A large capacity battery assembly and battery pack

Abstract

This utility model belongs to the field of batteries, specifically a large-capacity battery module and battery pack. It overcomes the problem of excessive localized heat at the terminals of existing individual batteries, leading to thermal runaway. The large-capacity battery module includes a battery module and two heat exchange components. The battery module includes individual batteries; each heat exchange component includes a heat exchange component body; the heat exchange component body has at least one cooling channel; the inner wall of the cooling channel is provided with an insulating layer; the two heat exchange components are welded to the polarity terminals of n individual batteries respectively, realizing parallel connection between the individual batteries, and heat exchange is achieved between the cooling water in the cooling water channel and the polarity terminals. The battery pack includes multiple large-capacity battery modules; the heat exchange components on each large-capacity battery module are interconnected to form a battery pack liquid circuit system, realizing heat exchange within the battery pack. The heat generated by the polarity terminals is conducted to the heat exchange components in close contact with them and dissipated through heat exchange, achieving efficient heat dissipation.

Description

Technical Field

[0001] This utility model belongs to the field of batteries, specifically a high-capacity battery component and battery pack. Background Technology

[0002] Currently, most common battery modules are composed of multiple batteries connected together electrically.

[0003] Temperature control of battery modules has always been a hot topic in this field. Most existing battery modules use air cooling or liquid cooling to control the temperature of the entire battery module. However, since the terminals of individual cells in the battery module are the parts with the most concentrated heat, if the local heat of the terminals is too high, it is very likely to cause thermal runaway of individual cells in the battery module, which will seriously affect the safety and performance of the battery module and the battery pack it constitutes. Summary of the Invention

[0004] The purpose of this invention is to provide a high-capacity battery component and battery pack that overcomes the problem of excessive local heat at the terminals of existing single-cell batteries, which leads to thermal runaway.

[0005] The first aspect of this utility model provides a large-capacity battery assembly, including a battery module and two heat exchange components;

[0006] The aforementioned battery module includes n individual battery cells arranged along a first direction, where n is an integer greater than 1;

[0007] The heat exchanger includes a heat exchanger body; at least one cooling channel is provided on the heat exchanger body, the cooling channel extends along the length of the heat exchanger body and passes through both ends of the heat exchanger body; an insulating isolation layer is provided on the inner wall of the cooling channel to form a cooling water flow channel; the heat exchanger body is a conductor, and the insulating isolation layer realizes the insulation isolation between the cooling water and the heat exchanger body.

[0008] Both heat exchange components extend along the first direction. One of them is welded to the positive polarity terminal of n individual cells, and the other is welded to the negative polarity terminal of n individual cells, so as to realize the parallel connection between individual cells and the heat exchange is based on the cooling water in the cooling water channel and the polarity terminal.

[0009] This invention fixes a heat exchange component on the polar terminal (the polar terminal can be a terminal post or an integral structure after connecting a terminal post extension component to the terminal post). The heat generated by the battery polar terminal is conducted to the heat exchange component in close contact with it and dissipated through heat exchange, thereby achieving efficient heat dissipation.

[0010] Meanwhile, the heat exchanger body of this invention is a conductor and is connected to the polarity terminal, enabling parallel connection between individual battery cells. Therefore, in this invention, the heat exchanger not only serves as a heat exchange component but also as a current collector to achieve parallel connection of multiple individual battery cells, offering at least the following advantages:

[0011] Firstly, it eliminates the need for additional dedicated busbars, simplifying the overall structure of large-capacity battery modules. Secondly, since the heat exchange components simultaneously perform heat exchange and electrical conduction functions, it reduces the number of parts in large-capacity battery modules, thereby lowering assembly difficulty and cost.

[0012] Furthermore, this invention also incorporates an insulating layer on the inner wall of the cooling channel of the heat exchanger. This insulating layer provides insulation between the heat exchanger body and the cooling water, enabling heat exchange via water cooling. Compared to insulating oil cooling, water cooling better meets the efficient, economical, and environmentally friendly cooling requirements of battery systems.

[0013] Furthermore, in this invention, the polarity terminal is welded to the heat exchanger, which enables a tight connection between the polarity terminal and the heat exchanger. Compared with other connection methods, such as simple mechanical fixing, welding eliminates the tiny gaps between the connection parts, greatly reduces thermal resistance, improves the heat conduction efficiency between the two, and ensures effective heat transfer. Welding connection can also enhance the connection stability between the two, preventing the heat exchanger from separating from the polarity terminal due to vibration and other factors when the large-capacity battery module is working, thereby affecting the heat dissipation effect.

[0014] Furthermore, the aforementioned insulating layer adopts at least the following two structures:

[0015] The first structure: The insulating layer is a pipe nested within the cooling channel. The corresponding cooling channel can be a through hole opened in the heat exchanger body, or it can be a slotted structure. The slotted cooling channel helps to simplify the internal structure of the heat exchanger and makes the assembly of the heat exchanger body and the pipe more convenient.

[0016] The second structure: the insulating layer is an insulating coating applied to the inner wall of the cooling channel, and the corresponding cooling channel is a through hole opened on the heat exchanger body.

[0017] Furthermore, the aforementioned cooling channels consist of two sections, each with an insulating layer on its inner wall, forming two cooling water channels; one cooling water channel is the inlet channel, and the other is the outlet channel.

[0018] Furthermore, a first through groove extending in a first direction is formed on the aforementioned polarity terminal; the heat exchanger is fitted into the first through groove of each polarity terminal, and the outer wall of the heat exchanger is welded and fixed to the two side walls of the first through groove.

[0019] A first through slot is made on the terminal extension to hold the heat exchanger in place, ensuring good thermal contact between the heat exchanger and the polarity terminal. When heat is conducted to the polarity terminal, it is further transferred to the heat exchanger. The heat rapidly diffuses within the heat exchanger and is dissipated through the heat transfer medium inside the heat exchanger cavity and through heat exchange with the surrounding environment, thus achieving heat dissipation for the battery.

[0020] Furthermore, at least one groove is formed on the outer wall of the heat exchanger body, and the groove extends along the length direction of the heat exchanger body.

[0021] The outer wall of the heat exchanger body and the inner wall of the first through groove are coated with thermally conductive adhesive, and at least a portion of the inner cavity of the groove contains thermally conductive adhesive.

[0022] This invention introduces a thermally conductive adhesive, which, compared to traditional solid contact methods, enhances the thermal conductivity and connection strength between the polar terminals and the heat exchanger body. During assembly, even if there are differences in surface shape and roughness between the outer wall of the heat exchanger body and the mounting part, the thermally conductive adhesive can still fill tightly, ensuring uniform heat transfer between the polar terminals and the heat exchanger body.

[0023] Furthermore, the groove on the outer wall of the heat exchanger body in this invention can at least serve as a glue-receiving groove, and has the following functions:

[0024] 1) Anti-overflow adhesive control: During installation, when the heat exchanger is inserted into the first through groove, it can accommodate the excess adhesive squeezed out by the heat exchanger, preventing the adhesive from overflowing and causing pollution.

[0025] 2) Enhanced contact efficiency: The groove structure increases the contact area between the heat exchanger and the colloid, strengthens the heat transfer path, and improves the bonding stability by using a larger bonding surface, preventing loosening and falling off during long-term use.

[0026] Furthermore, the aforementioned polarity terminal includes a pole post and a pole post extension fixed on the pole post; and the top of the pole post extension body is higher than the top of the pole post; and a safe electrical conduction distance is maintained between the bottom surface of the aforementioned pole post extension and the top plate of the outer casing.

[0027] If the traditional pole is too low, it is difficult to fix the heat exchanger on it. This utility model increases the overall height of the pole by fixing the pole extension to the pole, which provides convenient conditions for the installation of the heat exchanger.

[0028] Furthermore, mounting holes are provided on the aforementioned pole extension; a portion of the aforementioned pole structure is inserted into the mounting holes and fixed.

[0029] This invention, by creating mounting holes in the electrode extension, allows for quick initial positioning during assembly simply by inserting the electrode into these holes. This eliminates the need for complex installation processes and specialized tools, significantly improving production efficiency and laying a solid foundation for large-scale production. After insertion, reliable fixing methods such as interference fit, welding, or threaded connection can be selected according to actual needs to firmly integrate the electrode and the extension, forming a new polarity terminal with significantly increased height.

[0030] Furthermore, the aforementioned mounting hole is a stepped through hole, with the inner diameter of the large-diameter section being larger than the outer diameter of the pole post, forming a welding cavity; the inner diameter of the small-diameter section matches the outer diameter of the pole post; part of the pole post structure is inserted into the small-diameter section, and the top end face of the pole post is flush with the bottom of the hole in the large-diameter section.

[0031] The bottom of the aforementioned large-diameter section serves as the welding surface, which is welded to the top end face of the pole post, and the depth of the large-diameter section is greater than or equal to the weld height.

[0032] After the heat exchanger is installed in the first through slot of the electrode extension, the depth of the large-diameter section is not less than the weld height, which effectively separates the heat exchanger from the weld. This means that even if the weld flatness is not perfect, it will not affect the contact between the heat exchanger and the bottom of the first through slot. In this way, heat can be smoothly transferred from the electrode and electrode extension to the heat exchanger, maintaining heat dissipation efficiency, avoiding battery overheating, ensuring performance, and extending service life.

[0033] Furthermore, the battery module also includes a housing with an explosion vent; n individual batteries are arranged inside the housing; the top plate of the housing has clearance holes corresponding to the polarity terminals of each individual battery; the polarity terminals of each individual battery extend out of the corresponding clearance holes, and the area corresponding to each clearance hole on the top plate of the housing is sealed to the top cover of the corresponding individual battery.

[0034] Inside the aforementioned casing, the internal cavities of each individual battery cell are interconnected; the electrolyte and / or gas are shared among the individual batteries.

[0035] The heat exchanger body is connected to the portion of each individual battery cell whose polarity terminal extends out of the corresponding clearance hole.

[0036] The electrolyte and / or gas inside each individual cell are interconnected, so that the electrolyte and / or gas of all individual cells are in the same system, reducing the differences between individual cells and improving the consistency between individual cells to a certain extent, thereby improving the cycle life of large-capacity battery modules to a certain extent.

[0037] Furthermore, the edge of each clearance hole near the individual battery is sealed to the corresponding individual battery cover plate by filler wire welding; or, the battery module also includes 2n hollow components; the 2n hollow components pass through the clearance holes and are fitted around each terminal post, the bottom of the hollow component is laser welded to the first area of ​​the corresponding individual battery, and the top of the hollow component is laser welded to the second area of ​​the outer shell top plate.

[0038] The first region mentioned above is the area surrounding any electrode post in the upper cover plate of any of the aforementioned individual cells;

[0039] The second region mentioned above is the area corresponding to any one of the clearance holes on the top plate of the outer casing.

[0040] Furthermore, the battery module also includes 2n insulating seals; each of the 2n insulating seals is disposed in the gap between the terminal post and the clearance hole of each individual battery cell; the terminal post extension applies pressure to the insulating seal along the height direction of the terminal post, so that the insulating seal is compressed and seals the gap between the terminal post and the clearance hole.

[0041] This invention utilizes 2n insulating seals and applies pressure along the height of the electrode post using an extension member to compress it, effectively filling the gap between the electrode post and the clearance hole, forming a tight and stable sealing structure. This ensures that harmful fumes can only escape through the predetermined vent in the event of thermal runaway, avoiding leakage problems caused by sealing defects, effectively protecting the structural integrity of the large-capacity battery module, and significantly reducing the risk of thermal runaway hazard diffusion.

[0042] Furthermore, the aforementioned insulating seal includes a flexible insulating sealing ring; the aforementioned flexible insulating sealing ring has a flexible stepped structure, the small diameter section of the stepped structure extends into the clearance hole and contacts the top cover plate of the single cell, the large diameter section of the stepped structure is located outside the outer casing, the end face of the large diameter section near the small diameter section contacts the top plate of the outer casing, and the end face away from the small diameter section contacts the aforementioned pole post extension.

[0043] The stepped structure of the flexible insulating sealing ring fits snugly against the clearance hole, the top cover of the individual battery cell, and the top plate of the outer casing on multiple sides. The smaller diameter section inserts into the clearance hole and makes tight contact with the top cover of the individual battery cell, while the larger diameter section is located outside the outer casing, with its two end faces contacting the top plate of the outer casing and the terminal extension, respectively. Under the pressure of the terminal extension, the gaps are filled, ensuring reliable sealing even if the internal pressure of the battery fluctuates or is subjected to vibration, thus improving the battery's sealing performance.

[0044] In addition, the stepped structure allows the flexible insulating sealing ring to be subjected to more uniform force. The end face of the large-diameter section contacts the top plate of the outer shell and the pole extension, which disperses the pressure and prevents the sealing ring from deforming due to excessive local stress, ensuring the long-term reliability and stability of the sealing structure.

[0045] Furthermore, the aforementioned insulating seal also includes a pressure ring; the pressure ring is a metal part and is disposed between the large-diameter section of the flexible insulating seal ring and the pole extension.

[0046] The metal pressure ring, with its excellent rigidity and pressure resistance, is positioned between the large-diameter section of the flexible insulating sealing ring and the terminal extension. This allows for a more even and stable transfer of pressure applied by the terminal extension to the flexible insulating sealing ring. Compared to relying solely on the terminal extension to directly act on the sealing ring, the pressure ring avoids pressure concentration that could lead to excessive localized deformation or damage. It ensures that the sealing ring is fully compressed throughout, further filling the gap between the terminal and the clearance hole, forming a tighter and more reliable sealing structure, effectively improving the overall sealing performance of the battery.

[0047] This invention can also employ the following two methods to form two seals at the clearance hole, further improving the sealing performance between the pole and the clearance hole:

[0048] Method 1: The edge of each clearance hole closest to the individual battery is welded to the corresponding individual battery cover plate using filler wire welding to achieve a sealed connection.

[0049] Method 2: The above-mentioned high-capacity battery assembly also includes 2n hollow components; the 2n hollow components pass through the clearance holes and are fitted around each terminal post, the bottom of the hollow component is laser-welded to the first area of ​​the corresponding single cell, and the top of the hollow component is laser-welded to the second area of ​​the above-mentioned outer shell top plate.

[0050] The first region mentioned above is the area surrounding any electrode post in the upper cover plate of any of the aforementioned individual cells;

[0051] The second region mentioned above is the region corresponding to any one of the clearance holes on the top plate of the outer casing;

[0052] The aforementioned insulating seal is located between the pole and the hollow component, sealing the gap between the pole and the hollow component.

[0053] The second aspect of this utility model provides a battery pack, including multiple high-capacity battery components as described above; the heat exchange components on each high-capacity battery component are interconnected to form a battery pack liquid circuit system to realize heat exchange of the battery pack.

[0054] Furthermore, the inlet channels of multiple heat exchangers are connected in series to form a total inlet path; the outlet channels of multiple heat exchangers are connected in series to form a total outlet path; the end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section.

[0055] After the coolant enters the inlet end of the main water inlet path, it flows through the inlet channels of each heat exchanger in sequence, and then through the outer pipe section, it flows through the outlet channels of each heat exchanger in sequence, and flows out from the outlet end of the main water outlet path.

[0056] Within a single heat exchanger, the coolant forms an efficient heat exchange through adjacent inlet and outlet channels, ensuring that each polarity terminal receives a balanced heat dissipation effect. For all heat exchangers, the temperature difference between the inlet and outlet channels remains essentially constant, effectively avoiding localized overheating or undercooling phenomena present in traditional series cooling (traditional series cooling: the coolant gradually heats up as it flows from the main inlet to the main outlet, resulting in a lower battery temperature near the main inlet and a higher battery temperature at the main outlet).

[0057] The beneficial effects of this utility model are:

[0058] This invention fixes a heat exchange component on the polar terminal (the polar terminal can be a terminal post or an integral structure after connecting a terminal post extension component to the terminal post). The heat generated by the battery polar terminal is conducted to the heat exchange component in close contact with it and dissipated through heat exchange, thereby achieving efficient heat dissipation.

[0059] Meanwhile, the heat exchanger body of this invention is a conductor and is connected to the polarity terminal, enabling parallel connection between individual battery cells. Therefore, in this invention, the heat exchanger not only serves as a heat exchange component but also as a current collector to achieve parallel connection of multiple individual battery cells, offering at least the following advantages:

[0060] Firstly, it eliminates the need for additional dedicated busbars, simplifying the overall structure of large-capacity battery modules. Secondly, since the heat exchange components simultaneously perform heat exchange and electrical conduction functions, it reduces the number of parts in large-capacity battery modules, thereby lowering assembly difficulty and cost.

[0061] Furthermore, this invention also incorporates an insulating layer on the inner wall of the cooling channel of the heat exchanger. This insulating layer provides insulation between the heat exchanger body and the cooling water, enabling heat exchange via water cooling. Compared to insulating oil cooling, water cooling better meets the efficient, economical, and environmentally friendly cooling requirements of battery systems.

[0062] Furthermore, in this invention, the polarity terminal is welded to the heat exchanger, which enables a tight connection between the polarity terminal and the heat exchanger. Compared with other connection methods, such as simple mechanical fixing, welding eliminates the tiny gaps between the connection parts, greatly reduces thermal resistance, improves the heat conduction efficiency between the two, and ensures effective heat transfer. Welding connection can also enhance the connection stability between the two, preventing the heat exchanger from separating from the polarity terminal due to vibration and other factors when the large-capacity battery module is working, thereby affecting the heat dissipation effect. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the structure of the large-capacity battery module in Example 1;

[0064] Figure 2 This is a schematic diagram of the exploded structure of the large-capacity battery module in Example 1;

[0065] Figure 3 This is a cross-sectional view of the high-capacity battery assembly in Example 1;

[0066] Figure 4 This is a schematic diagram of the structure of a heat exchanger in Example 1;

[0067] Figure 5 This is a schematic diagram of the exploded structure of a heat exchanger in Example 1;

[0068] Figure 6 This is a cross-sectional view of a heat exchanger in Example 1;

[0069] Figure 7 This is a schematic diagram of another heat exchanger in Example 1;

[0070] Figure 8 This is an exploded structural diagram of another heat exchanger in Example 1;

[0071] Figure 9 This is a partially enlarged structural schematic diagram of a heat exchanger in Example 1;

[0072] Figure 10 This is a first-view structural diagram of the battery pack in Example 1;

[0073] Figure 11 This is a second-view structural diagram of the battery pack in Example 1;

[0074] Figure 12 This is a schematic diagram of the heat exchanger structure in Example 2;

[0075] Figure 13 This is a cross-sectional view of the heat exchanger in Example 2;

[0076] Figure 14 This is a schematic diagram of the structure of the first heat exchanger in Example 4;

[0077] Figure 15 This is a cross-sectional view of the first heat exchanger in Example 4;

[0078] Figure 16 This is a schematic diagram of the structure of the second type of heat exchanger in Example 4;

[0079] Figure 17 This is a cross-sectional view of the second type of heat exchanger in Example 4;

[0080] Figure 18 This is a schematic diagram of the structure of the third type of heat exchanger in Example 4;

[0081] Figure 19This is a cross-sectional view of the third type of heat exchanger in Example 4;

[0082] Figure 20 This is a first-view structural diagram of the battery pack in Example 4;

[0083] Figure 21 This is a second-view structural diagram of the battery pack in Example 4;

[0084] Figure 22 This is a schematic diagram of the pole extension component in Example 5;

[0085] Figure 23 This is a cross-sectional view of the pole extension in Example 5;

[0086] Figure 24 This is a schematic diagram of the structure of the electrode extension piece installed on the single cell in Example 5;

[0087] Figure 25 This is a schematic diagram of the installation process of the single cell and the terminal extension in Example 5;

[0088] Figure 26 This is a cross-sectional view of the electrode extension piece installed on the single cell in Example 5;

[0089] Figure 27 This is a schematic diagram of the structure of the large-capacity battery module in Example 6;

[0090] Figure 28 This is a cross-sectional view of the high-capacity battery assembly in Example 6;

[0091] Figure 29 This is a first-view structural diagram of the battery pack in Example 6;

[0092] Figure 30 This is a cross-sectional view of the high-capacity battery assembly in Example 7;

[0093] Figure 31 This is a cross-sectional view of the high-capacity battery assembly in Example 8;

[0094] Figure 32 This is a partial cross-sectional view of the high-capacity battery assembly in Example 8;

[0095] The attached figures are labeled as follows:

[0096] 1. Heat exchanger; 11. Heat exchanger body; 12. Stepped structure; 13. Cooling channel; 14. Metal pipe; 15. Insulation layer; 16. Groove; 17. First heat exchanger; 18. Second heat exchanger; 19. Ceramic pipe; 10. Metal reinforcement layer; 111. Water inlet channel; 112. Water outlet channel; 2. Battery module; 3. Single cell; 31. Polar terminal; 311. Terminal post; 312. Terminal post extension; 313. First through groove; 314. Mounting hole; 3141. Large diameter section; 3142. Small diameter section; 315. Terminal post extension body; 316. Electrical connection post; 4. Outer shell; 41. Clearance hole; 5. Electrolyte sharing chamber; 6. Gas sharing chamber; 7. Insulating seal; 71. Flexible insulating sealing ring; 72. Pressure ring; 8. Hollow component. Detailed Implementation

[0097] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.

[0098] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0099] In the description of this utility model, it should be noted that the terms "top," "bottom," 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 do not indicate or imply that the device or element 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. Furthermore, the terms "first," "second," "third," "fourth," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0100] This utility model relates to a high-capacity battery assembly, including a battery module and a heat exchanger. The battery module is mainly composed of multiple individual cells. The heat exchanger is welded to the polarity terminals of the individual cells. While cooling the polarity terminals through water cooling, it can also realize the parallel connection between individual cells.

[0101] In the field of battery thermal management, common liquid cooling methods mainly use liquids such as water and insulating oil as cooling media, relying on a circulation system to achieve heat exchange. Among these, water has significant advantages over liquid cooling media such as insulating oil.

[0102] Regarding cooling efficiency: the specific heat capacity of water is 4.2 × 10⁻⁶. 3 The thermal conductivity is approximately 0.6 W / (m·K), while the specific heat capacity of insulating oil is 1.6 × 10⁻⁶ W / (kg·℃). 3 J / (kg·℃)-2.5×10 3 Its thermal conductivity is between 0.1 and 0.15 W / (m·K), with a J / (kg·℃) value. Therefore, compared to insulating oil, water can more efficiently remove heat from the battery's polarity terminals.

[0103] In terms of cost: insulating oil is relatively expensive; water is widely available and inexpensive.

[0104] In terms of environmental protection: Insulating oil leaks are difficult to degrade and pollute the environment; water leaks are harmless and produce no waste.

[0105] In summary, water cooling offers significant advantages over insulating oil cooling in the selection of heat exchanger cooling methods, better meeting the high-efficiency, economical, and environmentally friendly cooling requirements of battery systems. Therefore, this invention adopts water cooling and designs a specific heat exchanger structure based on this, as follows:

[0106] To enable the parallel connection of heat exchange components, the body of the heat exchanger must be a conductor, based on the connection between the conductor and the polarity terminal of the individual battery.

[0107] To achieve the function of cooling polarized terminals using water cooling, at least one cooling channel running through both ends of the main body is provided. To prevent short circuits caused by contact between the conductor and the cooling water, and to prevent safety issues caused by the cooling water becoming electrified, an insulating layer needs to be installed in the cooling channel to achieve insulation isolation between the cooling water and the conductor.

[0108] It should be noted that:

[0109] 1. The polar terminal described in this utility model can be a single battery terminal post, or it can be an integral structure of a single battery terminal post and a terminal post extension member connected thereto.

[0110] 2. The aforementioned insulating layer can be a pipe nested within the cooling channel, with insulation between the pipe and the inner wall of the cooling channel. Specifically, it can be a metal pipe with an insulating layer on its outer wall; or it can be an insulated pipe directly; the aforementioned insulating layer can also be an insulating coating applied to the inner wall of the cooling channel.

[0111] 3. The above-mentioned cooling channels can be two, each with an insulating layer on its inner wall, forming two cooling water channels; one cooling water channel is the inlet channel and the other is the outlet channel; in the battery pack, multiple inlet channels are connected in series to form a total inlet path; multiple outlet channels are connected in series to form a total outlet path; the end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section.

[0112] After entering the main inlet, the coolant flows through one inlet channel of each heat exchanger in sequence, and then through the external pipe section, flows through the outlet channel of each heat exchanger in sequence, and flows out from the main outlet.

[0113] 4. The above-mentioned battery modules may include at least the following three types:

[0114] Type 1 battery module:

[0115] The first type of battery module includes n individual batteries arranged along a first direction, where n is an integer greater than 1;

[0116] For ease of description, in this utility model, the arrangement direction of the individual battery cells is defined as the x-direction; the height direction of the individual battery cells is defined as the z-direction; and the direction perpendicular to both the x and z directions is defined as the y-direction.

[0117] Second type of battery module:

[0118] The second type of battery module adds at least one electrolyte sharing pipeline to the first type of battery module. Based on the electrolyte sharing pipeline, the electrolyte areas inside the cavities of multiple individual cells are connected to achieve electrolyte sharing, reduce the differences between individual cells, and optimize the cycle performance of the battery module. It may also include a gas sharing pipeline, which connects the gas areas inside the cavities of multiple individual cells to achieve gas balance and further optimize the cycle performance of the battery module.

[0119] Third type of battery module:

[0120] The third type of battery module, based on the first type of battery module, adds a shell, with multiple individual batteries arranged along the x-direction and placed inside the shell cavity.

[0121] The outer casing is equipped with an explosion vent, through which thermal runaway fumes are discharged.

[0122] This utility model does not specifically limit the above-mentioned shell structure, but at least the following two structures can be adopted:

[0123] The first structure includes a first cylinder with open ends (i.e., the port parallel to the yz plane is an open end) and end plates fixed to the two open ends of the first cylinder (i.e., the end plates are parallel to the yz plane).

[0124] The second structure includes a second cylinder with open ends at the top and bottom (i.e., the port parallel to the xy plane is the open end) and a top plate and a bottom plate respectively fixed to the open ends at the top and bottom of the second cylinder (i.e., the top plate and the bottom plate are both parallel to the xy plane, and the bottom plate or the top plate can be an integral structure with the second cylinder).

[0125] The top plate of the outer casing (here, the top plate of the first cylindrical body in the first structure, and the top plate in the second structure) has clearance holes corresponding to the polarity terminals of each individual battery cell; the polarity terminals of each individual battery cell extend out of the corresponding clearance holes, and the area corresponding to each clearance hole on the top plate of the outer casing is sealed to the top cover plate of the corresponding individual battery cell. The area corresponding to the clearance hole can be the wall of the clearance hole, or it can be the area surrounding the clearance hole on the top plate of the outer casing.

[0126] Inside the casing, the internal cavities of each individual cell are interconnected, enabling electrolyte sharing and / or gas balance, thereby reducing the differences between individual cells within the casing and improving the performance of high-capacity batteries.

[0127] The internal cavities of individual cells can usually be connected through a shared chamber located within the casing.

[0128] It should be noted that:

[0129] The aforementioned shared chamber can be an electrolyte shared chamber, with its inner cavity connected to the inner cavities of each individual battery cell. This shared chamber ensures that each individual battery cell is in a uniform electrolyte environment, guaranteeing electrolyte homogeneity and improving the performance and charge-discharge cycle life of the battery module. The electrolyte shared chamber described here is a liquid channel extending along the length (x-direction) of the casing between the casing's bottom plate and each individual battery cell. This liquid channel can be integrally formed with the casing's bottom plate or formed by providing a support between the lower cover plate of the individual battery cell and the casing's bottom plate. It should be noted that in the first type of casing structure, the casing's bottom plate here is the first cylindrical bottom plate; in the second type of casing structure, the casing's bottom plate here is a base plate.

[0130] The aforementioned shared chamber can also be a gas-sharing chamber located on the top plate of the outer casing, covering the gas inlets on the top of each individual battery cell.

[0131] It should be noted that in the first type of shell structure, the shell top plate here is the first cylinder top plate; in the second type of shell structure, the shell top plate here is the top plate.

[0132] It should also be noted that the gas port here has the following two meanings:

[0133] 1) The gas port is a through hole directly opened on the top cover of the single cell and penetrating the inner cavity of the single cell;

[0134] At this time, the gas-sharing chamber is connected to the gas area of ​​each individual cell through the gas port. Based on the gas-sharing chamber, the gas areas of each individual cell can be connected to achieve gas balance, so that the gas of each individual cell is shared to ensure the consistency of each individual cell and improve the cycle life of the battery module to a certain extent. When any individual cell experiences thermal runaway, the flue gas in the inner cavity of that individual cell enters the gas-sharing chamber and is discharged through the gas-sharing chamber, improving the safety of the battery module.

[0135] 2) The gas port is a vent or explosion-proof port installed on the top cover of the individual battery, and a vent membrane is provided at the vent or explosion-proof port.

[0136] At this time, the gas sharing chamber is used as a venting channel. When the venting membrane at the gas port of any single battery cell is ruptured by the flue gas in the inner cavity, the inner cavity of that single battery cell and the gas sharing chamber are connected, and the flue gas inside is discharged through the gas sharing chamber, thereby improving the safety of the battery module.

[0137] The aforementioned shared chamber can also be a gas-liquid shared chamber. Through a gas-liquid shared chamber, each individual battery cell can be placed in a unified electrolyte environment and gas environment, thereby improving the performance of the battery module and its charge-discharge cycle life.

[0138] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0139] Example 1

[0140] like Figure 1 , Figure 2 and Figure 3 The figures shown are a schematic diagram, an exploded view, and a cross-sectional view of the large-capacity battery module of this embodiment. As can be seen from the figures, the large-capacity battery module of this embodiment includes the first type of battery module and two heat exchange components 1.

[0141] As shown in the figure, the battery module 2 in this embodiment includes 12 individual battery cells 3 arranged along the x-direction. In this embodiment, the individual battery cells 3 are prismatic cells, and each individual battery cell 3 has an electrolyte region and a gas region inside its cavity. In other embodiments, the number of individual battery cells 3 can be adjusted according to actual needs, and the shape of the individual battery cells 3 can also be adjusted according to actual needs.

[0142] Each individual cell 3 has a terminal extension 312 connected to its terminal post 311 as a polarity terminal 31.

[0143] Each pole extension 312 is provided with a heat exchanger 1 mounting structure to fix the heat exchanger 1, and the heat exchange of the battery module 2 is realized based on the heat exchanger 1.

[0144] from Figure 2 and Figure 3 As can be seen from the diagram, in this embodiment, a first through groove 313 is formed on the pole extension 312 as a mounting structure for the heat exchanger 1. The first through groove 313 extends through the pole extension 312 along a first direction, and its inner cavity is used to install the heat exchanger 1.

[0145] The inner cavity shape of the first through groove 313 is adapted to the cross-sectional shape of the heat exchanger 1, ensuring that the heat exchanger 1 is tightly clamped within it. This ensures installation stability while also guaranteeing the heat transfer effect between the heat exchanger 1 and the pole extension 312. As can be seen from the figure, this embodiment uses a rectangular first through groove 313, and the heat exchanger 1 adapted to it is a square tube.

[0146] In some other embodiments, the heat exchanger 1 can also be directly welded to the outer wall of the electrode extension 312. However, compared to this embodiment, the contact area between the heat exchanger 1 and the electrode extension 312 is smaller, limiting the heat exchange effect of the heat exchanger 1. In contrast, in this embodiment, the first through groove 313 achieves a large-area surface contact between the heat exchanger 1 and the electrode extension 312, allowing heat to be quickly and evenly conducted from the electrode extension 312 to the heat exchanger 1, significantly improving the heat transfer rate and more effectively maintaining the appropriate operating temperature of the battery.

[0147] like Figure 4 , Figure 5 and Figure 6 As shown, the heat exchanger 1 in this embodiment includes a heat exchanger body 11, the overall structure of which can serve as a busbar, connecting to the polarity terminal 31 of the same polarity in the battery module 2, thereby realizing the parallel connection between the individual cells 3 of the large-capacity battery assembly. It can be made of a metal material with good electrical and thermal conductivity, such as silver, copper, or aluminum. However, considering both cost and electrical and thermal conductivity, aluminum is generally chosen as the material for the heat exchanger body 11.

[0148] In this embodiment, a cooling channel 13 is formed on the heat exchanger body 11. The cooling channel 13 extends along the length of the heat exchanger body 11 and passes through both ends of the heat exchanger body 11.

[0149] The cooling channel 13 can adopt the following two structures:

[0150] First type of structure: Through hole;

[0151] like Figure 5 and Figure 6 As shown, the cooling channel 13 is a through hole that runs through both ends of the heat exchanger body 11 in the length direction.

[0152] The second structure: the second through slot;

[0153] like Figure 7 and Figure 8As shown, the cooling channel 13 is a second through groove that runs through both ends of the heat exchanger body 11 in the length direction.

[0154] In this embodiment, a metal pipe 14 is nested inside the cooling channel 13, and an insulation layer 15 is provided on the outer wall of the metal pipe 14. The insulation layer 15 is tightly attached to the inner wall of the cooling channel 13 to achieve insulation isolation between the cooling water and the heat exchanger body 11.

[0155] The aforementioned insulating layer 15 can take at least the following two structures:

[0156] Structure 1: Enamel insulation layer;

[0157] A mature enamel process can be adopted. By controlling the thickness of the enamel insulation layer, excellent insulation performance can be ensured, blocking the current path between the cooling water and the heat exchanger body 11, without significantly affecting the thermal conductivity of the metal pipe 14. This ensures that heat can be quickly and efficiently transferred from the heat exchanger 1 to the metal pipe 14 and the cooling water inside the pipe, achieving a good heat dissipation effect.

[0158] The enamel insulation layer is made of porcelain enamel fired at high temperature. It has extremely high insulation resistance and can effectively block the current path between the cooling water and the heat exchanger body 11, thus avoiding short circuits and safety problems caused by the cooling water being electrified.

[0159] Furthermore, the enamel insulation layer, when tightly bonded to the metal pipe 14, does not significantly affect the thermal conductivity. Compared to some organic insulating materials, the enamel insulation layer maintains stable thermal conductivity even at high temperatures, and its heat dissipation efficiency is not reduced due to softening or decomposition caused by heat. This ensures that the heat generated by the battery polarity terminal 31 can be dissipated in a timely manner, maintaining the battery at a suitable operating temperature and improving its charge / discharge performance and lifespan.

[0160] Meanwhile, because the enamel insulation layer has a stable structure and good wear resistance, it will not deform or fall off due to slight external impact or squeezing, thus ensuring structural stability.

[0161] Corresponding to the structure of the insulating layer 15, the cooling channel 13 can be a through hole or a second through groove.

[0162] When the cooling channel 13 is a through hole, the heat exchanger body 11 can be cast to cover the metal pipe 14 with an enamel insulation layer on its outer wall, and the casting temperature is lower than the heat deformation temperature of the metal pipe 14 and the enamel insulation layer. During the casting process, the material of the heat exchanger body 11 fills the mold in a liquid state, tightly wrapping the metal pipe 14 with the enamel insulation layer. After cooling and solidification, a stable integral structure is formed, which greatly reduces the contact thermal resistance between the two.

[0163] When cooling channel 13 is the second through slot, such as Figure 8As shown, the heat exchanger body 11 can be machined first, and then the metal pipe 14 with an enamel insulation layer on its outer wall can be inserted into the second through groove from the opening end of the second through groove. However, compared with the casting process, the stability between the pipe and the heat exchanger body 11 is lower.

[0164] Structure 2: Insulating and thermally conductive adhesive layer;

[0165] First, the metal pipe 14 can be placed in a predetermined position within the cooling channel 13, ensuring accurate positioning. Then, insulating thermally conductive adhesive is poured between the metal pipe 14 and the cooling channel 13. The cured adhesive layer firmly adheres to the outer wall of the metal pipe 14 and the inner wall of the cooling channel 13, achieving not only insulation between the cooling water and the heat exchanger body 11, but also promoting heat transfer from the heat exchanger 1 to the cooling water due to its excellent thermal conductivity. Simultaneously, the adhesive properties of the insulating thermally conductive adhesive make the connection between the metal pipe 14 and the cooling channel 13 more stable, enhancing the overall stability of the heat exchanger 1 structure.

[0166] Corresponding to the structure of the insulation layer 15, the cooling channel 13 is preferably a second through groove. The open end of the second through groove can serve as a dispensing port. During dispensing, due to the openness of the second through groove, the adhesive can evenly fill the gap between the metal pipe 14 and the inner wall of the cooling channel 13 under the action of gravity and fluidity. When the size of the second through groove is larger than the size of the metal pipe 14 in the z-direction, an insulating and thermally conductive adhesive layer can be wrapped around the entire outer wall of the metal pipe 14. During the dispensing process, the thickness of the insulating and thermally conductive adhesive layer can be ensured to be uniform by controlling parameters such as dispensing speed and pressure, thus avoiding defects such as bubbles and voids.

[0167] The aforementioned insulating and thermally conductive adhesives can be silicone-based, epoxy resin-based, etc. Their thickness typically needs to comprehensively consider insulation, thermal conductivity, and adhesion requirements. Generally, while meeting insulation performance requirements, a thinner adhesive layer helps reduce thermal resistance and improve thermal conductivity, but excessive thinness may affect bond strength and insulation reliability. A thicker adhesive layer, while enhancing adhesion and insulation, increases thermal resistance and affects heat dissipation. In practical applications, the thickness of the insulating and thermally conductive adhesive layer must be controlled within a reasonable range based on the specific operating conditions and performance requirements of large-capacity battery modules to achieve a balance among various performance aspects.

[0168] It should be noted that, in the x direction, the metal pipe 14 with insulation layer 15 can extend from both ends of the heat exchanger body 11, which further effectively prevents accidental contact and conduction between the end face and inner wall of the metal pipe 14 and the heat exchanger body 11.

[0169] The above-mentioned high-capacity battery assembly can be installed using the following process:

[0170] First, each terminal extension 312 is connected to the corresponding terminal 311 of the single cell 3. After all terminal extensions 312 are fixed, one heat exchanger 1 is fixed along the x-direction in the first through groove 313 of each positive terminal extension 312 on the same side, and the other heat exchanger 1 is fixed along the x-direction in the first through groove 313 of each negative terminal extension 312 on the same side. The heat exchanger body 11 is then welded to the two side walls of the first through groove 313 on each polarity terminal.

[0171] Specifically, there are two feasible welding methods. First, the two large sidewalls of the first through groove 313 can be fully welded to the heat exchanger body 11 to form a strong connection, effectively enhancing the bonding strength and heat conduction performance of the two. Second, welding can also be performed along the contact area between the end face of the sidewall of the first through groove 313 and the tube wall of the heat exchanger body 11 to ensure that the weld is uniform and continuous, thereby achieving a tight connection between the two.

[0172] Welding enables a tight connection between the heat exchanger 1 and the electrode extension 312. Compared to other connection methods, such as simple mechanical fixing, welding eliminates tiny gaps at the connection point, significantly reducing thermal resistance and greatly improving the heat transfer efficiency between the two, ensuring effective heat transfer. Simultaneously, welding enhances the connection stability, preventing the heat exchanger 1 from separating from the electrode extension 312 due to vibration, impact, or other factors during the operation of the large-capacity battery module. This avoids affecting heat dissipation and ensures the continuous and stable operation of the large-capacity battery module.

[0173] In this embodiment, a stepped structure 12 can also be provided on the outer wall of the heat exchanger body 11 along its length. The horizontal surface of the stepped structure 12 is flush with the end face of the side wall of the first through groove 313, and a welded connection is made at the joint between the horizontal surface of the stepped structure 12 and the end face of the side wall of the first through groove 313. Figure 3 In the middle, region a is shown.

[0174] It should be noted that the horizontal plane of the aforementioned stepped structure 12 refers to the connection surface between the large-diameter section and the small-diameter section of the heat exchanger 1 in the z-direction.

[0175] A stepped structure 12 is provided on the outer wall of the heat exchanger body 11, and the horizontal plane of the stepped structure 12 is flush with the end face of the side wall of the first through groove 313. At the same time, the joint is welded together, which has at least the following advantages:

[0176] Improved stability: The stepped structure 12 provides a larger welding contact area, making the welded connection more robust, reducing the risk of connection loosening due to vibration, and improving the overall stability of the large-capacity battery module.

[0177] Optimize thermal conductivity and electrical conductivity: The horizontal plane of the stepped structure 12 is flush with the side wall end face of the first through groove 313, ensuring a tighter contact between the heat exchanger 1 and the pole extension 312, reducing the tiny gaps between the contact interfaces, significantly reducing thermal resistance, and improving thermal conductivity. At the same time, the tight contact between the two significantly reduces the contact resistance, allowing the current to be evenly distributed between the heat exchanger 1 and the pole extension 312, avoiding local current concentration or hot spots caused by poor contact.

[0178] Furthermore, during the welding process, conventional welding operations may damage the structure of heat exchanger 1 due to factors such as high temperature and stress concentration, thus leading to potential leakage hazards. The stepped structure 12, however, has a horizontal plane flush with the sidewall end face of the first through groove 313, providing an ideal operating plane for laser welding along the z-direction. This effectively avoids leakage problems caused by damage to the heat exchanger 1 structure during the welding process. When cooling water flows within the heat exchanger 1, this design effectively prevents cooling water leakage from the joints.

[0179] In this embodiment, the inner cavity of the metal pipe 14 is used as a cooling water channel. When the heat of the electrode post 311 is conducted to the electrode post extension 312, it will be further transferred to the cooling water in the cooling water channel of the heat exchanger 1 to achieve heat dissipation of the battery module 2.

[0180] Meanwhile, in this embodiment, the heat exchanger 1 is a conductor. The pole extension 312 on the same side of the large-capacity battery assembly has the same polarity, while the pole extension 312 on different sides has opposite polarities. The two heat exchangers 1 are fixed on the pole extension 312 on both sides respectively, so as to realize the parallel connection of multiple single cells 3.

[0181] Therefore, in this embodiment, the heat exchanger 1 not only serves as a heat exchange component but also as a conductor to realize the parallel connection of multiple individual cells 3, which has at least the following advantages:

[0182] Firstly, the elimination of the need for a dedicated busbar simplifies the overall structure of the large-capacity battery module. In traditional battery modules 2, heat exchange and conductivity are often handled by different components, requiring complex structural layouts and connection designs. In this embodiment, the heat exchanger 1 integrates both heat exchange and conductivity functions, reducing the need for a dedicated busbar design. This makes the overall structure of the large-capacity battery module simpler and more compact, reducing design complexity and the probability of errors.

[0183] Secondly, since heat exchanger 1 performs both heat exchange and electrical conduction functions, it reduces the number of components in a large-capacity battery module, thereby lowering assembly difficulty and cost. Previously, separate heat exchange tubes and busbars were used, which not only resulted in a large number of components and increased procurement costs, but also required precise installation of each component during assembly, demanding high skill levels from assembly workers and leading to long assembly times.

[0184] Thirdly, the heat exchanger 1, as a parallel connector, is directly embedded in the first through slot 313 of the pole post extension 312, making full use of the space of the pole post extension 312 and avoiding the problem of additional busbars occupying space, which is conducive to improving the integration of large-capacity battery modules.

[0185] Fourthly, as a parallel connector, heat exchanger 1 ensures a more uniform current distribution among multiple individual battery cells 3, preventing individual cells from overheating and being damaged due to excessive current. Heat exchanger 1 is made of uniform material with good conductivity, and its resistance characteristics are consistent when used as a parallel connector. According to electrical principles, current will be evenly distributed along paths with the same resistance. Therefore, after multiple individual battery cells 3 are connected in parallel through heat exchanger 1, the current can flow evenly to each individual battery cell 3, avoiding excessive current in individual cells due to uneven current distribution, which could lead to overheating and damage. This effectively improves the overall performance and stability of the battery module 2.

[0186] To further improve the connection strength between the heat exchanger 1 and the polar terminal 31 and optimize their thermal conductivity, this invention incorporates a thermally conductive adhesive layer between the heat exchanger 1 and the first through-slot 313 of the polar terminal 31. This adhesive layer tightly adheres to the heat exchanger 1 and the polar terminal 31, effectively fixing the heat exchanger 1 and significantly improving its installation stability. Simultaneously, the adhesive layer significantly optimizes thermal conductivity. Unlike traditional direct solid-to-solid contact methods, the adhesive layer better adapts to different surface shapes and roughnesses. At the microscopic scale, even with minor unevenness on both the heat exchanger 1 and the through-slot of the polar terminal 31, the adhesive layer can fill these gaps through its fluidity, forming an efficient thermal conduction path. This effectively avoids hotspots caused by localized thermal resistance differences, further enhancing the heat dissipation efficiency of the heat exchanger 1.

[0187] During installation, thermally conductive adhesive is typically applied evenly to the inner wall of the first through-groove 313 of the polarity terminal 31 of the individual battery cell 3, and then the heat exchanger 1 is inserted into it. However, when the heat exchanger 1 is inserted into the first through-groove 313, the thermally conductive adhesive flows under pressure, and a large amount of adhesive overflows from the groove opening. This overflowing adhesive not only easily contaminates the battery body and surrounding components, but also, if the adhesive flows and spreads to the welding area during subsequent welding of the polarity terminal 31 and the heat exchanger 1, it can cause impurities at the welding interface, leading to problems such as incomplete welding and desoldering, seriously affecting the welding quality and connection stability.

[0188] To overcome the above problems, this embodiment can form a groove 16 on the outer wall of the heat exchanger body 11, which serves as a glue-receiving groove. When the heat exchanger 1 is inserted into the through slot of the polarity terminal 31, the squeezed glue is guided into the groove 16 for storage, preventing glue overflow. In addition, the groove 16 structure can also increase the contact area between the heat exchanger 1 and the glue, strengthen the heat transfer path, and improve the bonding stability by using a larger bonding surface, preventing loosening and detachment during long-term use.

[0189] Specifically, such as Figure 3 and Figure 9 As shown, in this embodiment, a rectangular groove 16 is formed on the opposite sidewall of the heat exchanger body 11, and the groove 16 extends along the length of the heat exchanger body 11; the groove 16 serves as a glue container to hold the excess glue that is squeezed out.

[0190] In other embodiments, the number, position and cross-sectional shape of the grooves 16 can be adjusted according to actual needs. For example, two grooves 16 with trapezoidal cross-sections can be opened on opposite sidewalls of the heat exchanger body 11.

[0191] By designing the dimensions of the groove 16, it is possible to simultaneously meet the requirements of "ensuring that the extruded thermally conductive adhesive can be contained" and "not affecting the structural strength of the heat exchanger body 11".

[0192] If the groove 16 is too narrow or too shallow, it cannot fully accommodate the excess adhesive that is extruded, and the problem of adhesive overflow will still occur. If the groove 16 is too wide or too deep, it will significantly reduce the effective load-bearing cross-sectional area of ​​the heat exchanger body 11, which will significantly weaken its mechanical properties and make it prone to deformation or even breakage when subjected to external mechanical or thermal stress.

[0193] The thermally conductive adhesive layer can be made of silicone thermally conductive adhesive, which is based on silicone polymer and combined with high thermal conductivity filler material; or it can be made of acrylic thermally conductive adhesive, which can form a stable thermally conductive adhesive layer in a short time.

[0194] like Figure 10 and Figure 11 The diagram shown is a schematic of the battery pack structure in this embodiment, including four high-capacity battery components arranged along the y-direction. In other embodiments, the number of high-capacity battery components can be adjusted according to actual needs.

[0195] For ease of description, the two heat exchangers 1 on each high-capacity battery assembly are defined as the first heat exchanger 17 and the second heat exchanger 18, respectively.

[0196] In the entire battery pack, multiple first heat exchangers 17 are connected in series to form a total liquid inlet path; multiple second heat exchangers 18 are connected in series to form a total liquid outlet path; the end of the total liquid inlet path is connected to the beginning of the total liquid outlet path through an external pipe section.

[0197] After entering the main inlet, the cooling water flows through the first heat exchanger 17 of each large-capacity battery module in sequence, and then through the external pipe section, it flows through the second heat exchanger 18 of each large-capacity battery module in sequence, and flows out from the main outlet.

[0198] This series-connected fluid flow design allows cooling water to flow sequentially through each large-capacity battery module, carrying away the heat generated by each module. During the cooling water flow, each large-capacity battery module receives relatively even cooling, avoiding temperature differences caused by insufficient or excessive cooling of some modules, and achieving uniform temperature distribution across the entire battery pack.

[0199] In some other embodiments, the heat exchangers 1 may be connected in parallel.

[0200] Example 2

[0201] The large-capacity battery module in this embodiment differs from the large-capacity battery module in Embodiment 1 only in that it uses a heat exchanger 1 with a different structure.

[0202] like Figure 12 and Figure 13 As shown, the structure of the heat exchanger body 11 in this embodiment is the same as that in embodiment 1. The difference is that in this embodiment, a ceramic pipe 19 is nested inside the cooling channel 13 of the heat exchanger body 11. The inner cavity of the ceramic pipe 19 serves as a cooling water flow channel, and the cooling water can be insulated from the heat exchanger body 11 based on the ceramic pipe 19.

[0203] Ceramic itself is an excellent insulating material, which ensures the insulation between the cooling water and the heat exchanger body 11 by its material nature. Without the need for additional complicated insulation treatment processes, it can provide reliable electrical insulation protection for large-capacity battery modules and improve the safety of large-capacity battery modules.

[0204] Furthermore, the ceramic pipe 19 has a low coefficient of thermal expansion, which allows it to maintain dimensional stability during the operation of large-capacity battery modules in the face of frequent temperature changes. It is less prone to deformation due to thermal expansion and contraction, ensuring the structural integrity and flow stability of the cooling water channel. At the same time, the ceramic material has excellent thermal conductivity, which can quickly transfer the heat from the heat exchanger 1 to the cooling water inside the pipe, helping to improve the overall heat dissipation efficiency and maintain the battery at a suitable operating temperature.

[0205] Although ceramic materials have high hardness, they are relatively brittle and prone to cracking when subjected to external impact or vibration. To overcome this problem, this embodiment provides a metal reinforcing layer 10 on the inner wall of the ceramic pipe 19 to enhance its mechanical strength. The metal reinforcing layer 10 can be made of a material with good toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing the ceramic pipe 19 from cracking, and extending its service life.

[0206] Specifically, in this embodiment, an aluminum layer is selected as the metal reinforcement layer 10. Aluminum not only has excellent thermal conductivity but also good plasticity, making it easy to process and shape.

[0207] In some other embodiments, other metal-formed metal reinforcement layers 10 may also be selected, such as titanium alloys, nickel-based alloys, etc., to improve the mechanical strength of ceramic pipes 19.

[0208] In this embodiment, the aluminum layer and the heat exchanger body 11 can both be cast onto the inner and outer walls of the ceramic pipe 19, respectively, with the casting temperature strictly controlled below the heat deformation temperature of the ceramic pipe 19. This casting method allows the aluminum layer and the heat exchanger body 11 to fit tightly against the inner and outer walls of the ceramic pipe 19, forming a stable composite structure. Furthermore, the mature and easy-to-operate casting process allows for the integration of all three components in a single molding process, effectively reducing assembly steps and significantly improving production efficiency.

[0209] In some other embodiments, thermal spraying technology can also be used to form a metallic aluminum layer on the inner wall of the ceramic pipe 19.

[0210] In this embodiment, the battery pack is identical to that in Embodiment 1, except that the structure of the heat exchanger 1 is different from that in Embodiment 1. It will not be described again here.

[0211] Example 3

[0212] The large-capacity battery module in this embodiment differs from the large-capacity battery module in Embodiment 1 only in that it uses a heat exchanger 1 with a different structure.

[0213] The structure of the heat exchanger body 11 in this embodiment is the same as that in embodiment 1. The difference is that in this embodiment, an insulating coating is applied to the inner wall of the cooling channel 13 with the through hole structure to achieve insulation isolation between the cooling water and the heat exchanger body 11.

[0214] Insulating coatings can be epoxy resin coatings, polytetrafluoroethylene coatings, silicone rubber coatings, etc.

[0215] Compared to the embedded pipes used as insulating layers in Embodiments 1 and 2, coating the inner wall of the cooling channel 13 with an insulating coating results in a simpler structure. However, the bonding strength between the insulating coating and the inner wall of the cooling channel 13 is relatively weak. During long-term use, factors such as the scouring of cooling water, thermal expansion and contraction caused by temperature changes, and mechanical vibration can all lead to problems such as peeling and cracking of the coating. Once the coating is damaged, the insulation performance will drop significantly, or even lose its insulating effect, causing safety hazards. In contrast, the embedded pipes are physically nested or fixedly connected to the cooling channel 13, resulting in stronger structural stability and better resistance to the effects of harsh working conditions.

[0216] In practical applications, improvements can be made to the coating materials, surface treatment, and coating process to effectively optimize the adhesion between the insulating coating and the inner wall of the cooling channel 13. For example, a high-performance composite coating can be selected, or a tackifier can be added to strengthen the bond with the inner wall. The inner wall of the cooling channel 13 can also be treated to improve surface activity and contact area.

[0217] In this embodiment, the battery pack is identical to that in Embodiment 1, except that the structure of the heat exchanger 1 is different from that in Embodiment 1. It will not be described again here.

[0218] Example 4

[0219] The large-capacity battery module in this embodiment differs from the large-capacity battery module in the above embodiment only in that it uses a heat exchanger 1 with a different structure.

[0220] like Figures 14 to 19 As shown, in this embodiment, two cooling channels 13 are provided on the heat exchanger body 11. The two cooling channels 13 are isolated from each other. The rest of the structure of the heat exchanger body 11, the structure of each cooling channel 13, and the insulating isolation layer therein are the same as in the above embodiment.

[0221] Figure 14 and Figure 15 In the middle, both cooling channels 13 adopt a through-hole structure. Figure 16 and Figure 17 In this embodiment, both cooling channels 13 adopt a second through-slot structure; a metal pipe 14 is nested inside each cooling channel 13, and an insulation layer 15 is provided on the outer wall of the metal pipe 14. The insulation layer 15 is tightly attached to the inner wall of the cooling channel 13 to achieve insulation isolation between the cooling water and the heat exchanger body 11. The detailed structure of the insulation layer 15 has been described in Embodiment 1 and will not be repeated here.

[0222] like Figures 18 to 19 As shown, the structure of each cooling channel 13 and its internal insulation layer are the same as in Embodiment 2 above; a ceramic pipe 19 is nested inside the cooling channel 13 to achieve insulation isolation between the cooling water and the heat exchanger body 11. Specific structural details have been described in Embodiment 2 and will not be repeated here.

[0223] like Figure 20 and Figure 21 The diagram shown is a structural schematic of the battery pack from different perspectives in this embodiment. The battery pack includes three high-capacity battery modules arranged along the y-direction. In practical applications, the number of high-capacity battery modules can be flexibly adjusted according to specific needs.

[0224] In this embodiment, for ease of description, the two cooling water channels on each heat exchanger 1 are defined as inlet channel 111 and outlet channel 112, respectively. The inlet channels 111 of the three large-capacity battery modules are connected end to end in sequence to form a total inlet path; and the outlet channels 112 are also connected in series in sequence to form a total outlet path. The end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section, thus constructing a complete cooling circulation loop.

[0225] The specific cooling process is as follows: Cooling water enters from the main inlet (the inlet end of the main water inlet path), flows sequentially through the inlet channel 111 of each heat exchanger 1, then changes direction at the outer pipe section, and then flows sequentially through the outlet channel 112 of each heat exchanger 1, finally flowing out from the main outlet (the outlet end of the main water outlet path). Inside a single heat exchanger 1, the coolant relies on adjacent inlet channels 111 and outlet channels 112 to achieve efficient heat exchange, ensuring that each polarity terminal 31 receives uniform heat dissipation. For all heat exchangers 1 in the entire battery pack, the temperature difference between the inlet channel 111 and the outlet channel 112 remains stable, effectively overcoming the problem of local overheating or overcooling at both ends of the battery pack caused by the gradual temperature rise of the coolant during flow in traditional series cooling methods.

[0226] Example 5

[0227] Based on the above embodiments, this embodiment refines the fixing method of the pole extension 312 and the pole 311. An installation hole 314 is opened on the pole extension 312 for the pole 311 to be inserted. After the pole 311 is inserted, a reliable fixing method such as interference fit, welding, or threaded connection can be selected according to actual needs to firmly combine the pole 311 and the pole extension 312 into one.

[0228] Combination Figure 22 and Figure 23 As can be seen, the pole extension 312 includes the pole extension body 315. The pole extension body 315 is usually designed as a rectangular block structure, and its length, width and height can be customized according to the actual application scenario to adapt to different battery specifications.

[0229] In some other embodiments, the pole extension body 315 may also be cylindrical.

[0230] Metal materials with good electrical and thermal conductivity can be used, such as silver, copper, and aluminum. However, considering both cost and electrical and thermal conductivity, aluminum is generally chosen as the material for the 315 electrode extension body.

[0231] Mounting holes 314 are provided on the electrode extension body 315 for inserting part of the structure of the single cell electrode 311, thereby achieving effective connection between the two.

[0232] In this embodiment, the mounting hole 314 is located at the center of the bottom of the first through groove 313 and penetrates vertically through the bottom of the first through groove 313.

[0233] like Figures 24 to 26 During installation, the terminal post 311 is inserted into the mounting hole 314 of the terminal post extension 312 and fixedly connected to the terminal post extension 312. It is worth noting that after installation, a safe electrical conduction distance must be maintained between the bottom surface of the terminal post extension 312 and the top cover of the single cell 3. This is crucial and relates to the safe and stable operation of the entire battery.

[0234] Regarding the connection method between the pole post 311 and the pole post extension 312, there are mainly three options:

[0235] Interference fit connection: The diameter of the mounting hole 314 is adapted to the outer diameter of the three terminals 311 of the single battery cell. When the terminal 311 is inserted into the mounting hole 314, the two are tightly connected by an interference fit. This connection method requires a certain amount of external force to press the terminal 311 into the mounting hole 314 during assembly, which generates a large frictional force between the terminal 311 and the mounting hole 314. No additional fixing measures are needed to ensure a stable connection and effectively prevent the terminal extension 312 from loosening or shifting during use. It should be noted that the mounting hole 314 can be a through hole or a non-through hole, and the choice can be made flexibly according to specific requirements in practical applications.

[0236] Threaded Connection: The diameter of the mounting hole 314 is slightly larger than the outer diameter of the single-cell battery terminal 311. A threaded structure is provided on the wall of the mounting hole 314 near the single-cell battery terminal 311. Correspondingly, a matching threaded structure is provided on the terminal 311. After the terminal 311 is inserted into the mounting hole 314, the terminal 311 is tightly connected to the mounting hole 314 by rotating the terminal extension 312. The threaded connection is easy to operate and has good disassembly, making it easy to separate the terminal 311 from the terminal extension 312 during subsequent maintenance or replacement of battery module 2 components. At the same time, the position of the terminal 311 in the mounting hole 314 can be flexibly adjusted by controlling the screw depth. It should also be noted that the mounting hole 314 for the threaded connection can be either a through hole or a non-through hole, and can be flexibly selected according to specific needs in practical applications.

[0237] Welded connection:

[0238] Method 1: Mounting hole 314 is a stepped hole structure: such as Figure 23 and Figure 26 As shown, the mounting hole 314 is designed as a stepped hole, including a large-diameter section 3141 and a small-diameter section 3142. The inner diameter of the large-diameter section 3141 is significantly larger than the outer diameter of the pole post 311, thus forming a welding cavity. The inner diameter of the small-diameter section 3142 matches the outer diameter of the pole post 311, providing fitting space for the insertion of the pole post 311. During assembly, the pole post 311 is inserted into the small-diameter section 3142, ensuring that the top end face of the pole post 311 is flush with the bottom of the hole in the large-diameter section 3141. The bottom of the hole in the large-diameter section 3141 is then welded to the edge of the top end face of the pole post 311 (e.g., ...). Figure 26 (as shown in area b). It should be noted that, unlike the previous two connection methods, the mounting hole 314 corresponding to the welded connection must be designed as a through hole to meet the requirements of the welding process and the overall structure.

[0239] Since the inner cavity of the first through groove 313 in this embodiment is used to install the heat exchanger 1, if the bottom of the large-diameter section 3141 is welded to the top end face of the pole post 311, the weld height will be too high, exceeding the height of the welding cavity (i.e., exceeding the depth of the large-diameter section 3141), and the heat exchanger 1 will directly contact the weld. This will not only interfere with the full contact between the heat exchanger 1 and the bottom of the first through groove 313, but also, because the material changes after welding, a region with high thermal resistance may be formed. As a result, heat is difficult to transfer smoothly, and the heat transfer efficiency will decrease accordingly.

[0240] To overcome this problem, this embodiment limits the depth of the large-diameter section 3141, requiring the depth of the large-diameter section 3141 to be greater than the height of the weld, thereby separating the weld from the heat exchanger 1. This ensures that the heat exchanger 1 is in complete contact with the bottom of the first through groove 313, guaranteeing that heat can be conducted unimpeded along the electrode post 311 and the electrode post extension 312 to the heat exchanger 1, maintaining efficient heat dissipation performance, effectively preventing the battery from overheating due to poor heat dissipation, ensuring that the battery maintains good performance under various operating conditions, and extending the battery's service life.

[0241] Method 2: Mounting hole 314 is a through hole structure: During assembly, the pole post 311 is inserted into the mounting hole 314, ensuring that the top end face of the pole post 311 is flush with the opening of the mounting hole 314. The annular plane around the mounting hole 314 on the bottom of the first through groove 313 is used as the welding surface and welded to the top end face of the pole post 311. Based on the structure of the first through groove 313, end-face welding can be achieved, resulting in a high connection strength between the pole post 311 and the pole post extension 312.

[0242] However, if the weld flatness is poor, with protrusions or depressions, the heat exchanger 1 installed in the through slot in the battery component will not be able to fit tightly with the electrode extension 312. Gaps will appear in some areas, obstructing the heat transfer path, which will still have an adverse effect on the contact between the heat exchanger 1 and the electrode extension 312, resulting in a significant reduction in heat exchange efficiency.

[0243] Compared to threaded connections and interference fits, welded connections form a permanent bond through interatomic bonding, resulting in higher connection strength. This provides better resistance to complex operating conditions, ensuring a stable connection and effectively preventing electrical instability caused by loosening. Therefore, this embodiment adopts a welded connection method after comprehensive consideration.

[0244] In addition, to ensure that the bottom surface of the terminal extension 312 and the top cover of the single cell 3 reliably maintain a safe electrical conduction distance, at least the following two methods can be adopted in the design:

[0245] Insulating gasket and annular groove design: An insulating gasket is provided on the bottom surface of the terminal extension 312, and an annular groove is machined at the corresponding position on the top cover of the individual cell 3. The insulating gasket is embedded in the annular groove. The insulating gasket can effectively prevent abnormal current conduction, while the annular groove can position and protect the insulating gasket, ensuring that the insulating gasket is always in the correct position and performs its due insulation function during the operation of the battery assembly.

[0246] 311-step structure design of the pole column: combined with Figure 25 As can be seen, an annular stepped structure is provided along the circumference of the terminal post 311. When installing the terminal post extension 312, the small-diameter end of the terminal post 311 is inserted into the mounting hole 314 of the terminal post extension 312, and the stepped surface serves as a limiting surface to support the terminal post extension 312. By designing the size and position of the stepped structure of the terminal post 311, the height of the terminal post extension 312 after installation can be controlled, thereby ensuring that a safe electrical conduction distance is always maintained between the bottom surface of the terminal post extension 312 and the top cover plate of the single cell 3, effectively avoiding various electrical safety problems caused by improper distance, and providing a reliable guarantee for the safe and stable operation of the battery pack.

[0247] Since the stepped structure design of the pole post 311 does not require the introduction of an insulating pad, the stepped structure can be designed on the pole post 311. Therefore, the stepped structure design of the pole post 311 is preferred in this embodiment.

[0248] In specific design, when the height of the pole post 311 itself meets the requirement of directly creating an annular stepped structure, the annular stepped structure can be directly machined around the pole post 311. However, when the height of the pole post 311 does not meet the conditions for direct creation, an equivalent annular stepped structure can be formed by fixing a boss on the pole post 311.

[0249] Furthermore, in this embodiment, a conductive coating may be provided between the outer wall of the electrode post 311 and the mounting hole 314 of the electrode post extension 312. Metal coating materials (silver coating, copper coating, etc.), carbon-based coating materials (graphene coating, carbon nanotube coating, etc.), or conductive polymer coatings (polypyrrole coating, etc.) may be used.

[0250] The conductive coating possesses excellent conductivity, effectively filling minute gaps and unevenness between the terminal post 311 and the mounting hole 314. This allows current to flow more smoothly through the contact interface, reducing resistance loss, improving battery charging and discharging efficiency, and enhancing the energy utilization of the battery system. Furthermore, the conductive coating effectively improves the electrical contact stability between the terminal post 311 and the terminal extension 312. During battery operation, complex conditions such as vibration and temperature changes can alter the contact state between the terminal post 311 and the terminal extension 312, thus affecting electrical connection stability. The conductive coating adheres tightly to the outer wall of the terminal post 311 and the inner wall of the mounting hole 314, maintaining good conductivity even under external forces. This ensures a consistently stable and reliable electrical connection, preventing current fluctuations and power outages caused by poor contact, thus providing strong support for the stable operation of the battery system. Additionally, during the installation of the terminal extension 312, relative friction may occur between the terminal post 311 and the terminal extension 312, leading to surface wear. The conductive coating has a certain degree of wear resistance, which can reduce this friction and wear to a certain extent, protect the surface integrity of the terminal post 311 and the terminal post extension 312, maintain good electrical connection and mechanical properties, and reduce the risk of failure due to wear.

[0251] Example 6

[0252] Unlike the high-capacity battery modules in the above embodiments, this embodiment, based on the above embodiments, sets up an electrolyte sharing pipeline at the bottom of the first type of battery module. The inner cavity of the electrolyte sharing pipeline is connected to the electrolyte area of ​​each individual battery cell 3, so as to realize electrolyte sharing, reduce the difference between each individual battery cell 3, and optimize the cycle performance of the high-capacity battery module.

[0253] Example 7

[0254] like Figures 27 to 28 As shown, this is a high-capacity battery module in this embodiment. Its structure differs from that of the high-capacity battery modules in embodiments 1 to 5 in that the battery module 2 is the third type of battery module mentioned above.

[0255] In this embodiment, the third type of battery module arranges 12 individual batteries 3 in the inner cavity of the outer casing 4, and each terminal extension 312 is located outside the outer casing 4. A heat exchanger 1 is fixed on the terminal extension 312 located on the same side and of the same polarity. The structure of the heat exchanger 1, the structure of the terminal extension 312, the installation structure between the terminal extension 312 and the heat exchanger 1, and the installation structure between the terminal extension 312 and the terminal 311 are all the same as those in the above embodiments, and will not be repeated here. Figures 27 to 28 Taking a heat exchanger 1 with two cooling channels 13 as an example.

[0256] It should be noted that, in this embodiment, the bottom surface of the pole extension 312 and the top plate of the outer casing 4 maintain a safe electrical conductivity distance.

[0257] A support extending in the x-direction is provided between the bottom plate of the outer casing 4 and each individual battery cell 3 to form a liquid channel, serving as a shared electrolyte chamber 5.

[0258] On the top plate of the outer casing 4, a boss extending in the x direction may also be provided, and a gas channel is opened on the boss, which serves as a gas sharing chamber 6.

[0259] like Figure 29 The diagram shown is a schematic of the battery pack structure in this embodiment, including three high-capacity battery components arranged along the y-direction. In other embodiments, the number of high-capacity battery components can be adjusted according to actual needs.

[0260] In this embodiment, for ease of description, the two cooling water channels on each heat exchanger 1 are defined as inlet channel 111 and outlet channel 112, respectively. The inlet channels 111 of the three large-capacity battery modules are connected end to end in sequence to form a total inlet path; and the outlet channels 112 are also connected in series in sequence to form a total outlet path. The end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section, thus constructing a complete cooling circulation loop.

[0261] The specific cooling process is as follows: Cooling water enters from the main inlet end and flows sequentially through the inlet channel 111 of each heat exchanger 1. Then, its flow direction changes at the outer pipe section, and it flows sequentially through the outlet channel 112 of each heat exchanger 1, finally exiting from the main outlet end. Inside a single heat exchanger 1, the coolant achieves efficient heat exchange through adjacent inlet channels 111 and outlet channels 112, ensuring uniform heat dissipation for each polarity terminal 31. For all heat exchangers 1 in the entire battery pack, the temperature difference between the inlet channel 111 and outlet channel 112 remains stable, effectively overcoming the problem of localized overheating or undercooling at both ends of the battery pack caused by the gradual temperature increase of the coolant during flow in traditional series cooling methods.

[0262] Example 8

[0263] In the third type of battery module, in order for the terminal post 311 to smoothly extend into the corresponding clearance hole 41, the opening size of the clearance hole 41 must be slightly larger than the cross-sectional size of the corresponding terminal post 311. As a result, after the terminal post 311 is inserted, there will be a certain gap between them. The existence of this gap may cause the thermal runaway fumes to be discharged through this gap instead of being led out from the explosion vent of the outer casing 4 during thermal runaway. This will not only further damage the structural integrity of the large-capacity battery module itself and aggravate the degree of harm of thermal runaway, but will also cause the surrounding environment to be quickly filled with harmful fumes, posing a huge safety hazard to operators and surrounding facilities, and threatening life and property.

[0264] like Figure 30 As shown, this embodiment solves the above problem by sealing and fixing the insulating seal 7 between the pole post 311 and the corresponding clearance hole 41, and by using the pole post extension 312 to apply pressure to the insulating seal 7 along the height direction of the pole post 311 (along the z direction), so that the insulating seal 7 is compressed and undergoes radial deformation, thereby sealing the gap between the pole post 311 and the clearance hole 41.

[0265] The corresponding pole extension component 312 structure can be referenced. Figure 22 and Figure 23 The device includes a pole extension body 315. To facilitate the connection between the pole extension 312 and the pole 311, an electrical connection post 316 protruding from the pole extension body 315 is provided at the bottom of the pole extension body 315, and a mounting hole 314 passes through the electrical connection post 316.

[0266] As can be seen from the above figures, the dimensions of the electrode extension body 315 and the electrical connection post 316 in this embodiment are somewhat different. In the x-direction, the dimension of the electrode extension body 315 is equal to the dimension of the electrical connection post 316. This dimensional design ensures that the entire electrode extension body 312 is subjected to uniform stress in the x-axis direction, resulting in excellent stability. From a manufacturing perspective, the design with the same length facilitates unified dimensional planning and processing during production, reducing processing difficulty and improving production efficiency. In the y-direction, the dimension of the electrode extension body 315 is larger than the dimension of the electrical connection post 316. This design allows the smaller electrical connection post 316 to easily extend into the pre-drilled clearance hole 41 on the housing 4, thereby connecting with the electrode post 311 of the single battery 3 inside the housing 4. Simultaneously, a stepped structure is formed between the electrode extension body 315 and the electrical connection post 316, which can be used to press the insulating seal 7.

[0267] The insulating seal 7 is usually made of high-quality elastic material that is resistant to high temperature and chemical corrosion and has low air permeability. It can maintain stable performance in high temperature and complex chemical environments.

[0268] In this embodiment, the insulating seal 7 includes a flexible insulating sealing ring 71, which is a flexible stepped structure. The small diameter section of the stepped structure extends into the clearance hole 41 and contacts the upper cover plate of the single cell 3. The large diameter section of the stepped structure is located outside the outer shell 4. The end face of the large diameter section near the small diameter section contacts the top plate of the outer shell 4, and the end face away from the small diameter section contacts the pole post extension 312.

[0269] Under the downward pressure of the terminal extension 312, the inner wall of the flexible insulating sealing ring 71 is tightly fitted to the terminal 311, and the outer wall is tightly fitted to the wall of the clearance hole 41, ensuring the sealing between the terminal 311 and the outer shell 4. When thermal runaway occurs, the thermal runaway smoke is led out from the explosion vent of the outer shell 4 for treatment, minimizing the risk of thermal runaway and ensuring the safe and stable operation of the large-capacity battery module.

[0270] In order to ensure that the pole extension 312 can uniformly provide clamping force to the insulating seal 7, thereby ensuring the insulation seal 7, from Figure 30 As can be seen from this, the insulating seal 7 may also include a pressure ring 72.

[0271] In terms of materials, the pressure ring 72 is usually made of high-strength metal materials with good thermal conductivity and corrosion resistance, such as stainless steel and aluminum alloy. These metal materials can not only withstand the large pressure applied by the terminal extension 312, ensuring that they do not deform or get damaged during the pressure process, but also play a stable downward pressure role for a long time in the complex working environment of the battery pack, avoiding the sealing effect due to corrosion and other problems.

[0272] In terms of structural design, the inner diameter of the pressure ring 72 is matched with the inner diameter of the large diameter section of the flexible insulating sealing ring 71. The outer diameter of the pressure ring 72 is larger than the dimension of the pole extension body 315 in the y direction, so that during the pressing of the pole extension 312, the larger outer diameter of the pressure ring 72 can form a larger force-bearing surface, and can form a uniform pressure distribution on the flexible insulating sealing ring 71, preventing the seal from failing due to excessive or insufficient local pressure.

[0273] During assembly, first place a flexible insulating sealing ring 71 in the clearance hole 41; let the small diameter section of its stepped structure 12 extend into the clearance hole 41 and make tight contact with the upper cover plate of the single cell 3, while the large diameter section of the stepped structure 12 is located outside the outer casing 4 and fits against the top plate of the outer casing 4; then place a pressure ring 72 on the flexible insulating sealing ring 71. Figure 30In the process of clearly showing the clearance hole 41, the insulating seal 7 is not installed on one side. Then, the pole extension 312 is welded to the pole 311. During the welding process, a downward pressure is applied along the height direction of the pole 311 (along the z direction). Under the action of this downward pressure, the pressure ring 72 evenly transmits the pressure to the flexible insulating sealing ring 71, causing the inner wall of the flexible insulating sealing ring 71 to fit tightly against the pole 311 and the outer wall to fit tightly against the wall of the clearance hole 41. This significantly enhances the sealing performance between the pole 311 and the outer casing 4. When thermal runaway occurs in a large-capacity battery module, it can effectively prevent thermal runaway fumes from escaping from the gap between the pole 311 and the clearance hole 41, ensuring that the thermal runaway fumes are only led out from the explosion vent of the outer casing 4 for treatment, thereby minimizing the risk of thermal runaway and ensuring the safe and stable operation of the large-capacity battery module.

[0274] In some other embodiments, the insulating seal 7 may also be an insulating seal layer disposed at the gap between the clearance hole 41 and the pole post 311 by a casting process.

[0275] Example 9

[0276] Unlike Embodiment 8, this embodiment further enhances the sealing performance between the terminal post 311 and the clearance hole 41 by sealing the clearance hole 41 with the corresponding single cell 3 cover plate.

[0277] Specifically, in this embodiment, the edge of the clearance hole 41 near the single cell 3 can be sealed to the upper cover plate of the single cell 3 by filler wire welding.

[0278] During actual assembly:

[0279] First, place the 12 individual battery cells 3 into the housing 4, so that the terminals 311 of each individual battery cell 3 correspond one-to-one with the clearance holes 41.

[0280] Then, the edge of the clearance hole 41 near the single cell 3 is welded to the upper cover plate of the single cell 3 by filler wire welding to achieve a sealed connection.

[0281] Next, a flexible insulating sealing ring 71 is placed in the clearance hole 41, so that the small diameter section of its stepped structure 12 extends into the clearance hole 41 and is in close contact with the upper cover plate of the single cell 3, and the large diameter section of the stepped structure 12 is located outside the outer shell 4 and fits against the top plate of the outer shell 4; then a pressure ring 72 is placed on the flexible insulating sealing ring 71.

[0282] Afterwards, the pole extension 312 is welded to the pole 311. During the welding process, a downward pressure is applied along the height direction (along the z direction) of the pole 311. Under the action of this downward pressure, the pressure ring 72 transmits the pressure evenly to the flexible insulating sealing ring 71, causing the inner wall of the flexible insulating sealing ring 71 to fit tightly against the pole 311 and the outer wall to fit tightly against the wall of the clearance hole 41.

[0283] Finally, the heat exchanger 1 is fixed on each pole extension 312.

[0284] In this embodiment, the insulating sealant 7 tightly fills the gap between the terminal post 311 and the clearance hole 41, forming the first sealing barrier. This effectively prevents the leakage of gases, electrolytes, and other substances inside the battery, while also preventing external air, moisture, and impurities from entering the battery. The filler wire welding, by filling the gap between the clearance hole 41 and the top cover plate of the individual battery 3 with welding wire of varying thicknesses, allows the welding wire to fully fuse with the edge of the hole and the top cover plate at high temperatures, forming a continuous and dense weld, thus constituting the second sealing line. This line of defense, thanks to the flexible adjustment of the welding wire thickness in filler wire welding, fills the height differences between the individual batteries 3, ensuring a tight fit between the clearance hole 41 and the top cover plate of the individual battery 3, achieving reliable welding. The dual sealing structures work together; even if one line of defense fails partially, the other line of defense can still ensure the battery's sealing performance, significantly reducing the risk of leakage and ensuring the battery maintains a good sealing state under various operating conditions.

[0285] Example 10

[0286] Unlike Embodiment 8, this embodiment, based on Embodiment 8, also uses a hollow component 8 to seal the top plate area of ​​the outer shell 4 corresponding to the clearance hole 41 to the top cover plate of each individual battery 3, so as to further enhance the sealing performance between the pole post 311 and the clearance hole 41.

[0287] Specifically, such as Figure 31 and Figure 32 As shown, the high-capacity battery assembly in this embodiment also includes multiple hollow components 8, similar to a hollow tubular structure; each hollow component 8 is inserted through the clearance hole 41 and fitted around each terminal post 311. The bottom of the hollow component 8 is laser-welded to the first area of ​​the corresponding single cell 3, and the top of the hollow component 8 is laser-welded to the second area of ​​the top plate of the outer casing 4; wherein, the first area is the area around any terminal post 311 in the upper cover plate of any single cell 3; the second area is the area corresponding to any clearance hole 41 on the top plate of the outer casing 4; wherein the area corresponding to the clearance hole 41 can be the wall of the clearance hole 41, or it can be the area around the clearance hole 41 on the top plate of the outer casing 4.

[0288] After the hollow component 8 is installed, the insulating seal 7 is located between the pole post 311 and the hollow component 8, sealing the gap between the pole post 311 and the hollow component 8.

[0289] Taking the welding described above as an example, based on Example 8, the specific assembly process is as follows:

[0290] First, place the 12 individual battery cells 3 into the housing 4, so that the terminals 311 of each individual battery cell 3 correspond one-to-one with the clearance holes 41.

[0291] Then, each hollow component 8 is inserted into the clearance hole 41 and fitted around each pole post 311. The bottom of the hollow component 8 is laser welded to the first area of ​​the corresponding single cell 3, and the top of the hollow component 8 is laser welded to the second area of ​​the top plate of the outer shell 4.

[0292] Next, a flexible insulating sealing ring 71 is placed in the clearance hole 41, so that the small diameter section of its stepped structure 12 extends into the clearance hole 41 and is in close contact with the upper cover plate of the single cell 3, and the large diameter section of the stepped structure 12 is located outside the outer shell 4 and fits against the top plate of the outer shell 4; then a pressure ring 72 is placed on the flexible insulating sealing ring 71.

[0293] Afterwards, the pole extension 312 is welded to the pole 311. During the welding process, a downward pressure is applied along the height direction (along the z direction) of the pole 311. Under the action of this downward pressure, the pressure ring 72 transmits the pressure evenly to the flexible insulating sealing ring 71, causing the inner wall of the flexible insulating sealing ring 71 to fit tightly against the pole 311 and the outer wall to fit tightly against the wall of the clearance hole 41.

[0294] Finally, the heat exchanger 1 is fixed on each pole extension 312.

[0295] The hollow component 8 has a certain length redundancy design, which can cover the possible height difference between the top cover of the single cell 3 and the top plate of the outer shell 4. After the bottom of the hollow component 8 and the corresponding first area of ​​the single cell 3 are laser welded together, when the height of the single cell 3 is moderate, the top end face of the hollow component 8 is flush with the edge of the clearance hole 41. At this time, the joint between the two is welded. When the height of the single cell 3 is low, the top end face of the hollow component 8 will be lower than the opening of the clearance hole 41. At this time, the top end face of the hollow component 8 can be welded to the wall of the clearance hole 41.

[0296] Based on the above analysis, it can be seen that the hollow component 8 can also compensate for the height difference between each individual battery cell 3, ensuring reliable sealing and welding of the clearance hole 41.

[0297] In this embodiment, the insulating seal 7 tightly fills the gap between the terminal post 311 and the hollow component 8, forming the first sealing barrier. This effectively prevents the leakage of gases, electrolytes, and other substances inside the battery, while also preventing external air, moisture, and impurities from entering the battery. The hollow component 8, through laser welding of its bottom to the top cover of the individual battery 3 and its top to the top plate of the outer casing 4, along with flexible welding strategies tailored to the height differences of different individual battery 3s, constitutes the second sealing line. This dual sealing structure works in tandem; even if one line of defense fails partially, the other line can still ensure the battery's sealing performance, significantly reducing the risk of leakage and ensuring the battery maintains a good sealing condition under various operating conditions.

[0298] Example 11

[0299] Unlike embodiments 8 to 10, this embodiment can use the following three methods to achieve a sealed connection between the area corresponding to each clearance hole on the top plate of the outer casing and the corresponding single battery cover plate:

[0300] Method 1: The edge of the clearance hole 41 near the single cell 3 is welded to the top cover plate of the single cell 3 using filler wire welding to achieve a sealed connection between the area corresponding to each clearance hole on the top plate of the outer casing and the corresponding top cover plate of the single cell.

[0301] Method 2: Laser welding is used to weld the area around each clearance hole 41 on the top plate of the outer casing and the area around the corresponding electrode post 311 on the top cover of the individual battery 3.

[0302] Method 3: Using hollow components to seal the top plate area of ​​the casing corresponding to the clearance hole 41 to the top cover plate of each individual battery 3. Specifically, each hollow component is inserted through the clearance hole 41 and fitted around each terminal post 311. The bottom of the hollow component is laser-welded to the first area of ​​the corresponding individual battery 3, and the top of the hollow component is laser-welded to the second area of ​​the top plate of the casing. The first area is the area around any terminal post 311 in the top cover plate of any individual battery 3; the second area is the area corresponding to any clearance hole 41 on the top plate of the casing. The area corresponding to the clearance hole 41 can be the wall of the clearance hole 41 or the area around the clearance hole 41 on the top plate of the casing.

Claims

1. A large capacity battery assembly characterized by: Includes the battery module and two heat exchangers; The battery module includes n individual batteries arranged along a first direction, where n is an integer greater than 1; The heat exchanger includes a heat exchanger body; at least one cooling channel is formed on the heat exchanger body, the cooling channel extends along the length of the heat exchanger body and passes through both ends of the heat exchanger body; an insulating layer is provided on the inner wall of the cooling channel to form a cooling water flow channel; the heat exchanger body is a conductor, and the insulating layer realizes the insulation isolation between the cooling water and the heat exchanger body. Both heat exchange components extend along the first direction. One component is welded to the positive terminal of n individual cells, and the other component is welded to the negative terminal of n individual cells, thereby realizing parallel connection between individual cells and heat exchange between the cooling water in the cooling water channel and the polarity terminal.

2. The large capacity battery assembly of claim 1, wherein: The insulating layer is a pipe nested within the cooling channel or an insulating coating applied to the inner wall of the cooling channel.

3. The large capacity battery assembly of claim 2, wherein: The cooling channel consists of two channels, each with an insulating layer on its inner wall, forming two cooling water channels; one cooling water channel is the inlet channel, and the other is the outlet channel.

4. The large capacity battery assembly of claim 1, wherein: A first through slot extending in a first direction is formed on the polar terminal; The heat exchanger is installed in the first through slot of each polarity terminal, and the outer wall of the heat exchanger is welded and fixed to the two side walls of the first through slot.

5. The large capacity battery assembly of claim 4, wherein: At least one groove is formed on the outer wall of the heat exchanger body, and the groove extends along the length direction of the heat exchanger body. A thermally conductive adhesive is applied between the outer wall of the heat exchanger body and the inner wall of the first through groove, and at least a portion of the inner cavity of the groove contains the thermally conductive adhesive.

6. The large capacity battery assembly of claim 1, wherein: The polarity terminal includes a pole and a pole extension fixed on the pole; the top of the pole extension body is higher than the top of the pole; and the bottom surface of the pole extension and the top plate of the outer shell maintain a safe electrical conduction distance.

7. The large capacity battery assembly of claim 6, wherein: The pole extension has mounting holes; a portion of the pole structure is inserted into the mounting holes and fixed.

8. The large capacity battery assembly of claim 7, wherein: The mounting hole is a stepped through hole, with the inner diameter of the large-diameter section being larger than the outer diameter of the pole post, forming a welding cavity; the inner diameter of the small-diameter section matches the outer diameter of the pole post; part of the pole post structure is inserted into the small-diameter section, and the top end face of the pole post is flush with the bottom of the hole in the large-diameter section. The bottom of the large-diameter section serves as the welding surface, which is welded to the top end face of the pole post, and the depth of the large-diameter section is greater than or equal to the weld height.

9. The high capacity battery assembly of any one of claims 1 to 8, wherein: The battery module also includes a housing; the housing is provided with an explosion vent; n individual batteries are arranged inside the housing; the top plate of the housing is provided with clearance holes corresponding to the polarity terminals of each individual battery; the polarity terminals of each individual battery extend out of the corresponding clearance holes, and the area corresponding to each clearance hole on the top plate of the housing is sealed and connected to the top cover plate of the corresponding individual battery. Inside the outer casing, the internal cavities of each individual battery cell are interconnected; the electrolyte and / or gas are shared among the individual batteries. The heat exchanger body is connected to the portion of each individual battery cell whose polarity terminal extends out of the corresponding clearance hole.

10. The large capacity battery assembly of claim 9, wherein: The edge of each clearance hole near the individual battery is sealed to the corresponding individual battery cover plate by filler wire welding; or, the battery module also includes 2n hollow components; the 2n hollow components pass through the clearance holes and are fitted around each terminal post, the bottom of the hollow component is laser welded to the first area of ​​the corresponding individual battery, and the top of the hollow component is laser welded to the second area of ​​the outer shell top plate. The first region is the region surrounding any electrode post in the upper cover plate of any of the individual cells; The second region is the area corresponding to any one of the clearance holes on the top plate of the outer casing.

11. The large capacity battery assembly of claim 9, wherein: The battery module also includes 2n insulating seals; 2n insulating seals are installed one by one in the gap between the terminal post and the clearance hole of each individual battery cell; The pole extension applies pressure to the insulating seal along the pole height direction, compressing the insulating seal and sealing the gap between the pole and the clearance hole.

12. The large capacity battery assembly of claim 11, wherein: The insulating seal includes a flexible insulating sealing ring; The flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell. The large-diameter section of the stepped structure is located outside the outer shell. The end face of the large-diameter section near the small-diameter section contacts the top plate of the outer shell, and the end face away from the small-diameter section contacts the pole extension.

13. The large capacity battery assembly of claim 12, wherein: The insulating seal also includes a pressure ring; The pressure ring is a metal component and is disposed between the large-diameter section of the flexible insulating sealing ring and the pole extension component.

14. The large capacity battery assembly of claim 11, wherein: The edge of each clearance hole near the individual battery is sealed to the corresponding individual battery cover plate by filler wire welding; or the battery module also includes 2n hollow components; the 2n hollow components pass through the clearance holes and are fitted around each terminal post, the bottom of the hollow component is laser welded to the first area of ​​the corresponding individual battery, and the top of the hollow component is laser welded to the second area of ​​the outer shell top plate. The first region is the region surrounding any electrode post in the upper cover plate of any of the individual cells; The second region is the region corresponding to any one of the clearance holes on the top plate of the outer casing; The insulating seal is located between the pole and the hollow component, sealing the gap between the pole and the hollow component.

15. A battery pack, characterized by: It includes a number of large-capacity battery components as described in any one of claims 1 to 14; the heat exchange components on each large-capacity battery component are interconnected to form a battery pack liquid circuit system to realize battery pack heat exchange.

16. The battery pack of claim 15, wherein: The inlet channels of multiple heat exchangers are connected in series to form the total inlet path; the outlet channels of multiple heat exchangers are connected in series to form the total outlet path; the end of the total inlet path is connected to the beginning of the total outlet path through an external pipe section. After the coolant enters the inlet end of the main water inlet path, it flows through the inlet channel of each heat exchanger in sequence, and then through the outer pipe section, it flows through the outlet channel of each heat exchanger in sequence, and flows out from the outlet end of the main water outlet path.

Images