Built-in charging system for power battery

Abstract

The utility model relates to power battery pack technical field, concretely relates to a built -in charging system for power battery. It includes battery box, is equipped with charging layer, control layer and battery layer from top to bottom in battery box, each layer is separated through the baffle, charging layer sets up charger, control layer sets up battery controller, battery layer sets up battery package, three are mutually electric nature connection, the charger is fixed on the upper cap top, is protected by L type charger protection cover, and the protection cover is integrated with the cooling fan and display screen, and is equipped with the air inlet, and the battery box also is equipped with the air inlet, the alternating current input of charger connects the power grid, and the direct current output mouth links together with the battery pack charging mouth, and then is connected with the battery package. The utility model three -dimensional layered structure realizes function module physical isolation, and orderly integration of charging, control and battery each function layer, not only has improved the device integration, also reduced the system complexity and the failure risk, strengthened the overall reliability.

Description

Technical Field

[0001] This utility model relates to the field of power battery pack technology, and more specifically, to a built-in charging system for power batteries. Background Technology

[0002] In recent years, the widespread adoption of new energy vehicles has driven the rapid development of power battery technology, with charging efficiency and system integration becoming key research areas in the industry. Currently, mainstream solutions typically require power battery packs to be paired with independent external chargers, which connect to fixed charging stations or mobile charging devices via plug-in interfaces to replenish energy. While advancements in fast charging technology and charging station network construction have improved charging speed and convenience to some extent, the underlying logic still relies on the physical separation of the battery and charger.

[0003] Despite continuous technological optimization, existing solutions still have significant limitations: the binding relationship between external chargers and fixed charging stations prevents users from escaping location restrictions, making it difficult to achieve immediate power replenishment, especially in remote areas or emergency scenarios. At the same time, because the external charger and battery pack adopt a separate design, users must repeatedly physically connect the charger output terminal to the battery pack charging interface in different charging scenarios. Frequent plugging and unplugging of the charging interface can easily cause oxidation and wear of the connector's metal contacts. Long-term use may lead to problems such as poor contact and arc discharge, directly affecting charging safety and equipment lifespan. Utility Model Content

[0004] The purpose of this invention is to provide a built-in charging system for power batteries to solve the problems of limited charging scenarios and equipment damage caused by frequent plugging and unplugging of interfaces in the prior art due to reliance on external chargers.

[0005] To achieve the above objectives, a built-in charging system for power batteries is provided, including a battery box. The battery box contains, from top to bottom, a charging layer, a control layer, and a battery layer, all physically separated by partitions.

[0006] The upper and lower partitions of the control layer are coated with an electromagnetic shielding coating.

[0007] The partitions of the charging layer, control layer, and battery layer are all detachably and fixedly connected.

[0008] A charger is provided in the charging layer, a battery controller is provided in the control layer, and a battery pack is provided in the battery layer. The charger, battery controller, and battery pack are electrically connected through plug-in terminals.

[0009] In the above technical solution, by vertically separating the charging layer, control layer, and battery layer, the charger generates a large amount of heat due to energy loss during the power conversion process of converting AC to DC. Therefore, the charger is placed on the top layer and equipped with a heat dissipation system to prevent the high temperature generated from being conducted to the control layer and battery layer, thus affecting their function and stability. The control layer is placed in the middle, and its upper and lower partitions are coated with electromagnetic shielding coatings to shield electromagnetic interference between the charger and the battery pack, ensuring the signal stability of the battery controller. The battery pack is heavy and is placed on the bottom layer to lower the center of gravity of the overall structure and improve stability. The partitions of each layer are connected by bolts and electrically connected by plug-in terminals, allowing maintenance or replacement of a single functional layer. For example, when the charger fails, only the charging layer components need to be disassembled, without disassembling the entire system, thus improving maintenance efficiency.

[0010] Based on this, the charger is fixedly installed on the top cover, and a charger protective cover is also fixedly connected to the top cover. The charger protective cover is L-shaped and the horizontal plate completely covers the top of the charger. The horizontal plate of the charger protective cover integrates multiple cooling fans, and the cooling fans are located above the charger.

[0011] The charger protective cover has an air inlet on one side of the stand, and a battery box air inlet is located on the other side of the charger, corresponding to the side wall of the battery box.

[0012] In this technical solution, external cold air enters from both the air inlet of the protective cover and the air inlet of the battery box, flows laterally along the surface of the charger and absorbs heat, and is finally forced to be exhausted upward by the cooling fan. The horizontal airflow maximizes the contact heat dissipation area, and combined with the top active exhaust to accelerate heat exchange, it effectively prevents local high temperature of the charger and avoids heat diffusion to the lower layers, thus improving heat dissipation efficiency.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] 1. In this power battery's built-in charging system, the charger is integrated into the battery box. The battery box employs a layered design, with the charging layer, control layer, and battery layer physically separated by partitions. This compact and orderly layout improves the overall integration of the charging system, reduces the number of external components and connection complexity, and lowers the risk of system failure. Simultaneously, the compact structure saves space, facilitating installation and placement in different equipment or vehicles, thus improving space utilization.

[0015] 2. The built-in charging system of this power battery incorporates multiple cooling fans integrated into the charger's protective cover, working in conjunction with the air inlets of the protective cover and the battery box. Combined with the charger's own integrated cooling fan and fins, this allows the heat generated during charger operation to be quickly dissipated, preventing performance degradation and malfunctions caused by heat buildup. This excellent heat dissipation helps maintain the charger and battery within a suitable operating temperature range, improving the stability and reliability of the entire charging system, thereby ensuring the charging efficiency and lifespan of the power battery. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the overall cross-sectional structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the charger assembly of this utility model;

[0019] Figure 4 This is a schematic diagram of the airflow direction of the heat dissipation system of this utility model.

[0020] The meanings of the labels in the diagram are as follows:

[0021] 1. Charger protective cover; 2. Display screen; 3. Cooling fan; 4. Charger; 5. Battery controller; 6. Battery pack; 7. Battery box; 8. Battery pack charging port; 9. DC output port; 10. AC input port; 11. Top cover; 12. Protective cover air inlet; 13. Battery box air inlet. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0025] Please see Figures 1-2 As shown, the purpose of this embodiment is to provide a built-in charging system for power batteries, including a battery box 7. The battery box 7 has a rectangular parallelepiped structure, and its interior is divided into three independent cavities from top to bottom by horizontal partitions: a charging layer at the top, a control layer in the middle, and a battery layer at the bottom. The layers are physically isolated by metal partitions. The upper and lower partitions of the control layer are coated with an electromagnetic shielding coating to ensure electromagnetic interference shielding and heat zone management.

[0026] like Figure 2 As shown, the charging layer is located on the top layer of the battery box 7, and its main body is the charger 4. The charger 4 is fixed to the top surface of the cover 11 with bolts and is arranged horizontally. The charger 4 is covered by an L-shaped charger protective cover 1. The horizontal plate of the charger protective cover 1 completely covers the top area of ​​the charger 4, and the bottom of the vertical plate is fixed to the cover 11 with bolts. The two sides of the horizontal plate are also fixed to the battery box 7 with bolts. The charger protective cover 1 is made of aluminum alloy, which provides mechanical protection and heat dissipation. The charger 4 has an AC input port 10 on the left side for connecting to the external power grid, and a DC output port 9 on the right side. The DC output port 9 is directly connected to the battery pack charging port 8 fixed to the surface of the cover 11 through a cable, thus forming an electrical path with the lower battery pack 6.

[0027] like Figure 2As shown, the control layer is located directly below the charging layer, and a battery controller 5 is installed inside. The battery controller 5 is fixed to the center of the control layer partition by a bracket. It integrates various electronic components to support its functions, and establishes electrical connections with the upper charger 4 and the lower battery pack 6 through vertical wiring channels, realizing functions such as charging power regulation, battery status monitoring, and system fault diagnosis. The control layer partition adopts a double-layer metal shielding structure to effectively block electromagnetic interference generated by the upper charger 4 during operation. Figure 2 As shown, the battery layer occupies the lower half of the battery box 7 and contains a battery pack 6. The battery pack 6 adopts a modular design and is composed of multiple battery cell units connected in series and fixed in a dedicated frame. The positive and negative terminals of the battery pack 6 are electrically connected to the battery pack charging port 8 through plug-in terminals and wire harnesses.

[0028] like Figure 3 As shown, two sets of cooling fans 3 are embedded in the horizontal surface of the charger protective cover 1, with the axis of the cooling fans 3 facing the heat-generating components inside the charger 4. An LCD screen 2 is integrated at the front end of the horizontal plate. The screen 2 is connected to the battery controller 5 via a flexible circuit board, displaying information such as charging voltage, current, and remaining battery capacity in real time. A strip-shaped air inlet 12 is opened in the middle of the vertical plate of the charger protective cover 1, and a corresponding air inlet 13 is opened on the side wall of the battery compartment 7 on the right side of the charger 4, forming a bidirectional air intake channel. The charger 4 integrates a heat dissipation fin array and an axial flow fan. The heat dissipation fin array is arranged horizontally at 90° to the air inlet 12 of the protective cover and the air inlet 13 of the battery compartment, allowing the longitudinal airflow entering from the air inlet 12 of the protective cover and the air inlet 13 of the battery compartment to penetrate the gaps between the heat dissipation fins, creating a turbulence effect on the fin surface and improving heat exchange efficiency.

[0029] Working principle: such as Figure 4 As shown, during system operation, external cold air enters the charging layer through the air inlet 12 of the protective cover and the air inlet 13 of the battery box. Combined with the built-in cooling fan of the charger 4 and the heat dissipation fins next to the fan, the heat dissipation contact area is increased. The airflow flows laterally along the surface of the charger 4, carrying away heat, and is then forcibly exhausted by the top cooling fan 3. The charger 4 converts the AC power from the grid to DC power and charges the battery pack 6 through the DC output port 9. The battery controller 5 collects battery voltage and temperature parameters in real time, adjusting the charging power and controlling the speed of the cooling fan 3 accordingly. When an abnormal temperature rise or insulation fault is detected, the battery controller 5 immediately cuts off the charging circuit and triggers an audible and visual alarm.

[0030] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A built-in charging system for a power battery, comprising a battery box (7), characterized in that: The battery box (7) is provided with a charging layer, a control layer and a battery layer arranged sequentially from top to bottom. The charging layer, control layer and battery layer are physically separated by partitions, wherein: The upper and lower partitions of the control layer are coated with an electromagnetic shielding coating. The partitions of the charging layer, control layer, and battery layer are all detachably and fixedly connected. A charger (4) is provided in the charging layer, a battery controller (5) is provided in the control layer, and a battery pack (6) is provided in the battery layer. The charger (4), the battery controller (5), and the battery pack (6) are electrically connected through plug-in terminals.

2. The built-in charging system for power batteries according to claim 1, characterized in that: The charger (4) is fixedly installed above the top cover (11), and a charger protective cover (1) is also fixedly connected above the top cover (11).

3. The built-in charging system for power batteries according to claim 2, characterized in that: The charger protective cover (1) is L-shaped and the horizontal plate completely covers the top of the charger (4).

4. The built-in charging system for power batteries according to claim 3, characterized in that: The horizontal plate of the charger protective cover (1) integrates multiple cooling fans (3), and the cooling fans (3) are located above the charger (4); The horizontal plate of the charger protective cover (1) also integrates a display screen (2), which is electrically connected to the battery controller (5).

5. The built-in charging system for a power battery according to claim 3, characterized in that: The charger protective cover (1) has an air inlet (12) on its upright plate located on one side of the charger (4).

6. The built-in charging system for a power battery according to claim 5, characterized in that: The charger (4) has a battery box air inlet (13) on the other side corresponding to the side wall of the battery box (7).

7. The built-in charging system for power batteries according to claim 2, characterized in that: The charger (4) has an AC input port (10) on one side and a DC output port (9) on the other side.

8. The built-in charging system for a power battery according to claim 7, characterized in that: The DC output port (9) is electrically connected to the battery pack charging port (8), which is fixedly connected above the top cover (11) and is electrically connected to the battery pack (6).

9. The built-in charging system for a power battery according to claim 1, characterized in that: The battery controller (5) has multiple sets of electronic components inside, all of which are fixedly connected to the control layer partition.

10. The built-in charging system for a power battery according to claim 1, characterized in that: The battery layer is provided with a battery pack fixing frame, and the battery pack (6) is fixedly installed in the frame.

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