Air-cooled heat dissipation design

[0021] Aluminum alloy fins and embedded fan work together to dissipate heat: The heat dissipation cover is made of aluminum alloy and has radially distributed heat dissipation fins on the outer surface, which increases the heat dissipation area and improves the efficiency of natural heat dissipation; at the same time, a fan is embedded in the top of the cover, and a fan cover with heat dissipation holes is covered above the fan to actively guide airflow and accelerate heat dissipation.

[0022] The handle and heat dissipation area are separated: the handle is independently set on the top of the heat dissipation cover and separated from the heat dissipation surface by a fan cover plate. The heat dissipation fins and fan area are physically isolated to prevent heat from being conducted to the handle and ensure that users can move it immediately.

[0023] (2) High-reliability electrical connection structure

[0024] Copper busbars replace traditional wiring harnesses: The battery module and the BDC module are electrically connected by copper busbars. One end of the copper busbar is soldered to the positive and negative terminals of the battery module's cell connection bar, and the other end is connected to the BDC module with screws. The cylinder body is equipped with copper busbar fixing parts to provide insulation protection for the copper busbar, reducing failures caused by aging or vibration of the wiring, while also saving internal space.

[0025] (3) Modular split design

[0026] Detachable housing design: The heat dissipation cover is connected to the body with screws, and IP65 waterproof rating is achieved with sealant; the BDC module is fixed to the inside of the heat dissipation cover with copper pillars, and the battery module is fixed to the body with pressure strips. Any module can be removed individually during maintenance to avoid the risk of electrode exposure.

[0027] Insulation protection and shock absorption design: The battery module is wrapped with epoxy resin insulation board on five sides (except for the series and parallel connection sides); the contact surface between the battery module and the cylinder body is filled with shock-absorbing foam to take into account both insulation and impact resistance.

[0028] (4) Intelligent function integration

[0029] External 4G module design: The 4G module is embedded inside the handle and waterproofed by a rubber sealing gasket. The module is connected to the BDC module through a wiring harness and uploads battery data to the backend in real time, supporting remote monitoring and fault warning.

[0030] Based on the above, this utility model has the following beneficial technical effects:

[0031] 1. Excellent waterproof performance. This invention utilizes sealant at the connection between the heat dissipation cover and the edge of the battery pack, and adds a sealing gasket at the connection between the handle (including the 4G module) and the heat dissipation cover, both of which contribute to waterproofing. This prevents damage to the internal structure of the battery pack from water ingress, ensuring the battery pack structure meets the IP65 waterproof rating.

[0032] 2. Excellent heat dissipation. Due to the high power consumption and high heat dissipation requirements of the BDC module used in the large-capacity battery pack structure, the air-cooling design provides ample conditions for heat dissipation inside the battery pack. Simultaneously, the fan is placed externally on the battery pack for easy disassembly, simplifying assembly and maintenance.

[0033] 3. Integrated structure for easier assembly. This utility model adopts a modular, split design, supporting quick replacement of BDC modules or battery modules without overall disassembly. The connection between the BDC module and the battery module uses copper busbars, improving system integration, reducing the number of parts, reducing process steps, and reducing internal space occupation, making battery pack assembly more convenient. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the external structure of the battery pack in an embodiment of this utility model.

[0035] Figure 2 This is an exploded view of the overall structure of the battery pack in an embodiment of this utility model.

[0036] Figure 3 This is a schematic diagram of the battery module structure of the battery pack in an embodiment of this utility model.

[0037] Figure 4 This is a schematic diagram of the heat dissipation cover and BDC module structure of the battery pack in this embodiment of the present invention.

[0038] In the diagram: 1—Heat dissipation cover, 11—Handle, 12—Fan cover, 121—Positioning hole, 122—Cover connection hole, 123—Fan heat dissipation hole, 13—Heat dissipation fins, 14—Discharge port, 15—Charging port, 16—Fan, 2—Body, 21—Copper busbar fixing piece, 22—Pressure strip fixing block, 3—BDC module, 31—Heat dissipation aluminum block, 32—Copper busbar, 33—PCBA board, 4—Battery module, 41—Pressure strip, 42—Cell connection bar, 43—Insulation board, 44—Cell. Detailed Implementation

[0039] To describe the present invention in more detail, the technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0040] like Figures 1-4 As shown, this embodiment provides a battery pack structure with better heat dissipation performance, including a heat dissipation cover 1, a cylindrical body 2, a BDC module 3, and a battery module 4. The battery module 4 and the BDC module are installed in the box formed by the heat dissipation cover 1 and the cylindrical body 2. The heat dissipation cover 1 is provided with a charging port 15 for an external charger, a discharging port 14 for an external electric vehicle, and a handle 11.

[0041] like Figure 1 As shown, in this embodiment, the charging port 15 and discharging port 14 are evenly distributed side by side on the surface of the heat dissipation cover 1, both with waterproof design. A handle 11 for mounting the 4G module is provided on the top of the heat dissipation cover 1; the 4G module is visible after the handle 11 is removed. The edges of the heat dissipation cover 1 and the body 2 are connected by connectors (screws), with evenly distributed connection holes. Sealant is used to reinforce the edges for sealing, achieving an IP65 waterproof rating for the battery pack structure. The 4G module is located on the outside of the housing, integrated with the handle, and installed outside the body, saving internal space and eliminating the need to consider the heat dissipation requirements of the module within the battery pack. The bottom of the body 2 also has anti-slip textured surfaces for anti-slip and shock absorption protection of the battery pack.

[0042] like Figure 4 As shown, the fan cover 12 is provided with positioning holes 121 for positioning and fixed connection with the handle 11; the fan cover 12 and the heat dissipation cover 1 are fixedly connected by connectors (screws) passing through the cover plate connection holes 122; the upper surface of the fan 16, which contacts the fan cover 12, is provided with heat dissipation holes 123, the area of ​​which matches the size of the fan 16. The fan 16 is embedded in the upper side of the heat dissipation cover 1, and the heat dissipation fins 13 around the fan 16 are higher than the fan 16. The fan 16 is reinforced to the heat dissipation cover 1 by connectors passing through the cover plate connection holes. During battery pack operation, the heat inside the battery pack is discharged from bottom to top by the fan 16 through the fan cover heat dissipation holes 123. The fan 16 provides air cooling and the heat dissipation fins 13 utilize air for heat dissipation, resulting in better heat dissipation. The fan cover 12 is provided between the handle 11 and the heat dissipation cover 1 to prevent the handle 11 from overheating.

[0043] like Figure 2As shown, the BDC module 3 includes a heat sink aluminum block 31, a PCBA board 33, a copper busbar 32, and thermal pads. The PCBA board 34 has positioning holes along its edge, which are connected to the screw holes on the back of the heat sink cover 1 via screws. The positioning holes and screw holes are correspondingly and evenly distributed. The heat sink aluminum block 31 is positioned above the critical power components of the PCBA board 33 and is fixed to the PCBA board 33 with screws, providing heat dissipation for the critical power components. The thermal pads are tightly attached to the back of the PCBA board, providing heat dissipation support for the components on the other side of the PCBA board.

[0044] The copper busbar 32 is connected to the B-end port of the PCBA board 33, enabling the PCBA board 33 to effectively monitor the charging and discharging of the battery module 4. The battery module 4 is also connected to the battery temperature and voltage sampling interface of the PCBA board 33 for battery voltage detection, temperature detection, current detection and protection, and alarm and protection parameter settings can be configured via a host computer.

[0045] Charging port 15 is connected to the positive and negative P-terminal interfaces of PCBA board 33 via a charging terminal harness to collect information such as charging terminal voltage. Charging port 15 provides RS485 communication connectivity during operation, allowing isolated communication with a PC or charger via RS485, supporting a maximum baud rate of 115200, and uploading the collected information. Discharging port 14 is connected to the P+ and P- terminals of PCBA board 33 via a discharging terminal harness to collect information such as discharging terminal voltage.

[0046] like Figure 3 As shown, the pressure strip fixing block 22 is laser-welded to the cylinder body 2 and works with the pressure strip 41 to fix the battery module 4. The positive and negative terminals of the cell connection busbar 42 are connected by copper busbars 32 to achieve electrical connection between the PCBA board 33 and the battery module 4. The copper busbar fixing component 21 is laser-welded to the cylinder body 2 and is used to fix and protect the connection busbar 32. The insulating plate 43 is fixed to the side of the battery module 4 for insulation. The battery module 4 is installed and fixed inside the cylinder body 2. Shock-absorbing foam is added to the contact surface between the cylinder body 2 and the battery module 4 to provide shock absorption and protection for the battery module. The connection busbar 32 saves more internal volume of the battery pack than traditional wire harnesses, making the entire pack smaller, easier to disassemble and replace, and with a lower damage rate than wire harnesses.

[0047] An epoxy board is installed on top of the battery module 4 for protection and insulation, preventing the tabs of the battery module 4 from being exposed during maintenance and assembly. Mylar sheets are fixed to the back of the BDC module 3 with rivets for insulation.

[0048] In other embodiments, the battery module 4 may also use one or more hard-pack cells 44 or cells 44 of different sizes that conform to the battery pack structure; the BDC module 3 and the battery module 4 may also be designed in other ways to achieve insulation; the cylinder body 2 may also be a square or a structure with four equal walls, that is, compared with the above embodiments, the length and width of the four side walls of the cylinder body 2 are not equal; the handle 11 may also omit the 4G module device and be used only for carrying and lifting, and the battery pack does not use 4G communication function.

[0049] The above description of the embodiments is provided to enable those skilled in the art to understand and apply the present invention. Those skilled in the art can readily make various modifications to the above embodiments and apply the general principles described herein to other embodiments without creative effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made to the present invention by those skilled in the art based on the disclosure of the present invention should be within the protection scope of the present invention.

Claims

1. A battery pack structure with better heat dissipation performance, characterized in that, The device includes a heat dissipation cover, a cylindrical body, a battery module, and a BDC module. The heat dissipation cover is fixed to the top of the cylindrical body, and the battery module and BDC module are installed in the housing formed by the heat dissipation cover and the cylindrical body. The BDC module is connected to the battery module and is used to convert the output voltage of the battery module or the external input voltage and to monitor the working status of the battery module. The heat dissipation cover is equipped with a fan, a fan cover plate, a handle, and heat dissipation fins. The fan is embedded and fixed on the heat dissipation cover. The heat dissipation fins around the fan are radially distributed and fixed on the outer surface of the heat dissipation cover. The fan cover plate covers the heat dissipation fins and the fan and is fixedly connected to the heat dissipation cover plate through connectors. The handle is fixedly connected to the fan cover plate through positioning holes. The fan cover plate has heat dissipation holes in the corresponding area covering the fan.

2. The battery pack structure according to claim 1, characterized in that: The handle contains a 4G module, which is connected to the BDC module. The 4G module is used to wirelessly transmit the relevant electrical information of the BDC module and the battery module to the host computer, so that the host computer can remotely monitor the operation of the entire battery pack. The contact surface between the 4G module and the fan cover is equipped with a sealing gasket to achieve an IP65 waterproof rating.

3. The battery pack structure according to claim 1, characterized in that: The heat dissipation cover is made of aluminum alloy heat dissipation material. Its side is provided with a charging port for an external charger and a discharging port for an external electric vehicle. Both the charging port and the discharging port are waterproof.

4. The battery pack structure according to claim 1, characterized in that: The heat dissipation holes have a mesh structure and are matched with the fan size. The height of the heat dissipation fins around the fan is higher than the fan embedding depth, and the fan cover and heat dissipation fins form a convection channel.

5. The battery pack structure according to claim 1, characterized in that: The heat dissipation cover is detachably connected to the edge of the cylinder by screws, and the connection is sealed with sealant, so that the battery pack structure achieves an IP65 waterproof rating; the bottom of the cylinder is provided with anti-slip ridges for anti-slip, shock absorption and protection of the battery pack.

6. The battery pack structure according to claim 1, characterized in that: The BDC module includes a PCBA board and a heat sink aluminum block. The PCBA board is fixed to the inner side of the heat sink cover by copper pillars. The heat sink aluminum block is placed above the power device and fixed to the PCBA board by connectors to provide heat dissipation for the power device on the PCBA board. Thermal pads are attached to the power device to assist in heat dissipation.

7. The battery pack structure according to claim 1, characterized in that: The BDC module adopts a battery management system with intelligent bidirectional DC-DC conversion function, which has charge and discharge control function, voltage, current and temperature detection and protection function, short circuit protection function, SOC calculation function and charging equalization function.

8. The battery pack structure according to claim 1, characterized in that: The battery module is fixed inside the cylinder by pressure strips. It includes one or more battery cells, which are connected by aluminum busbars and connected to the BDC module by copper busbars. The battery module is wrapped with insulating board around its perimeter and bottom. The space between the insulating board and the cylinder is filled with shock-absorbing foam to protect the battery module from shock.

9. The battery pack structure according to claim 1, characterized in that: An epoxy board is installed on top of the battery module for protection and insulation, preventing the battery module's tabs from being exposed during maintenance and assembly; Mylar sheets are fixed to the back of the BDC module with rivets for insulation.

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