Double-layer battery pack with rapid heat dissipation

Abstract

The application discloses a double-layer battery pack with rapid heat dissipation, comprising: an outer shell, upper and lower layer cell module, a metal heat-conducting plate between the two, and two soft heat-conducting gaskets. The metal heat-conducting plate is in contact with the two side cell modules, playing a supporting and heat-conducting role; the two soft heat-conducting gaskets are respectively arranged between the upper and lower layer cell modules and the side wall of the outer shell, closely adhering to enhance lateral heat conduction. The design forms a multi-path heat dissipation system through the synergistic effect of the metal heat-conducting plate and the soft heat-conducting gaskets. The metal heat-conducting plate efficiently leads out the heat in the middle area, preventing local overheating; the soft heat-conducting gaskets conduct the heat to the upper and lower sides of the outer shell, making the overall temperature more uniform. The structure not only improves the heat management efficiency, reduces the risk of thermal runaway and prolongs the battery life, but also takes into account the compactness of the structure, and is suitable for high energy density scenes. In addition, the metal heat-conducting plate also bears the mechanical support function, disperses the weight of the upper layer module, and avoids pressure on the lower layer.

Description

Technical Field

[0001] This utility model belongs to the field of battery pack technology, and in particular relates to a double-layer battery pack with fast heat dissipation. Background Technology

[0002] Currently, battery packs in electric vehicles and energy storage systems typically employ a double-layer cell module stack layout to improve energy density. However, this structure places higher demands on heat dissipation performance. Existing heat dissipation solutions mainly rely on adding heat sink fins to the battery pack casing to enhance external convection, or using active cooling methods such as air cooling or liquid cooling. However, these methods have significant limitations in double-layer battery packs: air cooling systems struggle to evenly cool the upper and lower cell layers, easily creating temperature gradients; liquid cooling piping is complex and increases system weight and cost; and traditional single-layer thermal pads cannot effectively solve the thermal coupling problem between the upper and lower cell modules. In particular, the heat generated by the cells in the middle layer is difficult to dissipate quickly, easily forming localized hot spots, leading to uneven temperature distribution inside the battery pack. This not only affects battery charge / discharge efficiency and cycle life but also poses a risk of thermal runaway. Furthermore, existing structures often sacrifice thermal conductivity while ensuring electrical insulation, further restricting the improvement of overall heat dissipation performance. Utility Model Content

[0003] (I) Purpose of the utility model

[0004] To overcome the above shortcomings, the purpose of this utility model is to provide a fast heat dissipation double-layer battery pack, so as to solve the problems of uneven heat dissipation path, serious heat accumulation in the middle layer, and low thermal management efficiency in the existing double-layer battery pack heat dissipation scheme.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the technical solution provided in this application is as follows:

[0007] A fast heat dissipation dual-layer battery pack includes: a shell, an upper battery cell module and a lower battery cell module disposed inside the shell and distributed vertically, a metal heat-conducting plate disposed between the upper battery cell module and the lower battery cell module and connected to the inner sidewall of the shell, and two flexible heat-conducting pads; the metal heat-conducting plate contacts the upper battery cell module and the lower battery cell module and is used to support the upper battery cell module; the two flexible heat-conducting pads are respectively disposed between the upper battery cell module and the corresponding inner sidewall of the shell and between the lower battery cell module and the corresponding inner sidewall of the shell, and each flexible heat-conducting pad contacts the corresponding battery cell module and the inner sidewall of the shell.

[0008] This structure, through the synergistic effect of a metal heat-conducting plate and flexible thermal pads, constructs a highly efficient multi-path heat dissipation system, significantly improving the thermal management efficiency of the dual-layer battery pack. The metal heat-conducting plate, in direct contact with the cell module, efficiently dissipates heat accumulated in the central area and conducts it to the outer casing, effectively preventing localized overheating. The flexible thermal pads, tightly fitted between the cell module and the sidewalls of the outer casing, effectively enhance lateral heat conduction, transferring heat to the upper and lower sides of the casing, thus ensuring a more uniform temperature distribution throughout the battery pack. Furthermore, the flexible thermal pads also act as a buffer, helping to mitigate vibration and impact. This design not only helps reduce the risk of thermal runaway and extend battery cycle life but also maintains the compactness of the overall structure, making it suitable for high-energy-density applications. The metal heat-conducting plate also provides mechanical support, effectively distributing the weight of the upper cell module and preventing excessive pressure on the lower cell module.

[0009] In some embodiments, the outer surface of the housing is provided with a plurality of heat dissipation fins.

[0010] The introduction of heat dissipation fins significantly improves the heat dissipation capacity of the casing, promoting rapid heat release by increasing the effective heat dissipation area. This not only reduces the surface temperature of the battery pack but also enhances overall thermal stability, especially under high-temperature or high-load conditions, effectively preventing heat accumulation and improving system reliability. At the same time, it eliminates the need for a complex active cooling system, saving costs and space.

[0011] In some embodiments, the inner sidewall of the housing is provided with a plurality of fixing sleeves, which are connected to a metal heat-conducting plate.

[0012] The fixed sleeve design enhances the connection rigidity between the metal heat-conducting plate and the outer casing, reduces contact thermal resistance, and allows heat to be transferred to the outside more efficiently. This not only improves heat dissipation performance but also enhances the overall structural strength and vibration resistance, facilitates installation and maintenance, ensures reliability under long-term operation, and is suitable for dynamic or harsh environments.

[0013] In some embodiments, it further includes: a first insulating pad disposed on both sides of the metal heat-conducting plate.

[0014] The first insulating pad effectively isolates the electrical path, improving battery pack safety and preventing potential short circuits. Simultaneously, its thermal conductivity ensures smooth heat transfer without compromising heat dissipation. This balance of safety and performance enhances the system's applicability and reliability.

[0015] In some embodiments, the invention further includes: a second insulating pad with two second insulating pads respectively disposed between the upper battery cell module and the corresponding flexible thermally conductive pad and between the lower battery cell module and the corresponding flexible thermally conductive pad.

[0016] The second insulating pad further enhances electrical insulation, reduces the risk of lateral short circuits, and ensures the cooling system operates safely. Its design does not affect thermal conductivity, helps maintain temperature balance, and is particularly suitable for applications with stringent safety standards, such as electric vehicles or energy storage devices, thus improving the overall protection level.

[0017] In some embodiments, the upper battery cell module and the lower battery cell module have the same structure, both including: a bracket and a battery cell stack installed in the bracket, and further including: multiple guide posts vertically passing through the bracket between the upper battery cell module and the lower battery cell module, and a guide groove is provided on the metal heat-conducting plate for the guide posts to pass through and guide their installation position.

[0018] The coordinated design of the guide pillars and guide grooves ensures precise positioning between the battery cell module and the metal heat-conducting plate, simplifying the assembly process and reducing installation errors. This not only improves the contact quality of the heat dissipation interface and reduces thermal resistance, but also enhances the stability and consistency of the overall structure, making it particularly suitable for automated production lines and improving production efficiency and product reliability.

[0019] In some embodiments, the end protrusions of the flexible thermal pads corresponding to the upper and lower battery cell module brackets form limiting portions, and the flexible thermal pads are provided with limiting grooves for engaging the limiting portions.

[0020] The engaging structure between the limiting part and the limiting groove effectively fixes the position of the flexible thermally conductive pad, preventing displacement during vibration or thermal cycling and ensuring continuous and uniform thermal contact. This design not only optimizes heat dissipation performance but also reduces maintenance requirements and improves the battery pack's durability and safety under harsh operating conditions.

[0021] In some embodiments, the metal heat-conducting plate is an aluminum plate.

[0022] The use of aluminum plates fully leverages their thermal conductivity, accelerating heat dissipation and contributing to lightweight design. This material choice balances performance and cost, improving the product's economy and applicability, making it suitable for applications with high requirements for weight and heat dissipation.

[0023] In some embodiments, the flexible thermal pad is a silicon thermal pad.

[0024] Silicon thermal pads optimize thermal interface contact and reduce thermal resistance and hot spot formation through their flexibility and thermal conductivity. Simultaneously, their insulation properties enhance safety, making them suitable for environments with vibration or temperature variations, and improving the durability and reliability of heat dissipation systems.

[0025] In some embodiments, the metal heat-conducting plate has multiple lifting holes for hoisting the upper battery cell module.

[0026] The lifting hole design greatly simplifies the assembly and maintenance process of the upper-layer battery cell module, improving operational efficiency and safety. It not only reduces assembly time but also lowers the risk of damage to other components while maintaining the integrity of the heat dissipation structure, making it suitable for scenarios requiring frequent maintenance or large-scale production. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the fast heat dissipation double-layer battery pack of this utility model;

[0028] Figure 2 This is a schematic diagram of the default outer shell of the fast heat dissipation double-layer battery pack of this utility model;

[0029] Figure 3 This is an exploded view of the default outer shell of the fast heat dissipation double-layer battery pack of this utility model.

[0030] Figure 4 This is an assembly diagram of the outer shell and the metal heat-conducting plate in the fast heat dissipation double-layer battery pack of this utility model;

[0031] Figure 5 This is a schematic diagram of the metal heat-conducting plate in the fast heat dissipation double-layer battery pack of this utility model.

[0032] Figure label:

[0033] 1. Outer shell; 101. Bottom shell; 1011. Heat dissipation fins; 1012. Fixing sleeve; 102. Top cover; 2. Upper cell module; 201. Bracket; 2011. Limiting part; 202. Cell stack; 203. Nickel sheet; 3. Lower cell module; 4. Metal heat-conducting plate; 401. Lifting hole; 402. Mounting hole; 403. Guide groove; 5. Soft thermally conductive pad; 501. Limiting groove; 6. First insulating pad; 7. Second insulating pad; 8. Guide post. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of this utility model. Furthermore, descriptions of well-known structures and technologies are omitted in the following description to avoid unnecessarily obscuring the concept of this utility model.

[0035] This utility model provides a fast heat dissipation dual-layer battery pack, comprising: a shell 1; an upper-layer battery cell module 2 and a lower-layer battery cell module 3 disposed inside the shell 1 and distributed vertically; a metal heat-conducting plate 4 disposed between the upper-layer battery cell module 2 and the lower-layer battery cell module 3 and connected to the inner sidewall of the shell 1; and two flexible heat-conducting pads 5. The metal heat-conducting plate 4 is in direct contact with the upper-layer battery cell module 2 and the lower-layer battery cell module 3, thereby efficiently conducting the heat accumulated in the intermediate layer. At the same time, the metal heat-conducting plate 4 also serves to mechanically support the upper-layer battery cell module 2, distributing its weight to avoid putting excessive pressure on the lower-layer battery cell module 3. Furthermore, two flexible thermal pads 5 are respectively installed between the inner sidewalls of the upper battery module 2 and the outer shell 1, and between the inner sidewalls of the lower battery module 3 and the outer shell 1. Each flexible thermal pad 5 is tightly fitted to the corresponding battery module and the inner sidewall of the outer shell 1. In this way, a multi-directional heat dissipation path is constructed from the battery module to the outer shell 1, significantly improving thermal uniformity and management efficiency. In particular, the metal heat-conducting plate 4 is fixed to the inner sidewall of the outer shell 1 by screws or welding to ensure structural stability and continuous heat conduction; while the flexible thermal pads 5 are installed by compression to fill the interface gaps and reduce contact thermal resistance. Preferably, the metal heat-conducting plate 4 is about 5mm thick to balance thermal conductivity and structural strength; copper plates can also be used as an alternative, but aluminum plates are more advantageous in terms of lightweight and cost. Based on this, from the perspective of electrical integration, both the upper cell module 2 and the lower cell module 3 adopt the 7S7P configuration. The positive and negative terminals of the cell are located on the upper and lower surfaces, and electrical connection is achieved by welding with nickel sheet 203. The nickel sheet 203 is then introduced into the PCB board. During the welding of nickel sheet 203, the nickel corner extends to collect voltage, thereby saving height space and improving electrical safety and maintainability.

[0036] Specifically, the outer shell 1 is composed of a bottom shell 101 and a top cover 102, which are locked and fixed by screws.

[0037] Furthermore, the outer surface of the housing 1 is provided with multiple heat dissipation fins 1011, which are evenly distributed along the surface of the housing 1 to significantly increase the effective heat dissipation area. It is worth noting that the heat dissipation fins 1011 can be integrally formed or welded to the housing 1, thereby enhancing the external convection heat dissipation effect, especially under high temperature or high load conditions, enabling rapid release of accumulated heat. Preferably, the height of the heat dissipation fins 1011 is approximately 10 mm, and the spacing can be adjusted according to the heat load, but a typical design is a uniform layout to optimize airflow.

[0038] Based on this, multiple fixing sleeves 1012 are provided on the inner sidewall of the outer casing 1, and mounting holes 402 are opened on the metal heat-conducting plate 4. The metal heat-conducting plate 4 is locked to the fixing sleeves 1012 by screws. This design not only enhances the connection rigidity between the metal heat-conducting plate 4 and the outer casing 1, but also plays a role in efficient heat transfer, transferring heat to the outside more efficiently. In particular, the fixing sleeves 1012 are made of metal materials, such as stainless steel or aluminum alloy, to ensure durability and thermal conductivity; preferably, there are four fixing sleeves 1012, symmetrically arranged on the inner side of the outer casing 1. Alternatively, the fixing sleeves 1012 can be integrally formed with the outer casing 1.

[0039] Furthermore, the heat dissipation structure also includes first insulating pads 6 disposed on both sides of the metal heat-conducting plate 4. The first insulating pads 6 are made of thermally conductive and insulating material, such as polyimide or ceramic-filled polymer, with a thickness of approximately 1 mm. This effectively isolates electrical paths to prevent short circuits without significantly hindering heat conduction. In this way, heat dissipation performance is maintained while ensuring safety. Preferably, the first insulating pads 6 are fixed by adhesive or mechanical pressing; alternatively, an elastic compression structure can be used to accommodate thermal expansion.

[0040] Furthermore, the upper-layer battery module 2 and the lower-layer battery module 3 have the same structure, both including a bracket 201 and a battery cell stack 202 installed within the bracket 201. Specifically, the bracket 201 includes upper and lower fixed panels and connecting posts connecting the upper and lower fixed panels. To achieve precise positioning and rapid installation of the module, the connecting posts are designed as hollow structures and multiple guide posts 8 are provided. The two ends of each guide post 8 are vertically inserted into the bracket 201 of the upper-layer battery module 2 and the lower-layer battery module 3, respectively. Correspondingly, the metal heat-conducting plate 4 has guide grooves 403 for the guide posts 8 to pass through.

[0041] During assembly, the guide post 8 is inserted through the connecting post of the lower cell module 3 bracket 201 at its lower end. Then, the guide groove 403 on the metal heat-conducting plate 4 is aligned with the guide post 8, and the metal heat-conducting plate 4 is precisely installed from top to bottom. Finally, the upper cell module 2 is guided into place. This guiding structure ensures the alignment of holes between components such as the cell module, the metal heat-conducting plate 4, and the insulating pad (a guide hole can be opened at the position corresponding to the guide groove 403 of the metal heat-conducting plate 4), significantly reducing the assembly difficulty, ensuring the uniformity and consistency of contact between various heat-conducting interfaces, thereby optimizing the heat dissipation effect and improving the structural rigidity.

[0042] Furthermore, the support 201 of the upper battery cell module 2 and the lower battery cell module 3 forms a limiting part 2011 at the end of the flexible thermal pad 5, and a limiting groove 501 for engaging the limiting part 2011 is provided on the flexible thermal pad 5. This limiting and mating structure can pre-position the flexible thermal pad 5 in the correct position at the initial stage of assembly, preventing it from slipping or falling off due to vibration or impact during subsequent installation or use. This not only ensures that the flexible thermal pad 5 maintains a stable and tight contact with the side wall of the battery cell module and the inner side wall of the outer shell 1, effectively reducing contact thermal resistance, but also simplifies the assembly process and improves the reliability and efficiency of production.

[0043] Furthermore, this application provides a second insulating pad 7 between the upper cell module 2 and the corresponding flexible thermally conductive pad 5, and also provides two insulating pads 7 between the lower cell module 3 and the corresponding flexible thermally conductive pad 5. The second insulating pad 7 also uses a thermally conductive insulating material, and its installation method is similar to that of the first insulating pad 6, further strengthening lateral electrical insulation and reducing the risk of short circuits. It is worth noting that the second insulating pad 7 can be made of silicone-based composite material, maintaining stable contact even under vibration or temperature changes, thereby ensuring long-term reliability.

[0044] Furthermore, both the metal heat-conducting plate 4 and the flexible heat-conducting pad 5 are adapted to the cross-sectional shapes of the upper battery cell module 2 and the lower battery cell module 3. For example, if the battery cell module is rectangular, the metal heat-conducting plate 4 and the flexible heat-conducting pad 5 are also designed to be correspondingly rectangular to achieve full-area thermal contact and reduce interface thermal resistance and hot spot formation. Preferably, the flexible heat-conducting pad 5 is approximately 2 mm thick, and fills the tiny gaps through compression deformation to ensure uniform heat conduction; this shape adaptation also simplifies the assembly process and reduces assembly errors.

[0045] Specifically, the metal heat-conducting plate 4 is made of aluminum, which has high thermal conductivity and lightweight properties, contributing to the overall lightweight design. Copper or aluminum alloy plates can also be used as alternatives, but aluminum plates are superior in terms of cost and processability, making them suitable for weight-sensitive applications such as electric vehicles.

[0046] Furthermore, the flexible thermal pad 5 is a silicon thermal pad, which combines flexibility and good thermal conductivity, and can adapt to surface unevenness. Preferably, the thermal conductivity of the silicon thermal pad is not less than 3W / m·K. Graphite-based pads can also be used as alternatives to optimize performance under different operating conditions.

[0047] Based on this, the metal heat-conducting plate 4 has multiple lifting holes 401 for hoisting the upper battery cell module 2. The lifting holes 401 are approximately 10mm in diameter and are evenly distributed along the edge of the metal heat-conducting plate 4. After opening the top cover 102, the module can be hoisted using ropes or special tools, thus simplifying the assembly and maintenance process. It is worth noting that the design of the lifting holes 401 not only facilitates operation in a compact space but also avoids significant weakening of structural strength. Preferably, there are four lifting holes 401, symmetrically arranged to balance the force, and they can be used in conjunction with the pre-embedded nut system to improve the overall structural integrity.

[0048] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of this utility model and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of this utility model should be included within its protection scope. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A double-layer battery pack capable of rapid heat dissipation, characterized by, include: The enclosure (1), an upper battery cell module (2) and a lower battery cell module (3) disposed inside the enclosure (1) and distributed vertically, a metal heat-conducting plate (4) disposed between the upper battery cell module (2) and the lower battery cell module (3) and connected to the inner wall of the enclosure (1), and two flexible heat-conducting pads (5); the metal heat-conducting plate (4) is in contact with the upper battery cell module (2) and the lower battery cell module (3); the two flexible heat-conducting pads (5) are respectively disposed between the inner wall of the upper battery cell module (2) and the corresponding inner wall of the enclosure (1) and between the inner wall of the lower battery cell module (3) and the corresponding inner wall of the enclosure (1), and each flexible heat-conducting pad (5) is in contact with the corresponding battery cell module and the inner wall of the enclosure (1).

2. The dual-layer battery pack of claim 1, wherein, The outer side of the outer casing (1) is provided with a plurality of heat dissipation fins (1011).

3. The dual-layer battery pack of claim 1, wherein, The inner wall of the outer shell (1) is provided with a plurality of fixed sleeves (1012), and the fixed sleeves (1012) are connected to the metal heat-conducting plate (4).

4. The dual-layer battery pack of claim 1, wherein, Also includes: The first insulating pads (6) are disposed on both sides of the metal heat-conducting plate (4).

5. The dual-layer battery pack of claim 1, wherein, Also includes: Two second insulating pads (7) are respectively disposed between the upper battery cell module (2) and the corresponding soft thermal conductive pad (5) and between the lower battery cell module (3) and the corresponding soft thermal conductive pad (5).

6. The dual-layer battery pack of claim 1, wherein, The metal heat-conducting plate (4) is an aluminum plate.

7. The dual-layer battery pack of claim 1, wherein, The flexible thermal pad (5) is a silicon thermal pad.

8. The dual-layer battery pack of any one of claims 1-7, wherein, The upper battery cell module (2) and the lower battery cell module (3) have the same structure, both including: a bracket (201) and a battery cell stack (202) installed in the bracket (201), and also including: multiple guide posts (8) vertically inserted between the upper battery cell module (2) and the lower battery cell module (3) bracket (201), and the metal heat-conducting plate (4) is provided with a guide groove (403) for the guide posts (8) to pass through and guide their installation position.

9. The dual-layer battery pack of any one of claims 1-7, wherein, The upper battery cell module (2) and the lower battery cell module (3) support (201) form a limiting part (2011) corresponding to the end protrusion of the flexible thermal pad (5). The flexible thermal pad (5) is provided with a limiting groove (501) that engages with the limiting part (2011).

10. The dual-layer battery pack of any one of claims 1-7, wherein, The metal heat-conducting plate (4) has multiple lifting holes (401) for hoisting the upper battery cell module (2).

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