A thermal runaway module testing device

Abstract

This utility model discloses a thermal runaway module testing device, belonging to the field of battery testing technology. The device includes a clamping plate, an integrated base, a heat insulation sheet, a heating element assembly, a temperature acquisition assembly, a battery cell, a cell separator, and an aluminum busbar. The integrated base is assembled with the clamping plate and is used to fix the heating element assembly leads, the temperature acquisition assembly leads, and the battery cell's positive and negative terminals. This utility model, through an integrated design, organically combines the heating element leads, thermocouple leads, and the module's positive and negative terminals on the integrated base, avoiding the problems of numerous assembly steps, complex wiring harnesses, difficult wiring, and high risk of module recharging associated with traditional methods.

Description

Technical Field

[0001] This utility model discloses a thermal runaway module testing device, which belongs to the field of battery testing technology. Background Technology

[0002] With the booming development of China's new energy vehicle industry, electric vehicle safety has become a core issue of great concern. As the core power source of new energy vehicles, the power battery contains enormous energy. Once thermal runaway occurs, it can easily and rapidly cause the entire vehicle to catch fire, seriously threatening the lives of passengers. Therefore, thermal runaway protection design for power batteries has become a top priority for vehicle manufacturers and battery producers in safety design.

[0003] Due to the high cost and long cycle of testing, designers typically use a modular approach to verify the safety of thermal runaway designs in the early development stages. The main purpose is to confirm the distance between cells, the selection of separators, the maximum temperature and severity during thermal runaway, thereby confirming the design of the battery pack's protective materials. Traditional verification methods involve first applying Teflon tape as insulation to the clamping plate during module stacking, then attaching thermal insulation material to prevent heat transfer from the heating element to the clamping plate side. The heating element is stacked between the clamping plate and the trigger cell, while thermocouples are placed between the remaining cells. The connecting wires of the heating element and the thermocouple harnesses are haphazardly extended outside the module as wire ends. When manually wiring each wire individually, the numerous and chaotic wires easily lead to connection errors and unstable signal transmission, resulting in rework. Since thermal runaway testing generally requires a state of charge (SOC) of over 95%, when the module is assembled and charged, the cells closest to the clamping plate are usually used as the main positive or negative leads. When welding aluminum busbars, they are prone to interference with the clamping plate, requiring specially made aluminum busbars that need to be bent or cut off after charging, increasing costs. Alternatively, the cells can be fully charged at the cell level and then welded after assembly, increasing the risk to on-site operators and potentially leading to safety accidents. Utility Model Content

[0004] The purpose of this utility model is to provide a thermal runaway module testing device. By adopting an integrated design, the heating element leads, thermocouple leads and the main positive / negative leads of the module are organically combined in an integrated base, which avoids the problems of multiple assembly steps, complicated wiring harnesses, difficult wiring and high risk of module power replenishment in traditional design schemes.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: This utility model provides a thermal runaway module testing device, including a clamping plate, an integrated base, a heat insulation sheet, a heating element assembly, a temperature acquisition assembly, a battery cell, a battery cell separator, and an aluminum busbar; the heat insulation sheet is adhered to the clamping plate; the heating element assembly is placed between the heat insulation sheet and the battery cell, and the heating element assembly lead extends along the direction of the battery cell; the temperature acquisition assembly and the battery cell separator are placed between pairs of battery cells, and the temperature acquisition assembly lead extends along the direction of the battery cell; the aluminum busbar is connected to the electrode of the battery cell; The integrated base is assembled with the clamping plate, and the integrated base includes: a heating element connector fixing part, a module high voltage output part, and a temperature sampling connector output part; The heating element connector fixing part is used to fix the heating element assembly lead wire, the temperature acquisition connector output part is used to fix the temperature acquisition assembly lead wire, and the module high voltage output part is used to fix the total positive and total negative leads of the battery cell.

[0006] Preferably, the clamping plate is coated with insulating spray on both sides.

[0007] In this preferred solution, the insulation effect is more durable by spraying insulating coating on both sides of the plywood instead of the traditional solution of sticking Teflon tape.

[0008] Preferably, the clamping plate has U-shaped grooves on both the upper and lower sides for leading wires in multiple directions.

[0009] In this preferred embodiment, U-shaped grooves are provided on both the upper and lower sides of the two side plates to facilitate wire leading in multiple directions and avoid numerous wire heads being concentrated on one side, which would cause chaos.

[0010] Preferably, the U-shaped groove is provided with a conical hole that mates with the conical boss at the bottom of the integrated base, and the integrated base is assembled with a conical surface through the conical boss and the conical hole on the clamping plate.

[0011] In this preferred embodiment, the conical surface assembly method provides good sealing performance, and the combination of the two components also exhibits excellent self-locking properties.

[0012] Preferably, the heating element assembly includes a heating element, a wire, and a heating element connector. The heating element is adhered between the heat insulation sheet and the battery cell. The wire extends along the direction of the battery cell to the heating element connector. The heating element connector is fixed on the heating element connector fixing part of the integrated base.

[0013] In this preferred embodiment, the heating element assembly is further defined as including a heating element, wires, and a heating element connector. The heating element wires are uniformly led out along the direction of the battery cell to the heating element connector. Based on this, wiring harness confusion is effectively avoided, and the process of identifying and wiring the heating element wires is greatly simplified.

[0014] Preferably, the bottom of the heating element connector is provided with a semi-circular snap-fit ​​structure, which is pressed and fixed with the round hole on the fixing part of the heating element connector.

[0015] In this preferred embodiment, a circular snap-fit ​​installation method is adopted, which eliminates the need for welding or complex tools and enables quick connection of components.

[0016] Preferably, the temperature acquisition component includes a thermocouple, a data acquisition cable, and a temperature acquisition connector. The thermocouple is in close contact with the battery cell, and the thermocouple and the battery cell spacer are arranged together between adjacent battery cells. The data acquisition cable is led out along the direction of the battery cell to the end face of the battery cell and is glued to the side of the battery cell with adhesive on one side. The end of the data acquisition cable is connected to the temperature acquisition connector, and the temperature acquisition connector is fixed on the temperature acquisition connector output part of the integrated base.

[0017] In this preferred embodiment, the temperature acquisition component is further defined as including a thermocouple, an acquisition cable, and a temperature acquisition connector. The thermocouple leads are uniformly led out along the direction of the battery cell and connected to the temperature acquisition connector at the end. Based on this, the wiring harness chaos is effectively avoided, and the identification and wiring process of the thermocouple leads is greatly simplified.

[0018] Preferably, the bottom of the temperature sensor connector is provided with a semi-circular snap-fit ​​structure, which is pressed and fixed with the round hole on the output part of the temperature sensor connector.

[0019] In this preferred embodiment, a circular snap-fit ​​installation method is adopted, which eliminates the need for welding or complex tools and enables quick connection of components.

[0020] Preferably, the high-voltage output section of the module is provided with an embedded nut, and the positive and negative leads of the battery cell are fixed to the high-voltage output section of the module by threads.

[0021] Preferably, threaded holes are provided at all four corners of the clamping plate, and the threaded holes on both sides of the clamping plate cooperate with the screw to realize module assembly.

[0022] In this preferred embodiment, the size of the assembled module can be adjusted by using the thread and screw in conjunction with the thickness of the extruded cell separator.

[0023] The beneficial effects achieved by this utility model are as follows: This utility model provides a highly integrated thermal runaway module testing solution, which simplifies the module assembly steps and the tedious wiring harness management. It adopts a quick-connect form for external output, which reduces the huge workload of wiring and the problems of poor signal transmission and difficulty in quality control. At the same time, it reduces the cost and workload of customizing lead-out bars when the module is recharged, and avoids the production risks that are prone to occur when the battery cells are fully charged and soldered. Attached Figure Description

[0024] Figure 1A schematic diagram of the thermal runaway module testing device provided by this utility model after conversion; Figure 2 Exploded view of the thermal runaway module testing device provided by this utility model; Figure 3 A schematic diagram of the heating element assembly provided by this utility model; Figure 4 A schematic diagram of the temperature acquisition component provided by this utility model; Figure 5 A schematic diagram of the integrated base structure provided by this utility model. Detailed Implementation

[0025] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The embodiments described below with reference to the accompanying drawings are illustrative and intended to explain this utility model, and should not be construed as limiting this utility model.

[0026] In the description of this utility model, it should be noted that the terms "upper", "lower", "front", "rear", "end", "bottom", "side", etc., 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 this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0027] In this utility model, unless otherwise explicitly specified and limited, the terms "connection," "installation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a direct connection, or a connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0028] Secondly, the term "an embodiment" or "embodiment" as used in this utility model refers to a specific feature, structure, or characteristic that can be included in at least one implementation of this utility model. The phrase "in an embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0029] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0030] This utility model provides a thermal runaway module testing device, see [link to related document]. Figure 1 and Figure 2 It includes a clamping plate 1, an integrated base 2, a heat insulation sheet 3, a heating element assembly 4, a temperature acquisition assembly 5, a battery cell 6, a battery cell separator 7, an aluminum busbar 8, and a screw 9. The clamp plate 1 is coated with insulating spray on both sides, replacing the traditional solution of sticking Teflon tape. U-shaped grooves are opened on both the upper and lower sides of the clamp plate to facilitate wires to be led in multiple directions.

[0031] The U-shaped groove is provided with a conical hole that mates with the conical boss at the bottom of the integrated base 2. The integrated base 2 forms a conical surface assembly through the conical boss and the conical hole on the clamping plate.

[0032] The clamping plate 1 has threaded holes at its four corners. The threaded holes on both sides of the clamping plate mate with the screw 9 to complete the module assembly. It should be noted that during the assembly process, the thickness of the assembled module is adjusted by pressing the cell separator 7.

[0033] In this invention, the heat insulation sheet 3 is attached to the clamping plate 1 to block the heat from being transmitted to the clamping plate 1, thus preventing thermal runaway from being triggered for a long time.

[0034] See Figure 3 The heating element assembly 4 includes a heating element 4a, a wire 4b, and a heating element connector 4c. The heating element 4a is attached between the heat insulation sheet 3 and the battery cell 6. The wire 4b is led out along the direction of the battery cell to the heating element connector 4c. The heating element connector 4c is fixed on the integrated base 2.

[0035] See Figure 4 The temperature acquisition component 5 includes a thermocouple 5a, a data acquisition cable 5b, and a temperature acquisition connector 5c. The thermocouple 5a is closely attached to the middle of the other cells and is arranged between adjacent cells together with the cell spacer 7. The data acquisition cable 5b is led out along the direction of the cell to the end face of the cell, and then is attached to the side of the cell with adhesive on one side in the form of an integrated cable or FPC. The end is connected to the temperature acquisition connector 5c, which is fixed on the integrated base 2.

[0036] See Figure 5 In this utility model, the integrated base 2 consists of three parts: a heating element connector fixing part 2a, a module high voltage output part 2b, and a temperature sampling connector output part 2c. Both the heating element connector 4c and the temperature acquisition connector 5c have two semi-circular snap-fit ​​structures at their bottoms. During assembly, these structures are pressed into the round holes on the heating element connector fixing part 2a and the temperature acquisition connector output part 2c, respectively, to secure them.

[0037] The high voltage output section 2b of the module is designed with an embedded nut, and the total positive and total negative leads at both ends of the aluminum busbar 8 are fixed on the high voltage output section 2b of the module by threads.

[0038] The assembly process of the thermal runaway module testing device provided by this utility model is as follows: First, assemble the clamping plate 1 and the integrated base 2. The heat insulation sheet 3 is adhered to the clamping plate 1 to block heat transfer towards the clamping plate, preventing prolonged failure to trigger thermal runaway. The heating element 4a from the heating element assembly 4 is adhered between the heat insulation sheet 3 and the battery cell 6. The wire 4b is led out along the direction of the battery cell to the heating element connector 4c. The heating element connector 4c is fixed to the heating element connector fixing part 2a on the integrated base 2 by a semi-circular clip below it. Next, the thermocouple 5a from the temperature acquisition assembly 5 is placed close to the middle of each remaining battery cell, arranged between each battery cell along with the battery cell spacer 7. The acquisition cable 5b is led out along the direction of the battery cell to the end face of the battery cell, and then single-sided adhesive is used to attach it to the side of the battery cell in the form of an integrated cable or FPC. The end is connected to the temperature acquisition connector 5c, and then fixed to the round hole of the temperature acquisition connector output part 2c on the integrated base 2 by a semi-circular clip. The aluminum busbar 8 is connected to the terminal post of the battery cell 6 by laser welding. The total positive and total negative leads at both ends are fixed to the high voltage output section 2b of the module by threads. Finally, the screws 9 are inserted into the pre-set threaded holes at the four corners of the clamping plate 1 to fix the clamping plates on both sides.

[0039] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A thermal runaway module testing device, characterized in that, The device includes a clamping plate, an integrated base, a heat insulation sheet, a heating element assembly, a temperature acquisition assembly, a battery cell, a battery cell spacer, and an aluminum busbar; the heat insulation sheet is adhered to the clamping plate; the heating element assembly is placed between the heat insulation sheet and the battery cell, and the heating element assembly leads are led out along the direction of the battery cell; the temperature acquisition assembly and the battery cell spacer are placed between pairs of battery cells, and the temperature acquisition assembly leads are led out along the direction of the battery cell. The aluminum busbar is connected to the terminal post of the battery cell; The integrated base is assembled with the clamping plate, and the integrated base includes: a heating element connector fixing part, a module high voltage output part, and a temperature sampling connector output part; The heating element connector fixing part is used to fix the heating element assembly lead wire, the temperature acquisition connector output part is used to fix the temperature acquisition assembly lead wire, and the module high voltage output part is used to fix the total positive and total negative leads of the battery cell.

2. The thermal runaway module testing device according to claim 1, characterized in that, The clamping plate is coated with insulating powder on both sides.

3. The thermal runaway module testing device according to claim 1, characterized in that, The clamp is provided with U-shaped grooves on both the upper and lower sides for leading wires in multiple directions.

4. The thermal runaway module testing device according to claim 3, characterized in that, The U-shaped groove is provided with a conical hole that mates with the conical boss at the bottom of the integrated base. The integrated base is assembled with a conical surface through the conical boss and the conical hole on the clamping plate.

5. The thermal runaway module testing device according to claim 1, characterized in that, The heating element assembly includes a heating element, a wire, and a heating element connector. The heating element is attached between the heat insulation sheet and the battery cell. The wire extends along the direction of the battery cell to the heating element connector. The heating element connector is fixed on the heating element connector fixing part of the integrated base.

6. The thermal runaway module testing device according to claim 5, characterized in that, The bottom of the heating element connector is provided with a semi-circular buckle structure, which is pressed and fixed with the round hole on the fixing part of the heating element connector.

7. The thermal runaway module testing device according to claim 1, characterized in that, The temperature acquisition component includes a thermocouple, a data acquisition cable, and a temperature acquisition connector. The thermocouple is in close contact with the battery cell, and the thermocouple and the battery cell spacer are arranged together between adjacent battery cells. The data acquisition cable is led out along the direction of the battery cell to the end face of the battery cell and is glued to the side of the battery cell with adhesive on one side. The end of the data acquisition cable is connected to the temperature acquisition connector, and the temperature acquisition connector is fixed on the temperature acquisition connector output part of the integrated base.

8. The thermal runaway module testing device according to claim 7, characterized in that, The bottom of the temperature sensor connector is provided with a semi-circular snap-fit ​​structure, which is pressed and fixed with the round hole on the output part of the temperature sensor connector.

9. The thermal runaway module testing device according to claim 1, characterized in that, The module's high-voltage output section is equipped with an embedded nut, and the battery cell's positive and negative leads are fixed to the module's high-voltage output section by threads.

10. The thermal runaway module testing device according to claim 1, characterized in that, The clamping plate has threaded holes at all four corners, and the threaded holes on both sides of the clamping plate cooperate with the screw to realize module assembly.

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