Forced convection heat management structure of battery module

Abstract

The utility model provides a forced convection heat management structure of a battery module, which comprises a confluence plate and a heat exchange plate, the interior of the confluence plate is divided into at least one inflow cavity and at least one outflow cavity, and the end part of the confluence plate is provided with a main inlet communicated with the inflow cavity and a main outlet communicated with the outflow cavity, so that a heat exchange medium enters and exits from the confluence plate; a sub-inlet is formed in the upper surface of the inflow cavity, a sub-outlet is formed in the upper surface of the outflow cavity, the bottom of the heat exchange plate communicates with the sub-inlet and the sub-outlet, and the two opposite side faces of the heat exchange plate abut against the battery cell. Through the structure, dense parallel convection heat exchange interfaces are realized, all battery cells can be synchronously cooled, the heat exchange efficiency is obviously improved, and due to the arrangement of the parallel convection heat exchange interfaces, a heat exchange flow channel is effectively shortened, namely the flow resistance increase caused by the flow channel process is avoided, and the heat exchange efficiency is improved. And the problems of insufficient heat exchange and non-uniform heat exchange caused by overlarge flow resistance between different battery cells are avoided.

Description

Technical Field

[0001] This utility model relates to the field of new energy battery technology, and in particular to a forced convection thermal management structure for a battery module. Background Technology

[0002] Battery modules are widely used in new energy vehicles and energy storage systems. With the rapid development of new energy technologies and the transformation of the energy structure, the application scope of battery modules is constantly expanding, and the requirements for their performance, safety, and thermal management are also increasing. Good thermal management is crucial for extending battery life, improving energy efficiency, and ensuring system safety. Excessively high temperatures may accelerate battery aging or even trigger thermal runaway, while excessively low temperatures may reduce the battery's discharge capacity.

[0003] Forced fluid convection heat transfer is the main method of current battery thermal management, including various fluid cooling methods such as forced air cooling, liquid cooling, and refrigerant cooling. By utilizing the large heat capacity and recyclable characteristics of the cooling medium (such as air, coolant, or refrigerant), excess heat in the battery pack can be effectively removed, maintaining the battery pack within its optimal operating temperature range.

[0004] However, existing fluid cooling systems have a limited number of heat exchange interfaces and long series flow channels, resulting in insufficient heat exchange between the cooling medium and the battery. Furthermore, excessively long flow channels increase flow resistance, leading to significant temperature differences between the front and rear ends of the channel, thus affecting overall cooling efficiency and temperature uniformity. Utility Model Content

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a forced convection thermal management structure for battery modules. This structure aims to solve the technical problems of insufficient convective heat transfer interfaces and excessively long series flow channels leading to increased flow resistance and consequently significant temperature differences between the front and rear ends of the flow channels. This invention also addresses the insufficient thermal expansion adaptability of existing battery module thermal management systems, achieving efficient temperature uniformity control of the battery cells and long-term stable system operation.

[0006] To achieve the above objectives, this utility model is implemented through the following technical solution:

[0007] A forced convection thermal management structure for a battery module includes a busbar and several heat exchange plates. The busbar is internally divided into at least one inflow chamber and at least one outflow chamber. The end of the busbar is provided with a main inlet communicating with the inflow chamber and a main outlet communicating with the outflow chamber, so that the heat exchange medium can enter and exit the busbar. A sub-inlet is provided on the upper surface of the inflow chamber and a sub-outlet is provided on the upper surface of the outflow chamber. The bottom of the heat exchange plate is connected to the sub-inlet and the sub-outlet. The two opposite sides of the heat exchange plate abut against the battery cells.

[0008] Furthermore, a connecting seat is provided at the bottom of the heat exchange plate, and an opening is provided at the bottom of the connecting seat. The opening corresponds to the sub-outlet and sub-inlet on the manifold. A barrier is provided on the manifold, which surrounds the sub-inlet and the sub-outlet. The barrier is used to accommodate and connect the connecting seat.

[0009] Furthermore, the two inner sidewalls of the enclosure are provided with first buckles, and the two outer sidewalls of the heat exchange plate are provided with second buckles spaced apart. The edges of the second buckles are provided with grooves that match the shape of the first buckles, so that the first buckles and the second buckles form an interlocking structure during assembly.

[0010] Furthermore, the second buckle, the connecting seat, and the heat exchange plate form a through hole. When glue is injected into the enclosure, the glue flows into the hole and hardens to form an interlaced hard glue layer, thereby forming a self-locking structure within the enclosure. The hard glue layer, the heat exchange plate, and the manifold are anchored to each other to improve the bonding strength and sealing performance.

[0011] Furthermore, the heat exchange plate has an internal cavity to accommodate the heat exchange medium, which can be a liquid, gas, or gas-liquid phase change refrigerant. Densely arranged support plates are disposed within the cavity, with each end of the support plates connected to opposite inner sidewalls of the heat exchange plate. The numerous independently distributed support plates create a significant dispersion effect in the flowing medium, resulting in a more uniform flow field within the heat exchange plate.

[0012] Furthermore, the bottom of the heat exchange plate is provided with a baffle extending to the top. The baffle is used to transfer the heat exchange medium to the top of the heat exchange plate to achieve uniform cooling. A gap is left between the baffle and the top of the heat exchange plate so that the heat exchange medium flows from the sub-inlet to the sub-outlet.

[0013] Furthermore, the support plate and the two inner sidewalls of the heat exchange plate have an "N"-shaped inclined structure, so that the heat exchange plate can be elastically compressed and the structure is stable.

[0014] Furthermore, the baffle and the two inner walls of the heat exchange plate form an "N"-shaped inclined structure, which allows the heat exchange plate to be elastically compressed and structurally stable. The elastic structure allows the expansion of the battery cell during use to be absorbed, thereby maintaining the structural stability of the battery module throughout its entire life cycle.

[0015] Furthermore, pressure constraint end plates are provided at both ends of the busbar, and several heat exchange plates and several battery cells are located between the two pressure constraint end plates.

[0016] Furthermore, each enclosure of the manifold is provided with several screw holes so that fasteners can pass through the screw holes on the manifold to connect to the heat exchange plate.

[0017] Compared with the prior art, the beneficial effects of this utility model are as follows: the manifold includes a main inlet and a main outlet, which can be connected to an external refrigeration device for efficient circulating cooling; by dividing the manifold into the inflow chamber and the outflow chamber, after the heat exchange medium enters the inflow chamber through the main inlet, it can simultaneously enter several heat exchange plates through several sub-inlets. After completing heat exchange with the battery cells within the heat exchange plates, it enters the outflow chamber through several sub-outlets and is discharged through the main outlet to complete the cycle. That is, through the corresponding structural setting, a dense parallel convective heat exchange interface is realized, which can simultaneously dissipate heat from all battery cells, significantly improving heat exchange efficiency. Moreover, due to the setting of the parallel convective heat exchange interface, while improving heat exchange efficiency, it effectively shortens the heat exchange flow path. This design avoids increased flow resistance during the flow process, preventing insufficient and uneven heat exchange between different battery cells due to excessive flow resistance. By setting the first and second clips, a stable interlocking structure can be formed when the potting layer is installed within the enclosure, ensuring the sealing and connection stability between the manifold and the heat exchange plate. The support plate provides support between the heat exchange plate and the battery cells, ensuring the stability of the overall structure. The support plate, designed as an "N"-shaped elastic structure, can accommodate the expansion of the battery cells during use and provide constant lateral pressure. The numerous discretely distributed support plates create a significant divergence effect during fluid flow, forming a more uniform flow field within the heat exchange plate. The baffles guide the liquid heat exchange medium to fully expel air from the heat exchange plate upon its initial entry, and guide the medium to the far end of the opening, allowing for sufficient flow within the heat exchange plate and improving heat dissipation uniformity and heat exchange efficiency. Attached Figure Description

[0018] Figure 1 This is a partial structural schematic diagram of the forced convection thermal management structure of the battery module in this embodiment of the present invention;

[0019] Figure 2 This is a schematic diagram of the forced convection thermal management structure of the battery module in this embodiment of the present invention;

[0020] Figure 3 This is a schematic diagram of the busbar structure in the forced convection thermal management structure of the battery module in this embodiment of the present invention;

[0021] Figure 4 This is a schematic diagram of the internal structure of the busbar in the forced convection thermal management structure of the battery module in this embodiment of the present invention.

[0022] Figure 5 This is a schematic diagram of the internal structure of the heat exchange plate in the forced convection thermal management structure of the battery module in this utility model embodiment;

[0023] Figure 6 This is a cross-sectional schematic diagram of the connection between the heat exchange plate and the busbar in the forced convection thermal management structure of the battery module in this embodiment of the present invention.

[0024] Figure 7 This is a schematic diagram showing the angular relationship between the support plate and the heat exchange plate in the forced convection thermal management structure of the battery module in this embodiment of the present invention.

[0025] Explanation of key component symbols:

[0026] 10. Busbar; 110. Inflow cavity; 120. Outflow cavity; 130. Main inlet; 140. Main outlet; 150. Sub-inlet; 160. Sub-outlet; 170. Enclosure; 171. First snap-fit; 172. Screw hole; 20. Heat exchange plate; 210. Connecting seat; 220. Opening; 232. Second snap-fit; 233. Hole; 235. Groove; 243. Gap; 250. Support plate; 260. Baffle; 30. Battery cell; 40. Pressure constraint end plate;

[0027] The following detailed description, in conjunction with the accompanying drawings, will further illustrate this utility model. Detailed Implementation

[0028] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Several embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this utility model will be more thorough and complete.

[0029] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0030] 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 is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] Please see Figures 1 to 7 The forced convection thermal management structure of the battery module in this embodiment includes a busbar 10 and several heat exchange plates 20. In this embodiment, there are twelve heat exchange plates 20, and each heat exchange plate 20 has a battery cell 30 attached to each side. The battery cell 30 is a ternary lithium soft-pack battery cell with a capacity of 50Ah. The overall battery module has an energy of approximately 4.4 kWh. This embodiment achieves a dense parallel convection heat exchange interface, which can simultaneously dissipate heat from all the battery cells 30, significantly improving heat exchange efficiency. Furthermore, due to the parallel convection heat exchange interface, it effectively shortens the heat exchange flow path while improving heat exchange efficiency, thus avoiding increased flow resistance caused by excessive flow resistance between different battery cells 30, preventing insufficient or uneven heat exchange. In this embodiment, the maximum temperature rise of the battery pack under 5C charge / discharge conditions does not exceed 3 degrees Celsius. The heat exchange plate 20 is shaped to conform to the contour of the battery cell 30. In some embodiments, the heat exchange plate 20 is planar to accommodate the box-type or soft-pack battery cell 30. In other embodiments, the heat exchange plate 20 is curved to accommodate the cylindrical battery cell 30. Preferably, thermally conductive adhesive is provided between the battery cell 30 and the heat exchange plate 20 to improve heat exchange efficiency.

[0032] The internal portion of the manifold 10 is divided into at least one inflow cavity 110 and at least one outflow cavity 120. In this embodiment, the internal portion of the manifold 10 is divided into one inflow cavity 110 and two outflow cavities 120. The inflow cavity 110 is located in the middle of the manifold 10, and the outflow cavities 120 are located on both sides of the manifold 10. By further limiting the number and position of the inflow cavity 110 and the outflow cavity 120, the heat exchange medium can enter from the middle of the manifold and flow out from both sides, making the flow of the heat exchange medium in the heat exchange plate 20 faster and more uniform, thereby improving the heat exchange efficiency and heat exchange uniformity. The manifold 10 has a main inlet 130 and a main outlet 140 at its end. In this embodiment, the manifold 10 has one main inlet 130 and two main outlets 140 at its end. The main inlet 130 communicates with the inflow cavity 110 to introduce the heat exchange medium into the inflow cavity 110, and the main outlet 140 communicates with the outflow cavity 120 to discharge the heat exchange medium from the outflow cavity 120. In other words, by providing the main inlet 130 and the main outlet 140, the heat exchange medium can enter and exit the manifold 10. The number of inflow cavities 110 and outflow cavities 120 depends on the size of the battery cell 30; larger battery cells can have more inflow cavities 110 and outflow cavities 120. The main inlet 130 and the main outlet 140 are connected to external circulation and refrigeration equipment via pipes.

[0033] In this embodiment, both the heat exchange plate 20 and the busbar 10 are formed by surface-exposure photopolymerization 3D printing. The material used is photopolymerization 3D printing resin, mainly composed of hydrophobic monomers, reactive diluents, and photoinitiators, with the addition of silane modifiers and fluorination aids to improve water and chemical resistance. The wall thickness of the heat exchange plate 20 is 0.5 mm, and the wall thickness of the busbar 10 is 1 mm. Approximately fifty support plates 250 are used, each 1.5 mm thick, and the part forming speed is 1.2 liters per hour. After printing, residual resin is cleaned with alcohol, the support plates are removed, a second curing process is performed, and the surface is polished.

[0034] Understandably, both the main inlet 130 and the main outlet 140 are connected to an external cooling device. The external cooling device is used to store the heat exchange medium and to cool the heat exchange medium so as to realize the recycling of the heat exchange medium.

[0035] The manifold 10 is provided with sub-inlet groups corresponding to the number of inflow chambers and sub-outlet groups corresponding to the number of outflow chambers. Specifically, in this embodiment, the manifold 10 has one sub-inlet group and two sub-outlet groups. Each sub-inlet group includes several sub-inlets 150 that communicate with the inflow chamber 110 and are evenly spaced. Each sub-outlet group includes several sub-outlets 160 that communicate with the outflow chamber 120 and are evenly spaced. Understandably, the sub-inlets 150 are evenly spaced from one end of the manifold 10 to the other end, and the sub-outlets 160 are evenly spaced from one end of the manifold 10 to the other end. In this embodiment, the number of sub-inlets 150 is the same as the number of heat exchange plates 20, and each sub-inlet 150 has two corresponding sub-outlets 160.

[0036] The bottom of the heat exchange plate 20 is connected to at least one of the sub-inlet 150 and at least one of the sub-outlets 160. In this embodiment, the bottom of the heat exchange plate 20 is connected to one of the sub-inlet 150 and two of the sub-outlets 160.

[0037] Specifically, a connecting seat 210 is provided at the bottom of the heat exchange plate 20. Each connecting seat 210 has an opening 220 at its bottom that communicates with the interior of the heat exchange plate 20. A baffle 170 is provided on the manifold 10. The baffle 170 surrounds the sub-inlet 150 and the sub-outlet 160. The baffle 170 is used to accommodate the connecting seat 210 so that the opening 220 communicates with the sub-inlet 150 or the sub-outlet 160. Understandably, the heat exchange medium enters the inflow chamber 110 through the main inlet 130, and enters the heat exchange plate 20 through the sub-inlet 150 and the opening 220 corresponding to the position of the sub-inlet 150. After heat exchange is completed, it enters the outflow chamber 120 through the opening 220 corresponding to the position of the sub-outlet 160 and the sub-outlet 160, and is discharged through the main outlet 140.

[0038] The two inner sidewalls of the enclosure 170 are provided with first buckles 171, and the two outer sidewalls of the heat exchange plate 20 are provided with second buckles 232 distributed at intervals. The second buckles 232 are located inside the enclosure 170, and the edge of the second buckle 232 is provided with a groove corresponding to the first buckle 171, so that the first buckle 171 and the second buckle 232 form an interlocking structure during assembly.

[0039] The second buckle 232, the connecting seat 210, and the heat exchange plate 20 form a through hole 233. After the enclosure 170 is assembled, potting compound is injected into the enclosure 170. The potting compound wets all material surfaces within the enclosure 170 and flows into the hole 233. After hardening, it forms an interlocking rigid potting compound layer, creating a self-locking structure within the enclosure 170. The rigid potting compound layer, the heat exchange plate 20, and the manifold 10 are mutually anchored. In this embodiment, the potting compound is a hardening potting compound, which mainly consists of epoxy resin, curing agent, filler, and additives. After curing, its hardness is approximately Shore D90.

[0040] The heat exchange plate 20 has a cavity for accommodating the heat exchange medium, which is a liquid, gas, or gas-liquid phase change refrigerant. Densely arranged support plates 250 are disposed within the cavity, with their opposite ends connected to the two opposite inner sidewalls of the heat exchange plate 20. In this embodiment, the heat exchange medium is a mixture of pure water and 20% ethylene glycol, and is circulated for cooling or heating by an external water pump. The water pump flow rate is 5 liters per minute.

[0041] After impacting the support plate 250, the heat exchange medium can cause lateral dispersion, allowing it to flow fully and disperse evenly within the heat exchange plate 20.

[0042] The heat exchange plate 20 has a baffle 260 extending from its bottom to its top. The baffle 260 is used to transfer the heat exchange medium to the top of the heat exchange plate 20 to achieve uniform cooling. A gap 243 is left between the baffle 260 and the top of the heat exchange plate 20 to allow the heat exchange medium to flow from the sub-inlet 150 to the sub-outlet 160. By setting the baffle 260, when the heat exchange medium first enters the heat exchange plate 20, it can guide the heat exchange medium to expel the air inside the heat exchange plate 20.

[0043] The two opposite ends of the support plate 250 are respectively connected to the two opposite inner sidewalls of the heat exchange plate 20. The support plate 250 and the two inner sidewalls of the heat exchange plate 20 form an "N"-shaped inclined structure with an included angle of 35 degrees. The baffle 260 and the two inner sidewalls of the heat exchange plate also form an "N"-shaped inclined structure with an included angle of 35 degrees, so that the heat exchange plate 20 can accommodate the lateral expansion of the battery cell 30 during use and provide a constant supporting force.

[0044] The busbar 10 has pressure-constraining end plates 40 at both opposite ends, providing a lateral pressure of approximately 50 kPa. Several heat exchange plates 20 and several battery cells 30 are located between two pressure-constraining end plates 40. Understandably, a battery cell 30 at one end abuts against one of its pressure-constraining end plates 40, and a battery cell 30 at the other end abuts against the other pressure-constraining end plate 40. By providing two pressure-constraining end plates 40, the battery cells 30 and the heat exchange plates 20 can be compressed, improving the cycle life of the battery cells 30.

[0045] Two screw holes 172 are provided in each enclosure of the manifold 10 so that fasteners can pass through the screw holes 172 on the manifold 10 and connect to the heat exchange plate 20. In this embodiment, the fasteners are self-tapping screws.

[0046] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0047] The above-described embodiments are merely one implementation of this utility model, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, such as changes in the dimensions of the heat exchange plate and manifold, optimization of the flow channel topology, and changes in the number and position of the inlet and outlet, etc., all of which fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A forced convection thermal management structure for a battery module, characterized in that, The device includes a manifold and several heat exchange plates. The manifold is internally divided into at least one inflow chamber and at least one outflow chamber. The end of the manifold is provided with a main inlet communicating with the inflow chamber and a main outlet communicating with the outflow chamber, so that the heat exchange medium can enter and exit the manifold. The upper surface of the inflow chamber is provided with a sub-inlet, and the upper surface of the outflow chamber is provided with a sub-outlet. The bottom of the heat exchange plate is connected to the sub-inlet and the sub-outlet. The two opposite sides of the heat exchange plate abut against the battery cell.

2. The forced convection thermal management structure for the battery module according to claim 1, characterized in that, A connecting seat is provided at the bottom of the heat exchange plate, and an opening is provided at the bottom of the connecting seat. The opening corresponds to the sub-outlet and sub-inlet on the manifold. A enclosure is provided on the manifold, which surrounds the sub-inlet and the sub-outlet. The enclosure is used to accommodate and connect the connecting seat.

3. The forced convection thermal management structure for the battery module according to claim 2, characterized in that, The two inner sidewalls of the enclosure are provided with first buckles, and the two outer sidewalls of the heat exchange plate are provided with second buckles spaced apart. The edges of the second buckles are provided with grooves that match the shape of the first buckles, so that the first buckles and the second buckles form an interlocking structure during assembly.

4. The forced convection thermal management structure for the battery module according to claim 3, characterized in that, The second buckle, the connecting seat, and the heat exchange plate form a through hole. When potting compound is injected into the enclosure, the potting compound flows into the hole and hardens to form an interlocking hard potting compound layer, thereby forming a self-locking structure within the enclosure. The hard potting compound layer, the heat exchange plate, and the manifold are mutually anchored.

5. The forced convection thermal management structure for the battery module according to claim 1, characterized in that, The heat exchange plate has a cavity inside, which is used to contain the heat exchange medium, which is a liquid, gas or gas-liquid phase change refrigerant. The cavity is provided with densely arranged support plates, and the two opposite ends of the support plates are respectively connected to the two opposite inner sidewalls of the heat exchange plate.

6. The forced convection thermal management structure for the battery module according to claim 2, characterized in that, The heat exchange plate has a baffle extending from the bottom to the top. The baffle is used to transfer the heat exchange medium to the top of the heat exchange plate to achieve uniform cooling. A gap is left between the baffle and the top of the heat exchange plate so that the heat exchange medium flows from the sub-inlet to the sub-outlet.

7. The forced convection thermal management structure for the battery module according to claim 5, characterized in that, The support plate and the two inner sidewalls of the heat exchange plate have an "N"-shaped inclined structure, so that the heat exchange plate can be elastically compressed and the structure is stable.

8. The forced convection thermal management structure for the battery module according to claim 6, characterized in that, The baffle and the two inner walls of the heat exchange plate are in an "N"-shaped inclined structure to make the heat exchange plate elastically compressible and structurally stable.

9. The forced convection thermal management structure for the battery module according to claim 1, characterized in that, Pressure constraint end plates are provided at both opposite ends of the busbar, and several heat exchange plates and several battery cells are located between the two pressure constraint end plates.

10. The forced convection thermal management structure for the battery module according to claim 1, characterized in that, The manifold has several screw holes in each enclosure so that fasteners can pass through the screw holes on the manifold to connect to the heat exchange plate.

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