A battery member and a battery pack

Abstract

This utility model belongs to the field of batteries, specifically a battery component and a battery pack, overcoming the problem of excessive localized heat at the terminals of individual cells in existing battery packs, leading to thermal runaway. The battery component includes a heat exchanger and individual cells; the heat exchanger includes a heat exchanger body; the heat exchanger body includes conductive and non-conductive bodies alternately arranged along its length, each conductive body connecting two adjacent individual cells to terminals of different polarities, realizing series connection of the individual cells; at least one cooling channel is formed on the heat exchanger body, and an insulating layer is provided on the inner wall of the cooling channel to form a cooling water flow channel; the battery pack includes multiple of the above-mentioned battery components; the heat exchangers on each battery component are interconnected to form a battery pack liquid circuit system. Compared to insulating oil cooling, water cooling can better meet the high-efficiency, economical, and environmentally friendly cooling requirements of battery systems.

Description

Technical Field

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

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

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

[0004] The purpose of this invention is to provide a battery component and battery pack that overcomes the problem of excessive local heat at the terminals of individual cells in existing battery packs, which leads to thermal runaway.

[0005] The first aspect of this utility model provides a battery component, including a heat exchanger and multiple individual batteries;

[0006] The heat exchanger includes a heat exchanger body; the heat exchanger body includes conductive and non-conductive bodies arranged alternately along its length, each conductive body connecting two adjacent single cell terminals of different polarities to realize the series connection of each single cell.

[0007] 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; the inner wall of the cooling channel is provided with an insulating isolation layer to form a cooling water flow channel; the insulating isolation layer realizes the insulation isolation between the cooling water and the conductive body.

[0008] This invention achieves efficient heat dissipation by fixing a heat exchange component on the polar terminal (the polar terminal can be a pole or an integral structure with a pole extension connected to it). 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.

[0009] Meanwhile, the heat exchanger body of this utility model is mainly composed of alternating conductive and non-conductive bodies. The conductive bodies are connected to the polarity terminals of adjacent individual cells of different polarities, enabling series connection between individual cells. The non-conductive bodies are positioned between two conductive bodies, effectively isolating adjacent conductive bodies, achieving insulation, and preventing short circuits. Therefore, in this utility model, the heat exchanger not only serves as a heat exchange component but also as a current collector to realize the series connection of multiple individual cells, offering at least the following advantages:

[0010] Firstly, there is no need to set up a special busbar, which simplifies the overall structure of the battery component; secondly, since the heat exchanger performs both heat exchange and conductivity functions, the number of parts in the battery component is reduced, thus reducing assembly difficulty and cost.

[0011] 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 conductor 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.

[0012] Furthermore, the aforementioned battery component also includes a housing; the housing is provided with an explosion vent; multiple individual cells are arranged inside the housing; the top plate of the housing is provided with clearance holes corresponding to the polarity terminals of each individual cell; the polarity terminals of each individual cell 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 cell.

[0013] The aforementioned casing is equipped with a venting channel that communicates with the venting port. The venting channel is sealed and covers the venting ports of each individual battery cell, and thermal runaway fumes are discharged in an orderly manner through the venting channel, thereby improving the safety performance of the battery components.

[0014] The conductors on the heat exchanger body are connected to the portions of each individual battery polarity terminals that extend out of the corresponding electrode clearance holes.

[0015] Furthermore, the aforementioned insulating layer adopts at least the following two structures:

[0016] The first structure: The insulating layer is a water-cooled pipe nested within the cooling channel. The corresponding cooling channel can be a through hole opened on the heat exchanger body, or it can be a first through slot structure. The first through slot type cooling channel helps to simplify the internal structure of the heat exchanger and makes the assembly of the heat exchanger body and the water-cooled pipe more convenient.

[0017] 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.

[0018] When the insulating layer is of the first structure, the water-cooled pipe includes a metal pipe, and the outer wall of the metal pipe is provided with an insulating layer.

[0019] From an insulation and safety perspective, the insulation layer of the outer wall of the metal pipe uses professional insulation materials such as polytetrafluoroethylene and epoxy resin, which can precisely isolate the cooling water from the conductive parts of the heat exchange components, avoid short circuits, and ensure electrical safety. Its excellent corrosion resistance can resist the chemical erosion of cooling water, maintain long-term stable insulation, and extend battery pack life.

[0020] In terms of thermal conductivity, metal pipes have excellent thermal conductivity, which can quickly absorb and transfer heat to the cooling water inside the pipe, promptly remove heat from the battery polarity terminals, avoid local heat accumulation, and achieve efficient heat dissipation.

[0021] Furthermore, the aforementioned insulating layer can be an enamel insulating layer or an insulating and thermally conductive adhesive layer.

[0022] The enamel insulation layer is made of special enamel and fired at high temperature. It has extremely high insulation resistance and can effectively block the current path between cooling water and metal pipes and conductors, thus avoiding the risk of short circuits at the source.

[0023] The insulating and thermally conductive adhesive layer has excellent bonding properties, allowing it to firmly adhere to the outer wall of the metal pipe and tightly bond with the heat exchanger body. During installation, it acts as an adhesive, securely fixing the water-cooled pipe within the cooling channel of the heat exchanger, enhancing the overall structural stability and reducing the risk of loosening or displacement of the water-cooled pipe due to vibration, impact, or other factors.

[0024] When the insulating layer has the first structure, the aforementioned water-cooled pipes can also be ceramic pipes. Ceramic materials have excellent insulation properties, eliminating the need for additional complex insulation processes to isolate the cooling water from the heat exchange components. Simultaneously, ceramic materials have a low coefficient of thermal expansion, ensuring the dimensional stability of the cooling water flow channel under temperature changes and maintaining smooth water flow; ceramic materials also have good thermal conductivity, enabling rapid heat dissipation and ensuring the battery operates at a suitable temperature.

[0025] Furthermore, the inner wall of the aforementioned ceramic pipe is provided with a metal reinforcement layer.

[0026] The addition of a metal reinforcement layer significantly enhances the mechanical strength of ceramic pipes. While ceramic materials are hard, they are relatively brittle and prone to cracking under external impact or vibration. The metal reinforcement layer, however, possesses excellent toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing ceramic pipe breakage, and extending their service life.

[0027] Furthermore, the aforementioned metal reinforcement layer is an aluminum layer. Compared to other metals, aluminum has better thermal conductivity, and is also highly malleable and easy to process.

[0028] 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.

[0029] The second aspect of this utility model provides a battery pack, including a plurality of the above-mentioned battery components; the heat exchange components on each battery component are interconnected to form a battery pack liquid circuit system to realize heat exchange of the battery pack.

[0030] Furthermore, each battery component includes two heat exchangers, which extend along a first direction and are arranged along a second direction; one heat exchanger is connected to the polar terminal on one side of each individual battery cell, and the other heat exchanger is connected to the polar terminal on the other side of each individual battery cell; wherein the first direction is the arrangement direction of the individual batteries in each battery component, and the second direction is the arrangement direction of multiple battery components.

[0031] Each heat exchanger includes one inlet channel and one outlet channel;

[0032] 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.

[0033] After entering the main inlet, the coolant flows through the inlet channels of each heat exchanger in sequence, and then through the outer pipe section, flows through the outlet channels of each heat exchanger in sequence, and flows out from the main outlet.

[0034] 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).

[0035] The beneficial effects of this utility model are:

[0036] This invention fixes a heat exchange component on the polarity terminal to directly dissipate heat from the battery polarity terminal, resulting in a better heat dissipation effect.

[0037] Meanwhile, the heat exchanger body of this utility model is mainly composed of alternating conductive and non-conductive bodies. The conductive bodies are connected to the polarity terminals of adjacent individual cells of different polarities, enabling series connection between individual cells. The non-conductive bodies are positioned between two conductive bodies, effectively isolating adjacent conductive bodies, achieving insulation, and preventing short circuits. Therefore, in this utility model, the heat exchanger not only serves as a heat exchange component but also as a current collector to realize the series connection of multiple individual cells, offering at least the following advantages:

[0038] Firstly, there is no need to set up a special busbar, which simplifies the overall structure of the battery component; secondly, since the heat exchanger performs both heat exchange and conductivity functions, the number of parts in the battery component is reduced, thus reducing assembly difficulty and cost.

[0039] 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. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the structure of a heat exchanger in Example 1;

[0041] Figure 2 This is an exploded structural diagram of a heat exchanger according to Example 1;

[0042] Figure 3 This is a cross-sectional view of a heat exchanger according to Example 1;

[0043] Figure 4 This is a schematic diagram of another heat exchanger in Example 1;

[0044] Figure 5 This is a schematic diagram of the structure of the first type of battery component in Example 1;

[0045] Figure 6 This is an exploded structural diagram of the first type of battery component in Example 1;

[0046] Figure 7 This is a cross-sectional view of the first type of battery component in Example 1;

[0047] Figure 8 This is a schematic diagram of the structure of the second type of battery component in Example 1;

[0048] Figure 9 This is an exploded structural diagram of the second type of battery component in Example 1;

[0049] Figure 10 This is a cross-sectional view of the second type of battery component in Example 1;

[0050] Figure 11 This is a first-view structural diagram of a battery pack according to Embodiment 1;

[0051] Figure 12 This is a second-view structural diagram of a battery pack according to Embodiment 1;

[0052] Figure 13 This is a schematic diagram of the heat exchanger structure in Example 2;

[0053] Figure 14 This is a cross-sectional view of the heat exchanger in Example 2;

[0054] Figure 15 This is a schematic diagram of the structure of the first heat exchanger in Example 4;

[0055] Figure 16 This is a cross-sectional view of the first type of heat exchanger in Example 4;

[0056] Figure 17 This is a schematic diagram of the structure of the second type of heat exchanger in Example 4;

[0057] Figure 18 This is a schematic diagram of the structure of the third type of heat exchanger in Example 4;

[0058] Figure 19 This is a cross-sectional view of the third type of heat exchanger in Example 4;

[0059] Figure 20 This is a first-view structural diagram of the battery pack in Example 4;

[0060] Figure 21 This is a second-view structural schematic diagram of the battery pack in Example 4.

[0061] The attached figures are labeled as follows:

[0062] 1. Heat exchanger; 11. Heat exchanger body; 111. Conductive body; 112. Non-conductive body; 12. Stepped structure; 13. Cooling channel; 131. Through hole; 132. First through slot; 14. Metal pipe; 15. Insulation layer; 16. Cooling water channel; 163. Inlet channel; 164. Outlet channel; 17. Ceramic pipe; 18. Metal reinforcement layer; 19. First heat exchanger; 10. Second heat exchanger; 2. Battery module; 21. Single cell; 22. Polar terminal; 221. Terminal post; 222. Terminal post extension; 23. Second through slot; 3. Outer shell; 31. Clearance hole; 5. Explosion venting channel; 6. Insulating seal. Detailed Implementation

[0063] 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.

[0064] 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.

[0065] 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," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0066] This utility model relates to a heat exchanger with electrical connection function, which is connected to the polar terminal of a single battery cell. While cooling the polar terminal through liquid cooling, it can also realize the series connection between single batteries.

[0067] 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.

[0068] 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.

[0069] In terms of cost: insulating oil is relatively expensive; water is widely available and inexpensive.

[0070] In terms of environmental protection: Insulating oil leaks are difficult to degrade and pollute the environment; water leaks are harmless and produce no waste.

[0071] 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:

[0072] To achieve the series connection function of the heat exchanger, its body includes conductive and non-conductive bodies arranged alternately along its length. Each conductive body is used to connect the polarity terminals of two adjacent single cells with different polarities, thereby realizing the series connection of each single cell. The non-conductive body is placed between two conductive bodies to effectively isolate adjacent conductive bodies, achieve insulation, and prevent short circuits.

[0073] To achieve the function of cooling polar terminals using water cooling, at least one cooling channel running through both ends of the heat exchanger 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.

[0074] This utility model also discloses a battery component, including a battery module and the aforementioned heat exchanger. The battery module is mainly composed of multiple individual cells. Each conductor in the heat exchanger body is connected to the polarity terminals of two adjacent individual cells, thereby realizing the series connection of the individual cells and heat exchange between the polarity terminals.

[0075] This utility model also discloses a battery pack, including multiple battery components as described above, with heat exchange components on each battery component interconnected to form a battery pack liquid circuit system to achieve heat exchange in the battery pack.

[0076] It should be noted that:

[0077] 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 thereon.

[0078] 2. The aforementioned insulating layer can be a water-cooled pipe nested within the cooling channel, with insulation between the water-cooled pipe and the inner wall of the cooling channel on the conductor. Specifically, it can be implemented using a metal pipe with an insulating layer on its outer wall; or it can be implemented directly using an insulated water-cooled pipe; the aforementioned insulating layer can also be an insulating coating applied to the inner wall of the cooling channel.

[0079] 3. The aforementioned insulating layer may be provided only on the inner wall of the cooling channel on the conductor;

[0080] 4. 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.

[0081] 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.

[0082] 5. The above-mentioned battery modules may include at least the following two types:

[0083] Type 1 battery module:

[0084] The first type of battery module includes multiple individual battery cells arranged along a first direction;

[0085] 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.

[0086] Second type of battery module:

[0087] The second 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.

[0088] The outer casing is equipped with an explosion vent, through which thermal runaway fumes are discharged. An explosion vent channel connecting the explosion vents can also be provided inside the casing. This channel seals over the explosion vents of each individual battery cell, allowing thermal runaway fumes to be discharged in an orderly manner through the channel, effectively preventing them from spreading into the casing and affecting other individual batteries, thus avoiding exacerbating thermal runaway.

[0089] This utility model does not specifically limit the above-mentioned shell structure, but at least the following two structures can be adopted:

[0090] 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).

[0091] 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).

[0092] 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.

[0093] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0094] Example 1

[0095] like Figure 1 , Figure 2 and Figure 3As shown, the heat exchanger 1 in this embodiment includes a heat exchanger body 11, which is a long columnar structure. Its cross-section is usually designed as rectangular or circular, and the size can be customized according to actual needs.

[0096] In this embodiment, part of the structure of the heat exchanger body 11 can be used as a busbar to connect with the polar terminal 22 in the battery component, thereby realizing the series connection between each individual cell 21 of the battery component.

[0097] Specifically, as can be seen from the figure, the heat exchanger body 11 of this embodiment includes conductive bodies 111 and non-conductive bodies 112 arranged alternately along its length. Each conductive body 111 is used to connect the polarity terminals of two adjacent single cells with different polarities to realize the series connection of each single cell. The non-conductive body 112 is disposed between two conductive bodies 111 to effectively isolate adjacent conductive bodies 111 and prevent short circuit.

[0098] The conductor 111 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 conductor 111. The non-conductive part 112 is usually made of plastic or rubber, which have good thermal conductivity.

[0099] In order to improve the connection stability between the heat exchanger and the polar terminal 22, this embodiment provides a stepped structure 12 on the outer wall of each conductor 111 along its length direction (x direction), and uses the horizontal surface of the stepped structure 12 as a welding part to weld to the polar terminal 22.

[0100] It should be noted that the horizontal plane of the aforementioned step structure 12 refers to the connection surface between the large-diameter section and the small-diameter section of the conductor 111 in the z-direction.

[0101] Welding enables a tight connection between the heat exchanger 1 and the polarity terminal 22. 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 separation of the heat exchanger 1 and polarity terminal 22 due to vibration, impact, or other factors during battery operation, thus avoiding impact on heat dissipation and ensuring continuous and stable operation of the battery. Furthermore, the tight contact significantly reduces contact resistance, allowing current to be evenly distributed between the heat exchanger 1 and polarity terminal 22, avoiding localized current concentration or hot spots caused by poor contact.

[0102] from Figures 1 to 3 As can be seen from the figure, in this embodiment, a cooling channel 13 is opened 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.

[0103] The cooling channel 13 can adopt the following two structures:

[0104] First structure: Through hole 131;

[0105] like Figure 2 As shown, the cooling channel 13 is a through hole 131 that runs through both ends of the heat exchanger body 11 in the length direction.

[0106] Second structure: First through groove 132;

[0107] like Figure 4 As shown, the cooling channel 13 is a first through groove 132 that runs through both ends of the heat exchanger body 11 in the length direction.

[0108] 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.

[0109] The aforementioned insulating layer 15 can take at least the following two structures:

[0110] Structure 1: Enamel insulation layer;

[0111] 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 body 11 to the metal pipe 14 and the cooling water inside the pipe, achieving a good heat dissipation effect.

[0112] 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.

[0113] 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 22 can be dissipated in a timely manner, maintaining the battery at a suitable operating temperature and improving its charge / discharge performance and lifespan.

[0114] 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.

[0115] Corresponding to the structure of the insulating layer 15, the cooling channel 13 can be a through hole 131 or a first through groove 132.

[0116] Structure 2: Insulating and thermally conductive adhesive layer;

[0117] 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 body 11 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.

[0118] Corresponding to the structure of the insulation layer 15, the cooling channel 13 is preferably a first through groove 132. The open end of the first through groove 132 can serve as a dispensing port. During dispensing, due to the openness of the first through groove 132, the adhesive can uniformly 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 first through groove 132 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.

[0119] 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; however, an excessively thin layer may affect bond strength and insulation reliability. A thicker adhesive layer, while enhancing adhesion and insulation, increases thermal resistance and hinders 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 the battery components to achieve a balance among various performance aspects.

[0120] 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.

[0121] like Figures 5 to 7 As shown, this is the first type of battery component in this embodiment, including a battery module 2 and the aforementioned heat exchanger 1. The battery module 2 in this embodiment is the aforementioned first type of battery module.

[0122] As shown in the figure, the battery module 2 in this embodiment includes 12 individual battery cells 21 arranged along the x-direction. In this embodiment, the individual battery cells 21 are prismatic cells, and the internal cavity of each individual battery cell 21 includes an electrolyte region and a gas region. In other embodiments, the number of individual battery cells 21 can be adjusted according to actual needs, and the shape of the individual battery cells 21 can also be adjusted according to actual needs.

[0123] Each individual cell 21 has a terminal extension 222 connected to its terminal post 221 as a polarity terminal 22.

[0124] A second through groove 23 for mounting the heat exchanger 1 is provided on the pole extension 222. The second through groove 23 extends along the x-direction, that is, the length direction of the second through groove 23 is parallel to the x-axis. The inner cavity shape of the second through groove 23 is adapted to the cross-sectional shape of the conductor 111, and it is necessary to ensure that the conductor 111 is tightly clamped in it to ensure installation stability while also ensuring heat transfer and electrical conductivity between the conductor 111 and the pole extension 222. As can be seen from the figure, this embodiment uses a rectangular second through groove 23, and the cross-section of the conductor 111 adapted to it is rectangular.

[0125] The specific installation process is as follows: First, connect each terminal extension 222 to the corresponding terminal 221 of the single cell 21. After all terminal extensions 222 are fixed, fix the heat exchanger 1 along the x-direction into the second through groove 23 of each terminal extension 222 located on the same side, and weld the conductor 111 to the two side walls of the second through groove 23. Figure 5 As can be seen from the image, in this embodiment, two heat exchange components 1 are provided on the top of the battery module 2.

[0126] To improve welding quality and connection stability, and to ensure efficient heat conduction and uniform current transmission, in this embodiment, the horizontal plane of the stepped structure 12 on the conductor 111 is flush with the side wall end face of the second through groove 23. Welding is performed at the joint between the horizontal plane of the stepped structure 12 and the side wall end face of the second through groove 23. Figure 7 The region shown in Figure a.

[0127] A stepped structure 12 is provided on the outer wall of the conductor 111, and the horizontal plane of the stepped structure 12 is flush with the end face of the side wall of the second through groove 23. At the same time, the joint is welded together, which has at least the following advantages:

[0128] 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 battery components.

[0129] Optimize thermal conductivity and electrical conductivity: The horizontal plane of the stepped structure 12 is flush with the side wall end face of the second through groove 23, ensuring a tighter contact between the conductor 111 and the pole extension 222, 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 conductor 111 and the pole extension 222, avoiding local current concentration or hot spots caused by poor contact.

[0130] Furthermore, during the welding process, conventional welding operations may damage the structure of the heat exchanger body 11 due to factors such as high temperature and stress concentration, thus causing potential leakage hazards. The stepped structure 12, however, has a horizontal plane flush with the sidewall end face of the second through groove 23, 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.

[0131] In this embodiment, the inner cavity of the metal pipe 14 is used as the cooling water channel 16. When the heat of the electrode post 221 is conducted to the electrode post extension 222, it will be further transferred to the cooling water in the cooling water channel 16 of the heat exchanger 1 to achieve heat dissipation of the battery module 2.

[0132] Meanwhile, in this embodiment, the conductor 111 of the heat exchanger body 11 is connected to the polarity terminals of adjacent single cells in the battery component with different polarities, thereby realizing the series connection of multiple single cells 21.

[0133] Therefore, in this embodiment, the heat exchanger 1 not only serves as a heat exchange component but also as a conductor 111 to realize the series connection of multiple individual cells 21, which has at least the following advantages:

[0134] Firstly, the elimination of the need for a dedicated busbar simplifies the overall structure of the 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 and making the overall structure of the battery module simpler and more compact, thus reducing design complexity and the probability of errors.

[0135] Secondly, since heat exchanger 1 performs both heat exchange and electrical conduction functions, it reduces the number of components in the battery assembly, thereby lowering assembly difficulty and cost. Previously, separate heat exchange tubes and manifolds were used, resulting in a large number of components, increased procurement costs, and the need for precise installation of each component during assembly, which placed high demands on the assembly workers' skills and resulted in a long assembly time.

[0136] Thirdly, the heat exchanger 1, as a series connector, is directly embedded in the second through slot 23 of the pole post extension 222, making full use of the space of the pole post extension 222 and avoiding the problem of additional busbars occupying space, which is conducive to improving the integration of battery components.

[0137] like Figures 8 to 10 As shown, this is the second type of battery component in this embodiment. Its structure differs from that of the first type of battery component in that the battery module 2 is the second type of battery module described above.

[0138] In this embodiment, the second type of battery module arranges 12 individual batteries 21 inside the housing 3, and each terminal extension 222 is located outside the housing 3. The heat exchanger 1 is fixed on the terminal extension 222 located on the same side. The structure of the terminal extension 222 and its installation structure with the heat exchanger 1 are the same as those of the first type of battery component, and will not be described again here.

[0139] On the top plate of the outer casing 3, there is a boss extending in the x direction. An explosion venting channel 5 is opened on the boss. The explosion venting channel 5 seals and covers the explosion venting port of each individual battery. When any individual battery experiences thermal runaway, the thermal runaway smoke is discharged in an orderly manner through the explosion venting channel 5 to the explosion venting port. This can effectively prevent the thermal runaway smoke from spreading into the casing and affecting other individual batteries, thus preventing the thermal runaway from occurring.

[0140] The assembly of such battery components can be achieved through the following process:

[0141] First, place 12 individual batteries 21 inside the outer casing 3, and fix and seal the top plate of the outer casing 3 corresponding to the clearance hole 31 to the top cover plate of the individual battery 21.

[0142] In this embodiment, a sealed connection can be achieved by welding the edge of the clearance hole 31 near the single cell 21 to the top cover plate of the single cell 21 using filler wire welding; alternatively, laser welding can be used to weld the area around each clearance hole 31 on the top plate of the outer casing to the area around the corresponding electrode post 221 on the top cover plate of the single cell 21. Hollow components can also be used to seal the area of ​​the top plate of the outer casing corresponding to the clearance hole 31 to the top cover plate of each single cell 2. Specifically, each hollow component is inserted through the clearance hole 31 and fitted around each electrode post 221. The bottom of the hollow component is laser-welded to the first area of ​​the corresponding single cell 21, and the top of the hollow component is laser-welded to the second area of ​​the top plate of the outer casing. The first area is the area around any electrode post 221 in the top cover plate of any single cell 21; the second area is the area corresponding to any clearance hole 31 on the top plate of the outer casing. The area corresponding to the clearance hole 31 can be the wall of the clearance hole 31 or the area around the clearance hole 31 on the top plate of the outer casing.

[0143] Furthermore, due to the small gap between the terminal 221 of the individual battery 21 and the clearance hole 31, the insulation between the terminal 221 of the individual battery 21 and the top plate of the outer casing 3 may be difficult to ensure. Additionally, if thermal runaway occurs, cracks may appear at the weld between the clearance hole 31 and the top cover of the individual battery 21, causing thermal runaway fumes to leak from that location. Therefore, if... Figure 10 As shown, in this embodiment, an insulating seal 6 is provided in the gap between each clearance hole 31 and the pole post 221. The insulating seal 6 can ensure the insulation between the polarity terminal 22 and the top plate of the housing 3. At the same time, even if leakage occurs at the welding position, the insulating seal 6 can also serve as a second barrier to prevent the leakage of thermal runaway flue gas.

[0144] Therefore, after fixing and sealing the top plate of the outer casing 3 corresponding to the clearance hole 31 to the top cover plate of the single cell 21, the insulating seal 6 is set between each clearance hole 31 and the terminal post 221. Then, the terminal post extension 222 is pressed tightly against the insulating seal 6, and finally the terminal post extension 222 is connected to the terminal post 221 of the single cell 21.

[0145] In some other embodiments, the insulating seal 6 may also be an insulating seal layer disposed at the gap between the clearance hole 31 and the pole post 221 by a casting process.

[0146] Finally, the heat exchanger 1 is fixed in the second through groove 23 of the pole extension 222.

[0147] like Figure 11 and Figure 12 The diagram shown is a schematic of the battery pack structure in this embodiment, including four battery components arranged along the y-direction (represented in the diagram as being of the above type). Figures 8 to 10 (Taking the battery component shown as an example), in other embodiments, the number of battery components can be adjusted according to actual needs.

[0148] For ease of description, the two heat exchangers 1 on each battery component are defined as the first heat exchanger 19 and the second heat exchanger 10, respectively.

[0149] In the entire battery pack, multiple first heat exchangers 19 are connected in series to form a total water inlet path; multiple second heat exchangers 10 are connected in series to form a total water outlet path; the end of the total water inlet path is connected to the beginning of the total water outlet path through an external pipe section.

[0150] After entering the main inlet, the cooling water flows through the first heat exchanger 19 of each battery component in sequence, and then through the outer pipe section, it flows through the second heat exchanger 10 of each battery component in sequence, and flows out from the main outlet.

[0151] This series-connected fluid flow design allows cooling water to flow sequentially through each battery component, carrying away the heat generated by each component. During the cooling water flow, each battery component receives relatively even cooling, avoiding temperature differences caused by insufficient or excessive cooling of some components, and achieving uniform temperature distribution across the entire battery pack.

[0152] In some other embodiments, the heat exchangers 1 may be connected in series.

[0153] Example 2

[0154] This embodiment is also a heat exchanger 1, but it differs from embodiment 1 in that, as Figure 13 and Figure 14 As shown, in this embodiment, a ceramic pipe 17 is nested inside the cooling channel 13. The inner cavity of the ceramic pipe 17 serves as a cooling water flow channel 16, and the cooling water can be insulated from the heat exchanger body 11 based on the ceramic pipe.

[0155] 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 for the battery components and improve the safety of the battery components.

[0156] Furthermore, the ceramic pipe 17 has a low coefficient of thermal expansion, which allows it to maintain dimensional stability during frequent temperature changes in battery operation. It is less prone to deformation due to thermal expansion and contraction, ensuring the structural integrity and flow stability of the cooling water channel 16. Simultaneously, the ceramic material has excellent thermal conductivity, enabling it to quickly transfer heat from the heat exchanger body 11 to the cooling water inside the pipe, thus improving overall heat dissipation efficiency and maintaining the battery's suitable operating temperature.

[0157] 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 18 on the inner wall of the ceramic pipe 17 to improve its mechanical strength. The metal reinforcing layer can be made of a material with good toughness and ductility, effectively absorbing and dispersing external forces, buffering external impacts, preventing the ceramic pipe 17 from cracking, and extending its service life.

[0158] Specifically, in this embodiment, an aluminum layer is selected as the metal reinforcement layer. Aluminum not only has excellent thermal conductivity but also good plasticity, making it easy to process and shape.

[0159] In other embodiments, other metal-formed metal reinforcement layers may also be selected, such as titanium alloys, nickel-based alloys, etc., to improve the mechanical strength of ceramic pipe 17.

[0160] In this embodiment, the aluminum layer can be deposited on the inner wall of the ceramic pipe 17 through a casting process, and the casting temperature is strictly controlled to be lower than the heat deformation temperature of the ceramic pipe 17. This casting method allows the aluminum layer to adhere tightly to the inner wall of the ceramic pipe 17, forming a stable composite structure.

[0161] 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.

[0162] The structure of the heat exchanger body 11 in this embodiment is the same as that in Embodiment 1, and will not be described again here.

[0163] Similar to Example 1, the battery components adapted to the heat exchanger 1 described above can also be of two types:

[0164] The first type of battery component includes a battery module 2 and a heat exchanger 1. Except for the structure of the heat exchanger 1, which differs from that of Embodiment 1, the rest are the same as the first type of battery component in Embodiment 1, and will not be described again here.

[0165] The second type of battery component is the same as that in Example 1, except that the structure of the heat exchanger 1 is different from that in Example 1. It will not be described again here.

[0166] 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.

[0167] Example 3

[0168] This embodiment is also a heat exchanger 1. Unlike the above embodiments, this embodiment coats the inner wall of the cooling channel 13 with an insulating coating to achieve insulation isolation between the cooling water and the conductor 111.

[0169] Insulating coatings can be epoxy resin coatings, polytetrafluoroethylene coatings, silicone rubber coatings, etc.

[0170] Compared to the embedded water-cooled pipes used as an insulating layer in Examples 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 water-cooled 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.

[0171] In practical applications, improvements can be made in coating materials, surface treatment, and coating processes to effectively optimize the adhesion between the insulating coating and the inner wall of the cooling channel. 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.

[0172] Similar to Example 1, the battery components adapted to the heat exchanger 1 described above can also be of two types, the only difference being the heat exchanger itself, while the rest of the structures are the same, and will not be described in detail here.

[0173] 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.

[0174] Example 4

[0175] The heat exchanger 1 in this embodiment differs from the one in the above embodiment in that the heat exchanger body 11 in this embodiment is provided with two cooling channels 13.

[0176] In this embodiment, the two cooling channels 13 are parallel to each other, and the structure of each cooling channel 13 and the insulating layer 15 therein are the same as in the above embodiment.

[0177] like Figures 15 to 17 As shown, the structure of each cooling channel 13 and the insulating layer 15 therein are the same as those in Embodiment 1 above; Figure 15 and Figure 16 In the middle, both cooling channels 13 adopt a through-hole 131 structure. Figure 17 In this embodiment, both cooling channels 13 adopt a first through groove 132 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.

[0178] like Figures 18 to 19 As shown, the structure of each cooling channel 13 and the insulating layer 15 therein are the same as in Embodiment 2 above; a ceramic pipe 17 is nested inside the cooling channel 13 to achieve insulation isolation between the cooling water and the conductor 111. Specific structural details have been described in Embodiment 2 and will not be repeated here.

[0179] Similar to the above embodiments, the battery components adapted to the heat exchanger 1 can also be of two types, differing only in the heat exchanger itself; the rest of the structure is the same and will not be described in detail here.

[0180] like Figure 20 and Figure 21The diagram shown is a structural schematic of the battery pack from different perspectives in this embodiment. The battery pack includes four battery components arranged along the y-direction (the diagram uses the second type of battery component as an example). In practical applications, the number of battery components can be flexibly adjusted according to specific needs.

[0181] In this embodiment, for ease of description, the two cooling water channels 16 on each heat exchanger 1 are defined as an inlet channel 163 and an outlet channel 164, respectively. The inlet channels 163 of the four battery components are connected end to end in sequence to form a total inlet path; and the outlet channels 164 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.

[0182] The specific cooling process is as follows: Cooling water enters from the main inlet end and flows sequentially through the inlet channels of each heat exchanger 1. Then, its flow direction changes at the outer pipe section, and it flows sequentially through the outlet channels 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 and outlet channels, ensuring uniform heat dissipation for each polarity terminal 22. For all heat exchangers 1 in the entire battery pack, the temperature difference between the inlet and outlet channels 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.

Claims

1. A battery component, characterized by: Including heat exchange components and multiple individual battery cells; The heat exchanger includes a heat exchanger body; the heat exchanger body includes conductive and non-conductive bodies arranged alternately along its length, each conductive body connecting two adjacent single cell terminals of different polarities to realize the series connection of each single cell. 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; the inner wall of the cooling channel is provided with an insulating isolation layer to form a cooling water flow channel; the insulating isolation layer realizes the insulation isolation between the cooling water and the conductive body.

2. The battery component according to claim 1, characterized in that: It also includes an outer casing; the outer casing is provided with an explosion vent; multiple individual batteries are arranged inside the outer casing; the top plate of the outer casing 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 outer casing is sealed and connected to the top cover plate of the corresponding individual battery. The outer casing is provided with an explosion vent channel that communicates with the explosion vent. The explosion vent channel is sealed and covers the explosion vent of each individual battery cell, and the thermal runaway flue gas is discharged in an orderly manner through the explosion vent channel. The conductors on the heat exchanger body are connected to the portions of each individual battery polarity terminals that extend out of the corresponding electrode clearance holes.

3. The battery component according to claim 1, characterized in that: The insulating layer is a water-cooled pipe nested within the cooling channel.

4. The battery component according to claim 3, characterized in that: The water-cooled pipe includes a metal pipe, and the outer wall of the metal pipe is provided with an insulating layer.

5. The battery component according to claim 4, characterized in that: The insulating layer is an enamel insulating layer or an insulating and thermally conductive adhesive layer.

6. The battery component according to claim 1, characterized in that: The water-cooled pipes are ceramic pipes.

7. The battery component according to claim 1, characterized in that: The cooling channel is a through hole opened on the heat exchanger body, and the insulating isolation layer is an insulating coating applied to the inner wall of the cooling channel.

8. The battery component according to any one of claims 1 to 7, characterized in that: 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.

9. A battery pack, characterized in that: It includes multiple battery components as described in any one of claims 1 to 8; the heat exchange components on each battery component are interconnected to form a battery pack liquid circuit system to realize battery pack heat exchange.

10. The battery pack according to claim 9, characterized in that: Each battery component includes two heat exchangers, which extend along a first direction and are arranged along a second direction; one heat exchanger is connected to the polar terminal on one side of each individual battery cell, and the other heat exchanger is connected to the polar terminal on the other side of each individual battery cell; wherein the first direction is the arrangement direction of the individual batteries in each battery component, and the second direction is the arrangement direction of multiple battery components. Each heat exchanger includes one inlet channel and one outlet channel; 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 entering the main inlet, the coolant flows through the inlet channels of each heat exchanger in sequence, and then through the outer pipe section, flows through the outlet channels of each heat exchanger in sequence, and flows out from the main outlet.

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