Testing organization for leaks in battery devices, electrical equipment, and components under test.

Abstract

This application provides a leakage detection mechanism for a battery device, electrical equipment, and a device under test. The battery device includes multiple battery cells; a heat exchange assembly is configured to exchange heat with the battery cells; at least one detection mechanism is disposed on the outside of the heat exchange assembly and includes an insulating base with a limiting groove and configured to switch between a first state and a second state; in the first state, the insulating base has a plate-like structure; in the second state, the insulating base has an arc-shaped structure; a liquid-absorbing element is disposed on the insulating base and in contact with the heat exchange assembly, and is configured to absorb heat exchange medium leaking from the heat exchange assembly; at least a portion of a sensing structure is disposed within the limiting groove of the insulating base and in contact with the liquid-absorbing element, and is configured to conduct through the heat exchange medium on the liquid-absorbing element; a processor is electrically connected to the sensing structure and is configured to detect electrical signals in real time to achieve leakage detection of the heat exchange assembly. Thus, leakage can be detected promptly, with high detection sensitivity and accuracy.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, and in particular to a battery device, electrical equipment, and a detection mechanism for leakage of the test component. Background Technology

[0002] Energy conservation and emission reduction are key to the sustainable development of the automotive industry, and electric vehicles, due to their energy-saving and environmentally friendly advantages, have become an important component of this sustainable development. For electric vehicles, battery technology is a crucial factor in their development.

[0003] Battery devices continuously generate heat during operation. To mitigate the impact of this heat, heat exchange components are installed inside the battery device, and heat exchange is achieved by introducing a heat exchange medium into these components. However, during the flow of the heat exchange medium within the components, leaks may occur at joints or other locations. Therefore, it is necessary to detect leaks in the heat exchange components.

[0004] However, the relevant technologies are difficult to detect leaks in a timely manner, or the detection sensitivity and accuracy are not high. Utility Model Content

[0005] The battery device, electrical equipment, and test component leakage detection mechanism provided in this application aims to solve the problems in existing related technologies, such as difficulty in timely detection of leakage or low detection sensitivity and accuracy.

[0006] To solve the above-mentioned technical problems, one technical solution adopted in this application is to provide a battery device, which includes:

[0007] Multiple battery cells;

[0008] The heat exchange assembly is configured to exchange heat with the individual battery cells;

[0009] At least one testing unit is located on the outside of the heat exchange assembly; the testing unit includes:

[0010] An insulating base is provided with a limiting groove, and the insulating base is configured to switch between a first state and a second state; wherein, in the first state, the insulating base has a plate-like structure; and in the second state, the insulating base has an arc-shaped structure.

[0011] A liquid suction element is disposed on an insulating base and in contact with the heat exchange assembly, and is configured to absorb heat exchange medium leaking from the heat exchange assembly;

[0012] The sensing structure is at least partially disposed within the limiting groove of the insulating base and in contact with the liquid suction element, and is configured to be conductive through the heat exchange medium on the liquid suction element.

[0013] The processor is electrically connected to the sensing structure and is configured to detect the electrical signals of the sensing structure in real time to enable leakage detection of the heat exchange components.

[0014] The aforementioned battery device includes a detection mechanism. This mechanism incorporates a sensing structure that is connected to the heat exchange medium on a liquid-absorbing component. A processor monitors the electrical signal of the sensing structure in real time, using the on / off state of the sensing structure to detect leaks in the heat exchange assembly. This not only allows for timely detection of leaks and prompt action on leaking battery devices, effectively reducing their impact, but also, compared to methods using liquid level sensors, enables the detection of even small leaks in the heat exchange medium, improving sensitivity and accuracy. Furthermore, the liquid-absorbing component, in contact with the heat exchange assembly, allows the sensing structure to be connected to the heat exchange medium. This concentrates the leaked heat exchange medium within the sensing structure, enabling the detection of even minute leaks and enhancing sensitivity. Additionally, collecting the leaked heat exchange medium within the liquid-absorbing component effectively reduces the probability of short circuits in internal battery cells caused by the leak. Furthermore, this detection mechanism does not affect the structure or operation of the original heat exchange components, ensuring high safety and reliability. Moreover, its subsequent maintenance allows for the replacement or repair of the liquid suction component based on actual conditions, eliminating the need to replace the entire detection mechanism, thus reducing maintenance difficulty and operating costs. Additionally, this design makes the detection mechanism adaptable to both plate-like structures and tubular structures of different diameters within heat exchange components, accommodating leak points of various shapes and demonstrating strong versatility. Furthermore, by placing the sensing structure within the limiting groove, the design not only limits the sensing structure but also facilitates the flow of heat exchange medium from the liquid suction component into the first limiting groove, resulting in better contact with the first sensing structure and improved detection sensitivity.

[0015] In one embodiment, the processor includes:

[0016] The signal acquisition unit is electrically connected to the induction structure and is configured to acquire the electrical signals of the induction structure.

[0017] The signal processing unit, electrically connected to the signal acquisition unit, is configured to compare the electrical signal with a standard threshold to confirm whether the heat exchange component is leaking.

[0018] The aforementioned scheme confirms whether a heat exchange component is leaking by comparing an electrical signal with a standard threshold. It effectively distinguishes between coolant leaks and interference from external condensate, water vapor, etc., reducing the impact of external water vapor and condensate on the detection results. It exhibits strong anti-interference capabilities, reducing the false alarm rate by over 90% and significantly improving detection accuracy. Furthermore, the standard threshold can be selected and set according to different conductivity levels of the heat exchange medium to detect leaks in heat exchange media with varying conductivity levels within the heat exchange component, resulting in a longer service life. Additionally, integrating each unit into the processor increases the overall integration level of the detection mechanism.

[0019] In one embodiment, the signal processing unit is further configured to generate and output an alarm signal when the heat exchange component leaks; the detection mechanism also includes an alarm, electrically connected to the signal processing unit, and configured to receive the alarm signal and provide an alarm prompt.

[0020] The above solution can automatically alarm in time when leakage occurs in the heat exchange components, so as to remind users to deal with the leakage in time, reducing the risk of overheating or damage to the battery device due to the expansion of heat exchange medium leakage; at the same time, compared with manual monitoring, it reduces the cost of manual inspection and improves the operation and maintenance efficiency of heat exchange components.

[0021] In one embodiment, the detection mechanism further includes: a sealing element, which is disposed on both sides of the liquid suction element at least along a first direction and is clamped between the insulating base and the heat exchange assembly.

[0022] The above solution can improve the sealing between the insulating base and the heat exchange components, thereby reducing the entry of external moisture into the liquid suction component, reducing the impact of external moisture on the test results, and effectively improving the accuracy of the test.

[0023] In one embodiment, the detection mechanism further includes a fixing structure configured to fix the insulating base to the heat exchange assembly.

[0024] The above-described solution, through its fixed structure, allows for rapid attachment of the detection mechanism to the heat exchange assembly, and enables a tighter fit between the liquid suction component and the heat exchange assembly. This facilitates better collection of leaked heat exchange medium, leading to more accurate detection of leaked heat exchange medium. The solution features a relatively simple structure and a high degree of integration.

[0025] In one embodiment, the fixing structure includes:

[0026] A strap is wrapped around the side of the insulating base away from the heat exchange assembly to secure the relative position of the insulating base and the heat exchange assembly; and / or

[0027] An adhesive structure is provided on the surface of the insulating base facing the liquid-absorbing element and is bonded to the heat exchange assembly.

[0028] The above solution uses straps and / or adhesive structures to fix the insulating base and heat exchange components relatively firmly, making the installation process simple and quick. It can be installed without the need for professional tools, is compatible with various heat exchange components, and has strong versatility.

[0029] In one embodiment, there are multiple testing institutions, each corresponding to a different location on the heat exchange component.

[0030] The above solution, by setting up a detection mechanism at different locations on the heat exchange component, supports multi-point distributed installation, can accurately locate the leakage location of the heat exchange component, and promptly address the leakage.

[0031] In one embodiment, it also includes:

[0032] The remote monitoring device is electrically connected to each testing institution and performs remote monitoring of each testing institution.

[0033] The above solution enables comprehensive monitoring and remote uploading of leakage information by simultaneously remotely monitoring multiple testing institutions; it supports unattended unified management, eliminating the need for on-site inspections and solving the problem of lagging manual inspections; and it facilitates quick location of leaks for timely repairs, improving the efficiency of intelligent operation and maintenance.

[0034] In one embodiment, the sensing structure includes a first sensing structure and a second sensing structure; a first limiting groove and / or a second limiting groove are formed on the side surface of the insulating base facing the liquid suction member; at least a portion of the first sensing structure is disposed in the first limiting groove; at least a portion of the second sensing structure is disposed in the second limiting groove.

[0035] The above-mentioned scheme can limit the first sensing structure through the first limiting groove, and facilitate the flow of heat exchange medium on the liquid suction element into the first limiting groove for better contact with the first sensing structure, thereby improving the detection sensitivity; and / or, limit the second sensing structure through the second limiting groove, and facilitate the flow of heat exchange medium on the liquid suction element into the second limiting groove for better contact with the second sensing structure, thereby improving the detection sensitivity.

[0036] In one embodiment, the insulating base has a plurality of drainage grooves on the side surface facing the liquid suction member, and the drainage grooves are connected to the first limiting groove and / or the second limiting groove.

[0037] The above solution, by adding a diversion channel, can better divert the heat exchange medium on the liquid suction component into the first limiting channel and / or the second limiting channel, reducing the risk of missed detection due to the induction structure not being able to contact the heat exchange medium, which helps to realize the detection of trace leaks and improves the detection accuracy.

[0038] In one embodiment, the sensing structure includes a first sensing structure and a second sensing structure; at least one of the first sensing structure and the second sensing structure is mesh-like.

[0039] The above solution, without increasing the volume of the battery device, can increase the contact area between the first sensing structure and / or the second sensing structure and the liquid absorption element, thereby increasing the sensing area of ​​the sensing structure, improving detection reliability, reducing the risk that the sensing structure cannot contact the heat exchange medium, and thus improving detection sensitivity.

[0040] In one embodiment, the sensing structure includes a first sensing structure and a second sensing structure spaced apart along a second direction; the first sensing structure and the second sensing structure extend along a first direction, and their dimensions along the first direction are both greater than or equal to half the dimension of the liquid-absorbing member along the first direction; wherein the orthographic projection of the first sensing structure onto the liquid-absorbing member extends along the first direction to at least a first side edge of the liquid-absorbing member; the orthographic projection of the second sensing structure onto the liquid-absorbing member extends along the first direction to at least a second side edge of the liquid-absorbing member; wherein the second direction is perpendicular to the first direction.

[0041] The above solution enables heat exchange medium leaking to any position along the first direction of the suction element to either contact the first sensing structure, or contact the second sensing structure, or contact both the first and second sensing structures. This effectively increases the probability that heat exchange medium leaking to any position along the first direction of the suction element can be detected, greatly improving detection sensitivity and accuracy, and reducing the risk of missed detection.

[0042] To solve the above-mentioned technical problems, another technical solution adopted in this application is to provide an electrical device including the battery device mentioned above.

[0043] To solve the above-mentioned technical problems, another technical solution adopted in this application is: to provide a detection mechanism for leakage of the test piece, comprising:

[0044] An insulating base is provided with a limiting groove, and the insulating base is configured to switch between a first state and a second state; wherein, in the first state, the insulating base has a plate-like structure; and in the second state, the insulating base has an arc-shaped structure.

[0045] A liquid-absorbing element is disposed on an insulating base and configured to contact the outer surface of the test piece to absorb conductive medium leaking from the test piece.

[0046] The sensing structure is at least partially disposed in the limiting groove of the insulating base and in contact with the liquid suction element, and is configured to conduct through a conductive medium on the liquid suction element.

[0047] The processor is electrically connected to the sensing structure and is configured to detect the conduction signal of the sensing structure to achieve leakage detection of the device under test.

[0048] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0049] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0050] Figure 1 The structural diagram of the electrical equipment provided in this application;

[0051] Figure 2 This is a disassembly diagram of a battery device provided in some embodiments of this application;

[0052] Figure 3 A disassembly diagram of a testing mechanism in a first state according to an embodiment of this application;

[0053] Figure 4 Provided for an embodiment of this application Figure 3 The diagram shows the detection mechanism in its second state.

[0054] Figure 5 for Figure 4 A disassembly diagram of the testing mechanism shown;

[0055] Figure 6 A partial structural schematic diagram of a heat exchange component provided in some embodiments of this application;

[0056] Figure 7 A disassembly diagram of a testing mechanism in a first state, provided for another embodiment of this application;

[0057] Figure 8 This is a schematic diagram of the structure of an insulating base provided in one embodiment of this application;

[0058] Figure 9 This is a schematic diagram of an embodiment of the present application showing a sensing structure disposed on an insulating base.

[0059] Explanation of reference numerals in the attached figures

[0060] 100 Electrical appliances; 200 Battery devices;

[0061] 10 Battery cell; 20 Heat exchange assembly; 21 Thermal management component; 22 Current collector; 23 Connecting pipe; 30 Detection mechanism; 31 Insulating base; 311 Sealing groove; 312 First limiting groove; 313 Second limiting groove; 314 Drainage groove; 32 Liquid suction component; 331 First sensing structure; 332 Second sensing structure; 34 Sealing component; 35 Fixing structure; 351 Binding strap; 352 Adhesive structure; 40 Battery housing. Detailed Implementation

[0062] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0063] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0064] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0065] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0066] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0067] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0068] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0069] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0070] Currently, judging from market trends, the application of power batteries is becoming increasingly widespread. Power batteries are not only used in energy storage systems such as hydraulic, thermal, wind, and solar power plants, but also extensively used in electric vehicles such as electric bicycles, electric motorcycles, and electric cars, as well as in military equipment and aerospace. With the continuous expansion of power battery applications, market demand is also constantly increasing.

[0071] Regardless of battery shape, temperature has a significant impact. Different temperatures affect the safety, lifespan, function, and performance of power batteries. Excessively high or low temperatures can lead to thermal runaway, severe lifespan degradation, and limited charge / discharge capabilities. Therefore, to maintain power batteries within a reasonable temperature range, heat exchange components, such as liquid cooling systems, are typically used in practical applications to regulate battery temperature. However, liquid cooling systems are prone to coolant leakage during use. Therefore, it is necessary to inspect the battery device for cooling leaks.

[0072] In related technologies, the following methods are mainly used for leak detection. The first method is manual periodic inspection; this method relies on workers visually inspecting cooling pipes, joints, water tanks, etc., for liquid seepage or water stains, while observing changes in the coolant level to determine if a leak has occurred. The second method is using a level sensor; this method involves installing a level sensor inside the coolant reservoir and monitoring the drop in coolant level to indirectly determine if a leak has occurred. The third method is using a pressure sensor; this method involves maintaining pressure inside the liquid cooling assembly and detecting coolant leaks by monitoring pressure changes.

[0073] However, manual inspection relies on manual operation, resulting in low detection efficiency and high lag, making it impossible to achieve real-time and uninterrupted monitoring. Furthermore, minor leaks are difficult to detect in a timely manner, leading to missed detections. Moreover, it cannot issue early warnings in the early stages of leaks, which can easily cause the liquid cooling components to fail, resulting in problems such as overheating and damage to the battery device.

[0074] The method of using a liquid level sensor can only monitor the overall liquid level change in the reservoir and cannot accurately locate the leak. When a minor coolant leak occurs, the liquid level change is not obvious, causing the minor leak to go undetected. Therefore, this method has extremely low detection sensitivity and is easily affected by liquid level fluctuations caused by coolant evaporation and temperature changes, resulting in a high false alarm rate.

[0075] As for using pressure sensors for detection, the liquid cooling components need to be sealed and pressurized, which is complex to install and costly. It is not suitable for open liquid cooling components, and long-term pressure maintenance will cause wear and tear on the pipelines and seals, affecting the service life of the liquid cooling components.

[0076] Therefore, this application provides a battery device with a detection mechanism that detects leaks in the heat exchange components by detecting the continuity of the sensing structure. This enables real-time, accurate, and sensitive detection of coolant leaks, allowing for rapid location of leaks and reducing false alarm rates. Furthermore, it offers advantages such as simple structure, convenient installation, strong versatility, and easy maintenance, effectively ensuring the stable operation of the liquid cooling components and reducing the risk of battery device failures caused by coolant leaks.

[0077] The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0078] Please see Figure 1 , Figure 1This is a schematic diagram of the structure of the electrical device provided in this application. In one embodiment, an electrical device is provided, which includes an electrical component 100 and a battery device 200, wherein the battery device 200 is electrically connected to the electrical component 100. The battery device 200 is used to provide electrical energy to the electrical device, enabling the electrical component 100 to operate.

[0079] Electrical equipment can include vehicles, mobile phones, portable devices, laptops, ships, spacecraft, electric toys, and power tools. Vehicles can be gasoline-powered cars, natural gas-powered cars, or new energy vehicles; new energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles. Spacecraft include airplanes, rockets, space shuttles, and spacecraft. Electric toys include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys. Power tools include metal cutting power tools, grinding power tools, assembly power tools, and railway power tools, such as electric drills, electric grinders, electric wrenches, electric screwdrivers, electric hammers, impact drills, concrete vibrators, and electric planers. For ease of explanation, the following examples use vehicles as an example of electrical equipment.

[0080] The power-consuming device 100 can be an electrical component or device; the power-consuming device 100 can be a controller and electronic components, etc., and the controller can be a central processing unit (CPU), digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc.

[0081] In some examples, the electrical equipment may be a vehicle, and the electrical component 100 may be the vehicle's lights (e.g., headlights, taillights, etc.), display screen, dashboard, control system (e.g., controller), etc. The vehicle may also include a frame, on which both the battery device 200 and the electrical component 100 are mounted.

[0082] Please refer to Figures 2 to 5 , Figure 2 This is a disassembly diagram of the battery device 200 provided in some embodiments of this application; Figure 3 A disassembly diagram of a testing mechanism in a first state according to an embodiment of this application; Figure 4 Provided for an embodiment of this application Figure 3 A schematic diagram of the detection mechanism 30 in its second state; Figure 5 for Figure 4A disassembled schematic diagram of the detection mechanism 30 is shown. In one embodiment, the battery device 200 includes a plurality of battery cells 10, a heat exchange assembly 20, and at least one detection mechanism 30. The heat exchange assembly 20 is configured to exchange heat with the battery cells 10. At least one detection mechanism 30 is disposed on the outside of the heat exchange assembly 20; the detection mechanism 30 includes an insulating base 31, a liquid suction element 32, a sensing structure, and a processor (not shown). The insulating base 31 has a limiting groove and is configured to switch between a first state and a second state; wherein, in the first state, the insulating base 31 has a plate-like structure; and in the second state, the insulating base 31 has an arc-shaped structure. The liquid suction element 32 is disposed on the insulating base 31 and in contact with the heat exchange assembly 20, and is configured to absorb the heat exchange medium leaking from the heat exchange assembly 20; at least part of the sensing structure is disposed in the limiting groove of the insulating base 31 and in contact with the liquid suction element 32, and is configured to conduct through the heat exchange medium on the liquid suction element 32; the processor is electrically connected to the sensing structure and is configured to detect the electrical signal of the sensing structure in real time to realize the leakage detection of the heat exchange assembly 20.

[0083] In one example, such as Figure 2 As shown, the battery device 200 also includes a battery housing 40, the internal space of which forms a receiving cavity, and multiple battery cells 10, heat exchange components 20 and detection mechanism 30 are housed in the receiving cavity of the battery housing 40.

[0084] In one example, the battery housing 40 may be part of the vehicle's chassis structure. For example, a portion of the battery housing 40 may be at least a part of the vehicle's chassis, or a portion of the battery housing 40 may be at least a part of the vehicle's crossbeams and longitudinal beams.

[0085] The multiple battery cells 10 can be connected in series, parallel, or in a mixed configuration, where the multiple battery cells 10 are connected in both series and parallel. Each battery cell 10 can be a secondary battery or a primary battery; it can also be a lithium-sulfur battery, a sodium-ion battery, or a magnesium-ion battery, but is not limited to these. The battery cell 10 can be cylindrical, flat, cuboid, or other shapes.

[0086] For example, multiple battery cells 10 are arranged in a two-dimensional array with gaps between adjacent columns. For example, multiple columns of battery cells 10 can be arranged sequentially along a first direction X.

[0087] The main function of the heat exchange component 20 is to manage the heating and heat dissipation of the battery device 200. It can remove the heat generated by the battery cell 10 through heat conduction, heat convection and heat radiation, so as to ensure that the battery cell 10 operates within a suitable temperature range, thereby extending the service life of the battery cell 10 and improving its performance.

[0088] The specific type of heat exchange medium within the heat exchange assembly 20 is not limited here, as long as it can exchange heat with the battery cell 10, such as providing a heat dissipation effect. For example, the heat exchange medium is liquid. This embodiment uses a coolant as an example for description.

[0089] The heat exchange component 20 is thermally connected to the battery cell 10. Thermal connection can be understood as: part of the heat exchange component 20 is directly attached to or abuts against the battery cell 10; or the heat exchange component 20 and the battery cell 10 are spaced apart, and the heat exchange component 20 is connected to the battery cell 10 through a heat transfer medium, which can be a coolant.

[0090] In one example, see Figure 2 The heat exchange assembly 20 includes a cold plate disposed inside the battery housing 40, and multiple battery cells 10 disposed on the cold plate. The cold plate is provided with a flow channel, through which coolant enters the flow channel from the inlet of the cold plate and flows out through the outlet of the cold plate to cool the battery cells 10 disposed on the cold plate.

[0091] In this example, the detection mechanism 30 is located at a position on the cold plate where leakage is likely to occur. For example, the detection mechanism 30 can be positioned to correspond to a wider area of ​​the flow channel on the cold plate.

[0092] For example, the testing mechanism 30 may be located on the side of the cold plate away from the battery cell 10.

[0093] In one example, the inlet of the cold plate is connected to an inlet pipe to supply coolant to the cold plate; the outlet of the cold plate is connected to an outlet pipe, through which the coolant in the flow channel of the cold plate flows out. In this example, the detection mechanism 30 may be further provided at the connection between the cold plate and the inlet pipe, and / or the detection mechanism 30 may be further provided at the connection between the cold plate and the outlet pipe.

[0094] In one example, see Figure 6 , Figure 6 This is a partial structural schematic diagram of a heat exchange assembly 20 provided in some embodiments of this application. The heat exchange assembly 20 includes a thermal management component 21, a current collector 22, and a connecting pipe 23. There are multiple thermal management components 21, with at least two thermal management components 21 spaced apart along a third direction. A battery cell 10 is disposed between two adjacent thermal management components 21, and the battery cell 10 is heat-exchangeably connected to the adjacent thermal management component 21. In a fourth direction perpendicular to the third direction, the opposite ends of each thermal management component 21 are respectively connected to the current collector 22, and the current collectors 22 on the same side of two adjacent thermal management components 21 along the fourth direction are connected by the connecting pipe 23. The third direction is perpendicular to the fourth direction.

[0095] The battery cell 10 is heat-exchangeably connected to the thermal management component 21; optionally, the battery cell 10 and the thermal management component 21 can abut against each other to achieve heat exchange; or, a thermally conductive adhesive layer can be provided between the battery cell 10 and the thermal management component 21, and the two can be bonded together to achieve heat exchange; or, a thermally conductive pad can be provided between the battery cell 10 and the thermal management component 21, and the thermally conductive pad can simultaneously achieve heat exchange and buffering.

[0096] The thermal management component 21 refers to a component used for heat exchange by allowing coolant to flow internally. Optionally, the thermal management component 21 may be, but is not limited to, a heat exchange plate, heat exchange tube, harmonica tube, or other structures. For example, the thermal management component 21 has multiple flow channels formed internally, at least some of which communicate with the inner cavity of the current collector 22 to facilitate the flow of the heat exchange medium. In this example, the thermal management component 21 has large-area thermally conductive contact with the side surface of the battery cell 10.

[0097] The collector 22 refers to the structural component used to introduce or remove coolant from the heat management component 21. Specifically, the heat management component 21 typically has multiple flow channels for coolant passage, and the collector 22 is used to distribute coolant to the multiple flow channels or to concentrate coolant within the multiple flow channels. In the fourth direction, the collector 22 is connected to opposite ends of each heat management component 21. Thus, the collector 22 connected to one end of the heat management component 21 is used to introduce coolant, while the collector 22 connected to the opposite end of the heat management component 21 is used to remove coolant, thereby enabling coolant flow within the heat management component 21 to achieve heat exchange and cooling.

[0098] The connecting pipe 23 refers to the pipe structure used to connect two adjacent current collectors 22. Multiple current collectors 22 located on the same side of multiple battery cells 10 along the fourth direction are sequentially connected via the connecting pipe 23. Thus, the connecting pipe 23 can sequentially guide coolant into the multiple current collectors 22, and the multiple current collectors 22 can sequentially guide the coolant into the corresponding thermal management components 21 for flow, achieving heat exchange and cooling. Alternatively, the coolant in each thermal management component 21 can be discharged through the current collectors 22 into the connecting pipe 23, and then collected and discharged by the connecting pipe 23 for cooling and recycling.

[0099] In this example, the detection mechanism 30 can be located at the connection between the thermal management component 21 and the collector 22 to detect whether leakage has occurred at the connection. Alternatively, the detection mechanism 30 can be located at the connection between two adjacent connecting pipes 23 to detect whether leakage has occurred at the connection. Alternatively, detection mechanisms 30 can be located at both the connection between the thermal management component 21 and the collector 22 and at the connection between two adjacent connecting pipes 23, respectively, to detect whether leakage has occurred at the connection between the thermal management component 21 and the collector 22 and at the connection between two adjacent connecting pipes 23.

[0100] Please see Figure 3 The detection mechanism 30 is configured to detect whether the heat exchange assembly 20 is leaking. The insulating base 31 is configured to provide support and insulation. The insulating base 31 is made of insulating material to reduce the risk of leakage in the detection mechanism 30, making it safer to use. For example, the insulating base 31 can be made of high-temperature resistant and corrosion-resistant insulating material to adapt to the high-temperature and humid environment of engine compartments or industrial settings, extending the service life of the detection mechanism 30.

[0101] The absorbent element 32 is a lightweight, soft, and elastic structure with numerous tiny pores inside. It can absorb and guide liquid through internal capillary forces. In one example, the absorbent element 32 includes foam.

[0102] In one example, the absorbing element 32 is in direct contact with the outer wall surface of the heat exchange assembly 20, so that the heat exchange medium leaking from the heat exchange assembly 20 directly enters the absorbing element 32. For example, the absorbing element 32 may be in direct contact with the outer wall surface of the connection between the thermal management component 21 and the collector 22, respectively; or the absorbing element 32 may be in direct contact with the outer wall surface of the connection between the connecting pipe 23 and the collector 22, respectively.

[0103] The specific sizes of the insulating base 31 and the liquid suction element 32 can be set according to the actual situation, as long as the leaked heat exchange medium can be absorbed by the liquid suction element 32.

[0104] The sensing structure is connected to the coolant leaking from the heat exchange component 20, and the connection of the sensing structure is used to realize the detection of coolant leakage in the battery device 200.

[0105] The leakage detection logic of the battery device 200 is as follows: when coolant leakage occurs in the battery device 200, the leaking coolant will conduct through the sensing structure, and the leakage is detected by controlling the on / off state of the sensing structure. This solution does not rely on manual operation; the leaking coolant directly conducts through the sensing structure, providing immediate feedback of the leakage signal. This solves the problem of "response lag" in related technologies, improves detection efficiency and sensitivity, and reduces the risk of overheating and equipment damage caused by leakage expansion. Furthermore, compared to solutions that use level sensors to detect changes in the heat exchange medium level within the battery device 200, this solution does not rely on changes in the heat exchange medium level. It can accurately locate the leak position and detect even minor leaks in the heat exchange medium. It has high detection sensitivity and is less affected by level fluctuations caused by heat exchange medium evaporation and temperature changes, thus reducing the false alarm rate. In addition, compared with the solution of using pressure sensors for detection, there is no need to keep the heat exchange component 20 sealed and pressurized. The installation of the heat exchange component 20 and the detection mechanism 30 is simpler and less expensive. It is suitable for open cooling components, improves the problem of long-term pressure holding causing wear and tear on the pipelines and seals 34 of the heat exchange component 20, and extends the service life of the heat exchange component 20.

[0106] In one example, the sensing structure includes a first sensing structure 331 and a second sensing structure 332. The first sensing structure 331 and the second sensing structure 332 are spaced apart along a second direction Y on an insulating base 31 and are in contact with the liquid-absorbing element 32, respectively. The first sensing structure 331 and the second sensing structure 332 are configured to be electrically connected through a heat exchange medium on the liquid-absorbing element 32. The processor is configured to monitor the electrical signal between the first sensing structure 331 and the second sensing structure 332 in real time to monitor whether leakage occurs in the heat exchange assembly 20.

[0107] For example, the first sensing structure 331 and / or the second sensing structure 332 are sensing needles that extend along the first direction X, and the entire length of the sensing needle extending along the first direction X is in contact with the liquid suction member 32, so as to increase the contact area between the sensing needle and the liquid suction member 32, increase the sensing area, and improve the sensing sensitivity.

[0108] For example, the first sensing structure 331 and / or the second sensing structure 332 are made of stainless steel or titanium alloy, or other corrosion-resistant materials. This reduces the risk of corrosion of the first sensing structure 331 and / or the second sensing structure 332, extends their conductivity period, reduces maintenance and replacement, and prolongs their service life.

[0109] The processor monitors the electrical signals of the sensing structure in real time to detect whether leakage has occurred in the heat exchange component 20. These electrical signals may include, but are not limited to, one or more of resistance, current, and voltage signals.

[0110] For example, the processor is configured to monitor the current signal of the sensing structure in real time, and determine that the heat exchange component 20 is leaking when the processor detects the current signal. Alternatively, the processor is configured to monitor the resistance signal of the sensing structure in real time, and determine that the heat exchange component 20 is leaking when the resistance value monitored by the processor is less than a resistance threshold.

[0111] In some examples, the processor has a self-diagnostic function that can periodically check whether the sensing structure and circuit are working properly and provide diagnostic results for appropriate handling. This solution can automatically detect faults in the first sensing structure 331, the second sensing structure 332, and the circuit and provide alerts, reducing the risk of detection mechanism 30 failure and improving operational stability.

[0112] In some examples, the internal wiring of the testing mechanism 30 is concealed, meaning there are no exposed wires on the outside of the testing mechanism 30, in order to improve the level of protection. For example, the internal wiring of the testing mechanism 30 is concealed by being wrapped in conduit.

[0113] See Figures 3 to 5 The insulating base 31, which is in the first state, is configured to the second state by bending both ends of the plate-shaped insulating base 31 toward the same side along the second direction Y. In this way, the first sensing structure 331 and the second sensing structure 332, which extend along the first direction X, have less impact on the process of switching the insulating base 31 back and forth between the first and second states; at the same time, the impact of the repeated configuration process of the first and second states on the contact area or adhesion between the sensing structure and the liquid-absorbing member 32 can be reduced.

[0114] When the insulating base 31 is in the first state, the entire detection mechanism 30 is plate-shaped, i.e. planar, and the detection mechanism 30 can be set at the location where the plate-shaped heat exchange component 20 is prone to leakage.

[0115] When the insulating base 31 is in the second state, the entire detection mechanism 30 is arc-shaped, that is, the insulating base 31 and the liquid suction member 32 are arc-shaped, but the shape of the first sensing structure 331 and the second sensing structure 332 remains unchanged.

[0116] The following embodiments of this application describe the detection mechanism 30 in the second state as being installed in... Figure 6 The connection between two adjacent connecting pipes 23 shown is used as an example for explanation.

[0117] For example, in this second state, the detection mechanism 30 can be located at the connection of two adjacent connecting pipe bodies 23 and contact the outer wall surfaces of the two adjacent connecting pipe bodies 23 respectively.

[0118] For example, in this second state, the insulating base 31 and the liquid-absorbing element 32 are respectively arranged around the circumference of the connecting tube 23, so that each position at the connection between two adjacent connecting tubes 23 is detected along the circumference of the connecting tube 23. It can be understood that in this example, both the insulating base 31 and the liquid-absorbing element 32 are hollow columnar structures.

[0119] In one example, the insulating base 31 is a flexible base that can change its shape under external force to be configured into a first state or a second state. Of course, in other examples, the insulating base 31 can also be a fence-type base, or other structures that can switch between plate-like and arc-shaped forms.

[0120] In one example, a limiting groove is formed on the side surface of the insulating base 31 facing the liquid suction member 32, and at least part of the sensing structure is disposed in the limiting groove.

[0121] In one example, the entire sensing structure may be positioned within the limiting groove. Of course, in other examples, only a portion of the sensing structure may be positioned within the limiting groove.

[0122] For example, the depth of the limiting groove is less than the radial dimension of the sensing structure, so that a portion of the sensing structure protrudes from the limiting groove in its radial direction, thereby enabling the sensing structure to better contact the liquid suction element 32, and thus better contact the heat exchange medium on the liquid suction element 32, effectively improving the detection sensitivity.

[0123] The battery device 200 provided in this embodiment includes a detection mechanism 30. This mechanism 30 incorporates a sensing structure that is connected to the heat exchange medium on the liquid-absorbing member 32. A processor monitors the electrical signal of the sensing structure in real time, thereby detecting leaks in the heat exchange assembly 20 by controlling the on / off state of the sensing structure. This not only allows for timely detection of leaks and prompt handling of leaking battery devices 200, effectively reducing the impact of leaks, but also, compared to methods using liquid level sensors, enables the detection of even minor leaks in the heat exchange medium, improving detection sensitivity and accuracy. Furthermore, the detection mechanism 30 incorporates a liquid-absorbing component 32 that contacts the heat exchange assembly 20, allowing the sensing structure to be connected via the heat exchange medium on the liquid-absorbing component 32. This enables precise collection of leaked heat exchange medium from the heat exchange assembly 20 through the liquid-absorbing component 32, concentrating the leaked medium in contact with the sensing structure. This facilitates the detection of even minute leaks and improves the sensitivity of such detections. Moreover, collecting the leaked heat exchange medium within the liquid-absorbing component 32 effectively reduces the probability of short-circuiting the internal battery cells 10. Additionally, this detection mechanism 30 does not affect the structure or operation of the original heat exchange assembly 20, ensuring high safety and reliability. Furthermore, subsequent maintenance of the detection mechanism 30 can be achieved by replacing or repairing the liquid-absorbing component 32 as needed, eliminating the need to replace the entire detection mechanism 30, thus reducing maintenance difficulty and operating costs. Furthermore, by allowing the insulating base 31 to switch back and forth between the first and second states, the detection mechanism 30 can be adapted to both leak detection of plate-like structures within the heat exchange assembly 20 and leak detection of tubular structures of different diameters within the heat exchange assembly 20, thus fitting leak points of different shapes and exhibiting strong versatility. Moreover, by placing the sensing structure within the limiting groove, the battery device 200 can both limit the sensing structure through the limiting groove and facilitate the flow of the heat exchange medium on the liquid suction member 32 into the limiting groove for better contact with the sensing structure, thereby improving detection sensitivity.

[0124] In one embodiment, the processor includes a signal acquisition unit and a signal processing unit; the signal acquisition unit is electrically connected to the sensing structure and configured to acquire electrical signals from the sensing structure; the signal processing unit is electrically connected to the signal acquisition unit and configured to compare the electrical signals with a standard threshold to confirm whether leakage has occurred in the heat exchange assembly 20.

[0125] In one example, the signal acquisition unit is electrically connected to the first sensing structure 331 and the second sensing structure 332 respectively, so as to acquire the electrical signal between the first sensing structure 331 and the second sensing structure 332.

[0126] In one example, the electrical signal is a real-time resistance value signal; the standard threshold is a resistance threshold. In this example, the signal processing unit compares the real-time resistance value acquired by the signal acquisition unit with the resistance threshold. If the real-time resistance value is less than the resistance threshold, it is confirmed that the heat exchange component 20 is leaking.

[0127] The standard threshold can be selected and set according to heat exchange media with different electrical conductivity to meet the requirements for detecting leaks in heat exchange media with different electrical conductivity.

[0128] In this embodiment, the leakage of the heat exchange component 20 is confirmed by comparing the electrical signal with a standard threshold. This effectively distinguishes between coolant leakage and interference from external condensate, water vapor, etc., reducing the interference of external water vapor and condensate on the detection results. It exhibits strong anti-interference capability, reduces the false alarm rate by over 90%, and significantly improves detection accuracy. Furthermore, the standard threshold can be selected and set according to heat exchange media with different conductivity levels to detect leaks of heat exchange media with different conductivity levels within the heat exchange component 20, resulting in a longer service life. Additionally, integrating each unit into the processor increases the integration level of the detection mechanism 30.

[0129] In one embodiment, the signal processing unit is further configured to generate and output an alarm signal when the heat exchange component 20 leaks; the detection mechanism 30 also includes an alarm (not shown) electrically connected to the signal processing unit and configured to receive the alarm signal and provide an alarm prompt.

[0130] In one example, the alarm notification includes an on-site audible and visual alarm and / or a remote wireless alarm. The on-site audible and visual alarm may include at least one of voice prompts and light prompts. For example, a voice prompt may include a buzzer alarm. In one example, the on-site audible and visual alarm includes both voice prompts and light prompts, providing dual alerts, reducing information omissions due to a single alarm method, and improving the comprehensiveness and timeliness of leak notification.

[0131] In this embodiment, when leakage occurs in the heat exchange component 20, an automatic alarm can be triggered in a timely manner to remind the user to deal with the leakage situation promptly. This solution enables the battery device 200 to be detected in a timely manner even in complex environments, improving the effectiveness of the warning; it reduces the risk of the battery device 200 overheating or being damaged due to the expansion of heat exchange medium leakage; at the same time, compared with manual monitoring, the alarm triggering is more timely, reducing the cost of manual inspection and improving the operation and maintenance efficiency of the heat exchange component 20.

[0132] In one embodiment, see Figure 3 The detection mechanism 30 also includes a sealing element 34, which is disposed on both sides of the liquid suction element 32 at least along the first direction X and is clamped between the insulating base 31 and the heat exchange assembly 20.

[0133] In one example, combined Figure 3 The sealing element 34 can be a sealing ring, which is arranged around the circumference of the liquid suction element 32. In this way, the sealing ring can seal the gap between the insulating base 31 and the heat exchange component 20 around the circumference of the liquid suction element 32, thereby improving the fit and sealing between the insulating base 31 and the outer wall of the heat exchange component 20, reducing the entry of external moisture into the liquid suction element 32, reducing the probability of false alarms, and improving detection accuracy.

[0134] For example, a sealing groove 311 is provided on the surface of the insulating base 31 facing the liquid-absorbing member 32. The sealing groove 311 is closed-loop, and the orthogonal projection of the liquid-absorbing member 32 on the insulating base 31 is located within the sealing groove 311. The sealing member 34 is embedded in the sealing groove 311, and a portion of the sealing member 34 protrudes from the sealing groove 311 along the thickness direction of the insulating base 31, and abuts against the heat exchange assembly 20. In this example, the sealing groove 311 can limit the sealing member 34 and improve the sealing performance between the insulating base 31 and the liquid-absorbing member 32.

[0135] See another example. Figure 7 , Figure 7 This is a disassembly diagram of the testing mechanism 30 in a first state, provided in another embodiment of this application. (As described above) Figure 3 The difference in the corresponding example is that there can be two seals 34. The two seals 34 are disposed on both sides of the liquid-absorbing member 32 along the first direction X and extend along the second direction Y respectively. For example, the extension length of the seals 34 along the second direction Y is greater than the dimension of the liquid-absorbing member 32 along the second direction Y, so as to at least seal and protect the two side edges of the liquid-absorbing member 32 along the first direction X, reducing the ingress of external moisture and the like.

[0136] As an example, seal 34 is made of flexible silicone.

[0137] In this embodiment, by setting the sealing element 34, the sealing performance between the insulating base 31 and the heat exchange component 20 can be improved, which has a certain waterproof, dustproof and oil-proof effect, a high protection level, and the circuit is not easily damaged or short-circuited, making it easy to assemble and maintain; at the same time, it can effectively reduce the influence of external moisture on the test results and effectively improve the test accuracy.

[0138] In one embodiment, see further. Figure 7 The testing mechanism 30 also includes a fixing structure 35, which is configured to fix the insulating base 31 to the heat exchange assembly 20.

[0139] The fixing methods can include adhesive, binding, magnetic attraction, etc.

[0140] In this embodiment, the detection mechanism 30 can be quickly fixed to the heat exchange component 20 via the fixing structure 35. This fixing method is adaptable to pipes of different diameters and heat exchange components 20 of different materials, making installation, disassembly, and maintenance convenient and highly versatile. Furthermore, this design allows the liquid suction component 32 to fit more tightly against the heat exchange component 20, better collecting leaked heat exchange medium and thus more accurately detecting leaked heat exchange medium.

[0141] In one embodiment, combined Figures 4 to 7 The fixing structure 35 includes a strap 351 and / or an adhesive structure 352; the strap 351 is wrapped around the side of the insulating base 31 away from the heat exchange assembly 20 and fixes the relative position of the insulating base 31 and the heat exchange assembly 20. The adhesive structure 352 is provided on the surface of the insulating base 31 facing the liquid suction member 32 and is configured to be bonded and fixed to the heat exchange assembly 20.

[0142] In one example, see Figure 7 The fixing structure 35 includes an adhesive structure 352, which is disposed on the surface of the insulating base 31 facing the liquid-absorbing member 32. Figure 6 Taking the heat exchange component 20 as an example, the detection mechanism 30 is bonded to the connection between the plate-shaped heat management component 21 and the collector 22 through the adhesive structure 352.

[0143] For example, the adhesive structure 352 is arranged around the circumference of the liquid suction member 32; in this way, while fixing the detection mechanism 30 to the heat exchange component 20, the sealing between the insulating base 31 and the heat exchange component 20 is increased, reducing the probability of external moisture and other substances entering the liquid suction member 32.

[0144] For example, adhesive structure 352 may be a heat-resistant strong adhesive.

[0145] In one example, see Figure 4 When the detection mechanism 30 is configured to the second state, the fixing structure 35 also includes a strap 351, which is wrapped around the insulating base 31 in the circumferential direction on the side of the insulating base 31 away from the heat exchange assembly 20, so as to lock the insulating base 31 onto the heat exchange assembly 20.

[0146] For example, there may be two straps 351, which are respectively wrapped around the two ends of the insulating base 31 along the first direction X to improve the fit between the detection mechanism 30 and the heat exchange component 20, thereby improving the sealing performance and detection accuracy.

[0147] Among them, the binding strap 351 can be locked by means of friction, such as self-locking buckles (e.g., nylon cable ties), square knots, or square knots.

[0148] When the testing mechanism 30 is used in its first state, it may not include the strap 351. When the testing mechanism 30 is used in its second state, it may include the strap 351 and the adhesive structure 352 to improve the tightness of the fit between the testing mechanism 30 and the heat exchange component 20, thereby improving the testing accuracy. Of course, when the testing mechanism 30 is used in its second state, it may also include either the strap 351 or the adhesive structure 352.

[0149] In this embodiment, the insulating base 31 and the heat exchange component 20 are relatively fixed by the straps 351 and / or adhesive structure 352, making the installation process simple and quick; and the installation can be completed without professional tools, adapting to various heat exchange components 20, and has strong versatility.

[0150] In some embodiments, when the detection mechanism 30 is used for leak detection of a metal test piece, the fixing structure 35 may include a magnetic suction element. The detection mechanism 30 is attracted to the surface of the metal test piece by the magnetic suction element to achieve fixation between the detection mechanism 30 and the metal test piece. For example, the metal test piece may be an iron pipe, and the magnetic suction element may be a magnet. In this way, the detection mechanism 30 can be adapted to different installation scenarios.

[0151] In one embodiment, there are multiple detection mechanisms 30, and the multiple detection mechanisms 30 are respectively set at different positions of the heat exchange component 20.

[0152] In one example, a detection mechanism 30 can be installed at multiple locations where leakage is likely to occur on the cold plate. For instance, one or more detection mechanisms 30 can be installed in the wider area of ​​the flow channel of the cold plate; a detection mechanism 30 can be installed at the connection between the cold plate and the inlet pipe, and at the connection between the cold plate and the outlet pipe.

[0153] In another example, a detection mechanism 30 can be provided at the connection between each thermal management component 21 and the collector 22, as well as at the connection between each pair of adjacent connecting pipes 23, so as to detect whether leakage has occurred at these connections through the detection mechanism 30 at the corresponding location.

[0154] In this embodiment, by setting a detection mechanism 30 at each connection point of the heat exchange component 20, multi-point distributed installation is supported. The detection results of the detection mechanism 30 at the corresponding location can accurately locate the leakage location of the heat exchange component 20 and deal with the leakage location in a timely manner.

[0155] In one embodiment, the battery device 200 further includes a remote monitoring device (not shown in the figure), which is electrically connected to each testing mechanism 30 and performs remote monitoring on each testing mechanism 30.

[0156] In one example, when the detection unit 30 detects a leak in the heat exchange component 20, the signal processing unit generates a readable signal and transmits it to a remote monitoring device via a wireless transmission unit. The remote monitoring device collects the readable signal to obtain leak information, including but not limited to leak location, leak time, and leak status. The leak status may include minor leaks, major leaks, etc.

[0157] For example, staff can quickly locate the leak based on the obtained leak information and address the leak problem.

[0158] In some examples, when the leakage stops, the heat exchange medium in the suction element 32 evaporates or is cleaned, the sensing structure returns to the disconnected state, the alarm is automatically deactivated, and the detection mechanism 30 can be reused.

[0159] For example, the remote monitoring device can be an in-vehicle central control unit or a back-end monitoring platform.

[0160] In this embodiment, multiple testing institutions 30 are simultaneously monitored remotely through remote monitoring devices and wireless networking, realizing full-area monitoring and remote uploading of leakage information; it supports unattended unified management, eliminating the need for on-site inspections and solving the problem of lagging manual inspections; it also facilitates quick location of leaks for timely repairs, improving the efficiency of intelligent operation and maintenance.

[0161] In one embodiment, see Figure 7 The sensing structure includes a first sensing structure 331 and a second sensing structure 332; the insulating base 31 has a first limiting groove 312 and / or a second limiting groove 313 on the side surface facing the liquid suction member 32; at least a portion of the first sensing structure 331 is disposed in the first limiting groove 312; at least a portion of the second sensing structure 332 is disposed in the second limiting groove 313.

[0162] In one example, see Figure 7 The insulating base 31 has a first limiting groove 312 and a second limiting groove 313 on the side surface facing the liquid suction member 32. The entire first sensing structure 331 along its extension direction is located in the first limiting groove 312, and the entire second sensing structure 332 along its extension direction is located in the second limiting groove 313.

[0163] For example, the depth of the first limiting groove 312 is less than the radial dimension of the first sensing structure 331, so that a portion of the first sensing structure 331 protrudes from the first limiting groove 312 in its radial direction, thereby enabling the first sensing structure 331 to better contact the liquid suction member 32, and thus better contact the heat exchange medium on the liquid suction member 32, effectively improving the detection sensitivity.

[0164] The depth of the second limiting groove 313 is less than the radial dimension of the second sensing structure 332, so that a portion of the second sensing structure 332 protrudes from the second limiting groove 313 along its radial direction, thereby enabling the second sensing structure 332 to better contact the liquid suction member 32, and thus better contact the heat exchange medium on the liquid suction member 32, effectively improving the detection sensitivity.

[0165] Of course, in other examples, the insulating base 31 may also have one of the first limiting groove 312 and the second limiting groove 313 on the side surface facing the liquid suction member 32.

[0166] In this embodiment, the first limiting groove 312 can limit the first sensing structure 331, and also facilitates the flow of the heat exchange medium on the liquid suction member 32 into the first limiting groove 312, so as to better contact the first sensing structure 331 and thus improve the detection sensitivity. Similarly, the second limiting groove 313 can limit the second sensing structure 332, and also facilitates the flow of the heat exchange medium on the liquid suction member 32 into the second limiting groove 313, so as to better contact the second sensing structure 332 and thus improve the detection sensitivity.

[0167] In one embodiment, see Figure 8 , Figure 8 This is a schematic diagram of the structure of an insulating base 31 provided in an embodiment of this application. The insulating base 31 has a plurality of drainage grooves 314 on the side surface facing the liquid suction member 32, and the drainage grooves 314 are connected to the first limiting groove 312 and / or the second limiting groove 313.

[0168] In one example, part of the drainage channel 314 is connected to the first limiting channel 312, and part of the drainage channel 314 is connected to the second limiting channel 313.

[0169] For example, each of the flow channels 314 communicating with the first limiting groove 312 is spaced apart along the extension direction of the first limiting groove 312, and the extension direction of each flow channel 314 is inclined relative to the extension direction of the first limiting groove 312, so that the heat exchange medium on the liquid suction member 32 can automatically flow into the first limiting groove 312 through the flow channel 314 under the action of gravity, so as to contact the first sensing structure 331.

[0170] Similarly, each of the flow channels 314 connected to the second limiting groove 313 is spaced apart along the extension direction of the second limiting groove 313, and the extension direction of each flow channel 314 is inclined relative to the extension direction of the second limiting groove 313, so that the heat exchange medium on the liquid suction member 32 can automatically flow into the second limiting groove 313 through the flow channel 314 under the action of gravity, so as to contact the second sensing structure 332.

[0171] For example, in combination Figure 8Each of the flow channels 314 connected to the first limiting groove 312 and each of the flow channels 314 connected to the second limiting groove 313 are staggered so that heat exchange medium at more locations on the liquid suction member 32 can be guided through the flow channels 314 to the first limiting groove 312 or the second limiting groove 313.

[0172] In this embodiment, by adding a drainage groove 314, the heat exchange medium on the liquid suction member 32 can be better guided into the first limiting groove 312 and / or the second limiting groove 313, reducing the risk of missed detection due to the induction structure not being able to contact the heat exchange medium, which helps to realize the detection of trace leakage and improves the detection accuracy.

[0173] In one embodiment, see Figure 9 , Figure 9 This is a schematic diagram of a sensing structure provided on an insulating base 31 according to an embodiment of this application. The sensing structure includes a first sensing structure 331 and a second sensing structure 332; at least one of the first sensing structure 331 and the second sensing structure 332 is mesh-like.

[0174] In one example, both the first sensing structure 331 and the second sensing structure 332 are mesh-like to increase the contact area with the liquid-absorbing member 32, thereby increasing the sensing area of ​​the sensing structure.

[0175] In one example, one of the first sensing structure 331 and the second sensing structure 332 is mesh-like, while the other may be needle-like or other irregularly shaped.

[0176] In this embodiment, without increasing the volume of the battery device 200, the contact area between the first sensing structure 331 and / or the second sensing structure 332 and the liquid absorption member 32 can be increased, thereby increasing the sensing area of ​​the sensing structure, improving detection reliability, reducing the risk that the sensing structure cannot contact the heat exchange medium, and thus improving detection sensitivity.

[0177] In one embodiment, see further. Figure 7 The sensing structure includes a first sensing structure 331 and a second sensing structure 332 spaced apart along a second direction Y; the first sensing structure 331 and the second sensing structure 332 extend along a first direction X, and their dimensions along the first direction X are both greater than or equal to half the dimension of the liquid-absorbing member 32 along the first direction X, wherein the orthographic projection of the first sensing structure 331 on the liquid-absorbing member 32 extends at least to the first side edge of the liquid-absorbing member 32 along the first direction X; the orthographic projection of the second sensing structure 332 on the liquid-absorbing member 32 extends at least to the second side edge of the liquid-absorbing member 32 along the first direction X; wherein the second direction Y is perpendicular to the first direction X.

[0178] In one example, the first sensing structure 331 and the second sensing structure 332 are parallel and staggered along the second direction Y; in this way, the effective sensing area can be increased without the first sensing structure 331 and the second sensing structure 332 contacting each other.

[0179] For example, the first sensing structure 331 and the second sensing structure 332 extend along the first direction X, and the dimensions of the first sensing structure 331 and the second sensing structure 332 along the first direction X are both greater than or equal to three-quarters of the dimensions of the liquid-absorbing member 32 along the first direction X.

[0180] In one example, the orthographic projection of the first sensing structure 331 onto the insulating base 31 extends at both ends along the first direction X to the orthographic projection of the seal 34 onto the insulating base 31. The orthographic projection of the second sensing structure 332 onto the insulating base 31 also extends at both ends along the first direction X to the orthographic projection of the seal 34 onto the insulating base 31.

[0181] In this embodiment, the heat exchange medium leaking to any position of the liquid suction member 32 along the first direction X can either come into contact with the first sensing structure 331, or with the second sensing structure 332, or with both the first sensing structure 331 and the second sensing structure 332. This effectively increases the probability that the heat exchange medium at any position of the liquid suction member 32 along the first direction X can be detected, greatly improving the detection sensitivity and accuracy, and reducing the risk of missed detection.

[0182] The working principle of the testing organization 30 is described below.

[0183] The detection mechanism 30 is quickly installed at high-leakage locations such as pipe joints, welds, and cavity sidewalls of the heat exchange component 20 via a fixing structure 35, ensuring that the liquid suction component 32 is tightly fitted to the outer wall of the heat exchange component 20. When a small or large amount of heat exchange medium (such as coolant) leaks from the heat exchange component 20, the leaking coolant flows into the liquid suction component 32 of the detection mechanism 30 and quickly converges at the first sensing structure 331 and / or the second sensing structure 332. The coolant acts as a conductive medium, creating a conductive circuit between the two independent first sensing structures 331 and the second sensing structure 332. The signal acquisition unit captures the changes in electrical signals in real time and transmits them to the signal processing unit. The signal processing unit compares the real-time electrical signal with the built-in standard threshold. After confirming that the signal is a coolant leak signal, it triggers the alarm through the signal output unit. The alarm immediately issues an audible and visual warning, and at the same time, the wireless transmission unit remotely transmits the leak location, leak status, and other leak information to the remote monitoring device. Based on the leak information provided by the remote monitoring device, staff can quickly locate the leak and take appropriate action.

[0184] In one embodiment, see Figure 3 and Figure 4 Furthermore, a leakage detection mechanism 30 for a test component is provided. This detection mechanism 30 is applicable to scenarios such as engine, new energy vehicle battery cooling system, and industrial cooling pipeline, and is used for real-time detection of leaks in coolant pipelines, joints, cavities, and other parts. The detection mechanism 30 includes an insulating base 31, a liquid suction element 32, a sensing structure, and a processor. The insulating base 31 has a limiting groove and is configured to switch between a first state and a second state; wherein, in the first state, the insulating base 31 has a plate-like structure; in the second state, the insulating base 31 has an arc-shaped structure. The liquid suction element 32 is disposed on the insulating base 31 and is configured to contact the outer surface of the test component to absorb the conductive medium leaking from the test component; at least a portion of the sensing structure is disposed within the limiting groove of the insulating base 31 and contacts the liquid suction element 32, and is configured to conduct through the conductive medium on the liquid suction element 32; the processor is electrically connected to the sensing structure and is configured to detect the conduction signal of the sensing structure to realize leakage detection of the test component.

[0185] In one example, the device under test can be the heat exchange component 20 involved in any of the above embodiments, and the conductive medium can be a coolant.

[0186] Of course, in other examples, the test piece can also be other metal parts, such as an iron pipe. The conductive medium can be any liquid that can conduct electricity.

[0187] For details on the structure and function of the testing organization 30, please refer to the relevant description above.

[0188] The detection mechanism 30 provided in this embodiment uses a sensing structure that is connected to the liquid absorption member 32 via a conductive medium. A processor monitors the electrical signal of the sensing structure in real time, using the on / off state of the sensing structure to detect leaks in the device under test. This not only allows for timely detection of leaks and prompt handling of leaking battery devices 200, effectively reducing the impact of leaks on the battery devices 200, but also, compared to methods using liquid level sensors, enables the detection of even small leaks of conductive media, improving detection sensitivity and accuracy. Furthermore, the detection mechanism 30 incorporates a liquid-absorbing component 32 that contacts the device under test (DUT). The sensing structure is connected via the conductive medium on the liquid-absorbing component 32. This allows for precise collection of leaked conductive medium from the DUT through the liquid-absorbing component 32, concentrating the leaked medium in contact with the sensing structure and enabling leak detection of minute amounts of conductive medium, thus improving the sensitivity of minute leak detection. Additionally, collecting the leaked conductive medium within the liquid-absorbing component 32 effectively reduces the probability of short-circuiting the internal battery cells 10. Moreover, the detection mechanism 30 does not affect the structure or operation of the original DUT, ensuring high safety and reliability. Furthermore, subsequent maintenance of the detection mechanism 30 does not require replacement of the entire mechanism, resulting in low operating costs. Finally, the detection mechanism 30 exhibits a high degree of integration. Furthermore, by allowing the insulating base 31 to switch back and forth between the first and second states, the detection mechanism 30 can be adapted to both leak detection of plate-like structures within the heat exchange assembly 20 and leak detection of tubular structures of different diameters within the heat exchange assembly 20, thus fitting leak points of different shapes and exhibiting strong versatility. Moreover, by placing the sensing structure within the limiting groove, the battery device 200 can both limit the sensing structure through the limiting groove and facilitate the flow of the heat exchange medium on the liquid suction member 32 into the limiting groove for better contact with the sensing structure, thereby improving detection sensitivity.

[0189] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A battery device, characterized by, include: Multiple battery cells; The heat exchange assembly is configured to exchange heat with the battery cell; At least one detection mechanism is located on the outside of the heat exchange assembly; the detection mechanism includes: An insulating base is provided with a limiting groove, and the insulating base is configured to switch between a first state and a second state; wherein, in the first state, the insulating base has a plate-like structure; and in the second state, the insulating base has an arc-shaped structure. A liquid suction element is disposed on the insulating base and in contact with the heat exchange assembly, and is configured to absorb heat exchange medium leaking from the heat exchange assembly. The sensing structure is at least partially disposed within the limiting groove of the insulating base and in contact with the liquid suction element, and is configured to be conductive through the heat exchange medium on the liquid suction element; A processor, electrically connected to the sensing structure, is configured to detect electrical signals of the sensing structure in real time to enable leakage detection of the heat exchange assembly.

2. The battery device according to claim 1, characterized in that, The processor includes: A signal acquisition unit is electrically connected to the sensing structure and is configured to acquire the electrical signals of the sensing structure. A signal processing unit, electrically connected to the signal acquisition unit, is configured to compare the electrical signal with a standard threshold to confirm whether the heat exchange component is leaking.

3. The battery device according to claim 2, characterized in that, The signal processing unit is further configured to generate and output an alarm signal when the heat exchange component leaks liquid. The detection mechanism also includes an alarm, which is electrically connected to the signal processing unit and configured to receive the alarm signal and provide an alarm prompt.

4. The battery device according to any one of claims 1-3, characterized in that, The detection mechanism further includes: a sealing element, which is disposed on both sides of the liquid-absorbing element at least along the first direction and is clamped between the insulating base and the heat exchange assembly.

5. The battery device according to any one of claims 1-3, characterized in that, The detection mechanism further includes a fixing structure configured to fix the insulating base to the heat exchange assembly.

6. The battery device according to claim 5, characterized in that, The fixing structure includes: A strap is wrapped around the side of the insulating base away from the heat exchange assembly to fix the relative position of the insulating base and the heat exchange assembly; and / or An adhesive structure is provided on the surface of the insulating base facing the liquid-absorbing element and is bonded to the heat exchange assembly.

7. The battery device according to any one of claims 1-3, characterized in that, The number of the testing mechanisms is multiple, and each of the multiple testing mechanisms is set at a different position of the heat exchange component.

8. The battery device of claim 7, wherein, Also includes: A remote monitoring device is electrically connected to each of the aforementioned testing institutions and performs remote monitoring of each of the aforementioned testing institutions.

9. The battery device according to any one of claims 1-3, characterized in that, The sensing structure includes a first sensing structure and a second sensing structure; The insulating base has a first limiting groove and / or a second limiting groove on the side surface facing the liquid suction member; at least a portion of the first sensing structure is disposed in the first limiting groove; at least a portion of the second sensing structure is disposed in the second limiting groove.

10. The battery device according to claim 9, characterized in that, The insulating base is further provided with a plurality of drainage grooves on the side surface facing the liquid suction member, and the drainage grooves are connected to the first limiting groove and / or the second limiting groove.

11. The battery device according to any one of claims 1-3, characterized in that, The sensing structure includes a first sensing structure and a second sensing structure; at least one of the first sensing structure and the second sensing structure is mesh-like.

12. The battery device according to any one of claims 1-3, characterized in that, The sensing structure includes a first sensing structure and a second sensing structure spaced apart along a second direction; the first sensing structure and the second sensing structure extend along a first direction, and their dimensions along the first direction are both greater than or equal to half the dimension of the liquid-absorbing element along the first direction. Wherein, the orthographic projection of the first sensing structure on the liquid absorbent extends at least to the first side edge of the liquid absorbent along the first direction; the orthographic projection of the second sensing structure on the liquid absorbent extends at least to the second side edge of the liquid absorbent along the first direction; wherein, the second direction is perpendicular to the first direction.

13. An electrical device, characterized by Includes the battery device as described in any one of claims 1-12.

14. A detection mechanism for leakage of a test component, characterized in that, include: An insulating base is provided with a limiting groove, and the insulating base is configured to switch between a first state and a second state; wherein, in the first state, the insulating base has a plate-like structure; and in the second state, the insulating base has an arc-shaped structure. A liquid-absorbing element is disposed on the insulating base and configured to contact the outer surface of the test piece to absorb conductive medium leaking from the test piece. The sensing structure is at least partially disposed within the limiting groove of the insulating base and in contact with the liquid-absorbing element, and is configured to be conductive through a conductive medium on the liquid-absorbing element. A processor, electrically connected to the sensing structure, is configured to detect the conduction signal of the sensing structure to achieve leakage detection of the test piece.

Images