Battery pack integrated with direct current charging aluminum bar and automobile

Abstract

The utility model relates to the technical field of automobile battery, specifically disclose a kind of battery pack integrated with direct current charging aluminium row and automobile;Battery pack includes battery body, direct current charging aluminium row, insulating structure and heat conduction structure;Battery body includes battery box, cold plate and battery upper cover, and battery upper cover is provided with mounting hole;Direct current charging aluminium row is inserted into battery box inside and is connected with battery module output end by penetrating mounting hole;Insulating structure is covered in aluminium row surface and is fixed and sealed with mounting hole interference fit;Heat conduction structure is arranged in the section of aluminium row in box and is contacted with cold plate to form heat conduction path.The utility model inducts direct current charging aluminium row and battery upper cover depth integration, significantly improves battery pack space utilization and energy density, simplifies structure, reduces cost and weight;At the same time, integrated design combines multiple sealing and efficient heat conduction path, fundamentally improves the sealing reliability, thermal safety and long-term operation stability of system.

Description

Technical Field

[0001] This utility model relates to the field of automotive battery technology, specifically to a battery pack and automobile that integrates a DC charging aluminum busbar. Background Technology

[0002] With the increasing popularity of electric vehicles (EVs) and hybrid electric vehicles (HEVs), the market has placed higher demands on driving range, charging speed, and production costs, driving the development of power battery packs towards higher energy density, power density, and integrated design. The high-voltage connection system inside the battery pack, especially the DC charging circuit responsible for rapid energy replenishment, directly impacts the performance, safety, and cost of the entire battery pack. Against this backdrop, optimizing the high-voltage circuit through structural innovation has become a key factor in enhancing the overall competitiveness of battery packs.

[0003] Currently, Chinese utility model patent with publication number CN218351669U discloses a connection structure between a battery cell and an aluminum busbar, a CTP battery pack, and a vehicle. This prior art demonstrates a typical independent aluminum busbar connection scheme: the aluminum busbar, as an independent conductive component, is detachably electrically connected to the terminal post of the battery cell through limiting connectors and bolts.

[0004] The traditional solutions represented by the aforementioned existing technologies, while widely used, have obvious limitations. First, the independent aluminum busbars and the necessary installation space reduce the space utilization of the battery pack, limiting the improvement of energy density. Second, the split design results in a large number of parts and complicated assembly processes, increasing material costs, weight, and assembly time. Furthermore, mechanical connection points are at risk of loosening under the vibration of long-term vehicle operation, which may lead to increased contact resistance and local overheating, affecting the long-term reliability of the system. Utility Model Content

[0005] To address the technical problems in the prior art, this utility model provides a battery pack and automobile with an integrated DC charging aluminum busbar, aiming to solve the problems of low internal space utilization, excessive number of parts and connection points, high assembly complexity, and limited system reliability caused by the use of a split connection scheme in the prior art.

[0006] The technical solution of this utility model is implemented as follows: A battery pack integrating a DC charging aluminum busbar includes a battery body, a DC charging aluminum busbar, an insulating structure, and a heat-conducting structure, wherein... The battery body includes a battery box, a cold plate, and a battery cover. The battery box is used to integrate the battery module. The cold plate is located at the bottom of the battery box and is connected to an external liquid cooling system. The battery cover is located at the opening of the battery box and has mounting holes. The DC charging aluminum busbar extends through the mounting hole into the inside of the battery box and is electrically connected to the output terminal of the battery module. The insulating structure covers the surface of the DC charging aluminum busbar and is interference-fitted with the mounting hole. The heat-conducting structure is located in the section of the DC charging aluminum busbar inside the battery box and is in contact with the cold plate.

[0007] Optionally, the insulation structure includes an insulating covering layer and a sealing insert. The insulating coating layer is applied to the outer surface of the DC charging aluminum busbar. The sealing insert is disposed at the mounting hole to fill and seal the mounting hole.

[0008] Optionally, the insulation structure further includes a sealing skirt; The sealing skirt is located at the end of the sealing insert on the outside of the battery cover and extends outwards. The top surface of the battery cover is provided with a sealing groove corresponding to the position of the sealing skirt, and the sealing skirt can be embedded in the sealing groove.

[0009] Optionally, the insulating covering layer and the sealing insert are integrally injection molded structures.

[0010] Optionally, the thermally conductive structure includes a thermally conductive element and an insulating thermally conductive pad, wherein, The heat-conducting component is fixedly installed in the section of the DC charging aluminum busbar located inside the battery box. The insulating thermal pad is sandwiched between the thermally conductive component and the cold plate to achieve electrical insulation during heat conduction.

[0011] Optionally, the heat-conducting component includes a heat-conducting vertical plate and a heat-conducting contact plate, wherein, The heat-conducting vertical plate is fixed to the end of the DC charging aluminum busbar; The thermally conductive contact plate is fixedly disposed at the end of the thermally conductive vertical plate away from the DC charging aluminum busbar and is in contact with the insulating thermally conductive pad.

[0012] Optionally, the heat-conducting component may further include heat dissipation fins; The heat dissipation fins include multiple fins, which are evenly distributed on the outer surface of the heat-conducting vertical plate.

[0013] Optionally, the insulating thermal pad has a thermal groove corresponding to the thermal contact plate, and the thermal contact plate is accommodated in the thermal groove.

[0014] Optionally, the insulating thermal pad is made of a silicone-based thermally conductive material.

[0015] This utility model also provides a car, including the above-mentioned battery pack with an integrated DC charging aluminum busbar.

[0016] Compared with the prior art, the battery pack and automobile integrated with DC charging aluminum busbar provided by this utility model have the following advantages: (1) By deeply integrating the DC charging aluminum busbar with the battery cover, the independent connectors and cables are eliminated, significantly reducing the space occupied by the high voltage circuit inside the battery pack, making the battery pack layout more compact, creating conditions for accommodating more cells or enhancing structural protection, and directly improving the volumetric energy density and mass energy density of the system.

[0017] (2) Through the multiple and redundant sealing structure consisting of insulating covering layer, sealing block and sealing skirt, combined with interference fit with mounting hole and integrated injection molding process, the battery pack is ensured to meet the high protection level requirements for a long time under complex working conditions, which fundamentally improves the sealing reliability and long-term environmental durability of the system.

[0018] (3) By setting up heat-conducting components and insulating heat-conducting pads, an efficient and low thermal resistance heat conduction path is established from the DC charging aluminum busbar directly to the cold plate. This can quickly conduct and dissipate the Joule heat generated during high-current charging, effectively avoiding heat accumulation and local overheating at the aluminum busbar connection, and greatly improving the thermal safety and long-term reliability of the system under fast charging conditions. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of a battery pack integrating a DC charging aluminum busbar according to the present invention. Figure 2 This is a schematic diagram of the internal installation structure of a battery pack integrating a DC charging aluminum busbar according to the present invention. Figure 3 This is a schematic diagram showing the disassembled structure of a battery pack integrating a DC charging aluminum busbar according to the present invention. Figure 4 This is a schematic diagram of the insulation and heat conduction structure of a battery pack integrating a DC charging aluminum busbar according to this utility model.

[0020] In the diagram: 1. Battery body; 101. Mounting hole; 102. Sealing groove; 11. Battery box; 12. Cold plate; 13. Battery top cover; 2. DC charging aluminum busbar; 3. Insulation structure; 31. Insulation covering layer; 32. Sealing insert; 33. Sealing skirt; 4. Thermal conduction structure; 401. Thermal conduction groove; 41. Thermal conduction component; 411. Thermal conduction vertical plate; 412. Thermal conduction contact plate; 413. Heat dissipation fins; 42. Insulating thermal pad. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0022] In the description of the embodiments of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this utility model based on the specific circumstances.

[0023] In the description of the embodiments of this utility model, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" 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 utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this utility model.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0025] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0026] The following disclosure provides numerous different embodiments or examples for implementing various structures of the present invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of the invention. Furthermore, reference numerals and / or letters may be repeated in different examples. Such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, examples of various specific processes and materials are provided in this invention; however, those skilled in the art will recognize the applicability of other processes and / or the use of other materials.

[0027] Please see Figure 1-4 The present application proposes a battery pack integrating a DC charging aluminum busbar, comprising a battery body 1, a DC charging aluminum busbar 2, an insulating structure 3, and a heat-conducting structure 4.

[0028] like Figure 1-3 As shown, the battery body 1 includes a battery box 11, a cold plate 12, and a battery cover 13. The battery box 11 is used to integrate the battery module. The cold plate 12 is located at the bottom of the battery box 11 and is connected to an external liquid cooling system. The battery cover 13 is located at the opening of the battery box 11 and has a mounting hole 101. The DC charging aluminum busbar 2 extends into the battery box 11 through the mounting hole 101 and is electrically connected to the output end of the battery module. The insulating structure 3 covers the surface of the DC charging aluminum busbar 2 and is interference-fitted with the mounting hole 101 to achieve structural fixation and environmental sealing. The heat-conducting structure 4 is located in the section of the DC charging aluminum busbar 2 inside the battery box 11 and is in contact with the cold plate 12 to form a heat conduction path for heat dissipation at the connection of the DC charging aluminum busbar 2.

[0029] Specifically, the DC charging aluminum busbar 2 is upgraded from a traditional independent connector to an integrated functional component deeply integrated with the battery cover 13. This design significantly improves space utilization and energy efficiency. It eliminates independent cables and connectors, making the internal layout of the battery pack more compact and directly increasing the volumetric energy density. At the same time, the integrated structure effectively reduces system cost and overall weight, and reduces the number of parts and assembly processes. The interference fit between the insulation structure 3 and the mounting hole 101, as well as the contact between the heat-conducting structure 4 and the cold plate 12, together constitute a highly reliable sealing and heat dissipation system, enhancing the reliability and safety of the system from the two dimensions of environmental protection and thermal management.

[0030] In some embodiments, such as Figure 3-4 As shown, the insulation structure 3 includes an insulation covering layer 31 and a sealing block 32. The insulation covering layer 31 covers the outer surface of the DC charging aluminum busbar 2. The sealing block 32 is provided at the mounting hole 101 to fill and seal the mounting hole 101.

[0031] Specifically, this embodiment refines the insulation and sealing scheme; the insulation covering layer 31 provides basic insulation protection for the aluminum busbar body, while the sealing insert 32 is specifically used to solve the dynamic sealing problem of the mounting hole 101 penetrating the top cover; the two have a clear division of labor and together constitute a special sealing solution for integrated aluminum busbars; this design ensures that even under long-term vehicle vibration conditions, the battery pack can still achieve multiple seals and extremely high environmental protection reliability, meeting the requirements of high protection levels such as IP67, and fundamentally eliminating the risk of external environmental intrusion caused by seal failure.

[0032] In some embodiments, such as Figure 3-4 As shown, the insulating structure 3 also includes a sealing skirt 33; the sealing skirt 33 is located at the end of the sealing insert 32 located on the outside of the battery cover 13 and extends to the periphery; the top surface of the battery cover 13 is provided with a sealing groove 102 corresponding to the position of the sealing skirt 33, and the sealing skirt 33 can be embedded in the sealing groove 102.

[0033] Specifically, this embodiment provides a redundant sealing design; the cooperation between the sealing skirt 33 and the sealing groove 102 adds a radial sealing barrier on the basis of the axial sealing of the sealing insert 32; this constitutes a more complete axial and radial dual sealing interface, which greatly improves the sealing robustness under extreme working conditions. It is a key detail for achieving multiple sealing and extremely high environmental protection reliability, and further ensures the long-term safety of the battery system.

[0034] In some embodiments, such as Figure 4 As shown, the insulating covering layer 31 and the sealing insert 32 are integrally injection molded structures.

[0035] Specifically, this embodiment defines a preferred manufacturing process; through integral injection molding, there are no assembly seams between the insulating covering layer 31 and the sealing insert 32, eliminating potential leakage points from the source and achieving optimal sealing performance; this process also simplifies the structure and reduces cost and weight, combining the manufacturing and assembly of the two components into one, reducing the number of parts, simplifying the assembly process, and improving production efficiency and product consistency.

[0036] In some embodiments, such as Figure 4 As shown, the heat-conducting structure 4 includes a heat-conducting element 41 and an insulating heat-conducting pad 42. The heat-conducting element 41 is fixedly disposed in the section of the DC charging aluminum busbar 2 located inside the battery box 11. The insulating heat-conducting pad 42 is sandwiched between the heat-conducting element 41 and the cold plate 12 to achieve electrical insulation when conducting heat.

[0037] Specifically, this embodiment clarifies the composition of the core heat dissipation path; the heat-conducting component 41 serves as the medium for heat collection and conduction, while the insulating heat-conducting pad 42 simultaneously undertakes the dual functions of heat conduction and insulation; it ensures that heat can be efficiently transferred from the heat-conducting component 41 to the cold plate 12, and also ensures that the high voltage on the DC charging aluminum busbar 2 will not be conducted to the normally grounded cold plate 12, thereby constructing an efficient thermal management path and improving system safety, which is the key to solving the problem of aluminum busbar overheating during high-current fast charging.

[0038] In some embodiments, such as Figure 4 As shown, the heat-conducting component 41 includes a heat-conducting vertical plate 411 and a heat-conducting contact plate 412. The heat-conducting vertical plate 411 is fixed to the end of the DC charging aluminum busbar 2. The heat-conducting contact plate 412 is fixed at the end of the heat-conducting vertical plate 411 away from the DC charging aluminum busbar 2 and is in contact with the insulating heat-conducting pad 42.

[0039] Specifically, this embodiment provides a preferred form of the heat-conducting component 41; the heat-conducting vertical plate 411 realizes the transition from the end of the aluminum busbar to the heat dissipation interface, while the heat-conducting contact plate 412 provides a stable and flat pressing surface; this L-shaped or T-shaped structural design increases the contact area with the insulating heat-conducting pad 42, optimizes the heat flow path, and ensures that heat can be discharged more smoothly, thereby strengthening the construction of an efficient heat management path and avoiding local hot spots caused by poor contact.

[0040] In some embodiments, such as Figure 4 As shown, the heat-conducting component 41 also includes heat dissipation fins 413; the heat dissipation fins 413 include a plurality of fins, which are evenly disposed on the outer surface of the heat-conducting vertical plate 411 to increase the heat exchange area with the air inside the battery box 11.

[0041] Specifically, this embodiment adds an auxiliary heat dissipation mechanism; the heat dissipation fins 413 significantly increase the surface area of ​​the heat conductor 41 and utilize the weak convection of the gas inside the battery pack to achieve convective heat dissipation, which complements the dominant heat conduction path and constitutes a composite heat dissipation system of "conduction as the main method and convection as the auxiliary method", providing additional thermal safety margin and further improving the safety and reliability of the system in terms of thermal management.

[0042] In some embodiments, such as Figure 4 As shown, the insulating thermal pad 42 has a thermal groove 401 corresponding to the thermal contact plate 412. The thermal contact plate 412 is accommodated in the thermal groove 401 to increase the contact area between them and ensure uniform contact pressure, thereby avoiding poor local contact.

[0043] Specifically, this embodiment optimizes the heat dissipation interface through a sophisticated interlocking structure; the heat conduction groove 401 physically limits the heat conduction contact plate 412, which not only increases the effective heat conduction contact area, but more importantly, ensures the stability of the contact interface pressure under vibration, effectively preventing poor contact and increased thermal resistance caused by vibration or tolerance; this design directly contributes to building a stable and efficient thermal management path and improving system safety.

[0044] In some embodiments, the insulating thermal pad 42 is made of a silicone-based thermally conductive material.

[0045] Specifically, this embodiment specifies the preferred material for the insulating thermal pad 42; a silicone-based thermally conductive material is used due to its good flexibility, high compressibility, and excellent insulation properties. The flexibility ensures that it can fully fill the microscopic gaps between the thermally conductive component 41 and the cold plate 12, eliminating air and forming a low thermal resistance interface; the high compressibility absorbs assembly stress; and the excellent insulation properties ensure electrical safety between the high-voltage circuit and ground. This material selection is a reliable guarantee for achieving the dual goals of efficient thermal conduction and electrical insulation.

[0046] This invention also provides a car including the aforementioned battery pack with integrated DC charging aluminum busbar; by assembling the battery pack provided by this invention, the car, especially the electric car, can inherit all its beneficial effects, including longer driving range, faster charging speed, higher safety and potential cost advantages, thereby enhancing the market competitiveness of the whole vehicle product.

[0047] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A battery pack integrating a DC charging aluminum busbar, characterized in that, It includes the battery body (1), DC charging aluminum busbar (2), insulation structure (3), and heat-conducting structure (4), among which, The battery body (1) includes a battery box (11), a cold plate (12) and a battery cover (13). The battery box (11) is used to integrate battery modules. The cold plate (12) is located at the bottom of the battery box (11) and is connected to an external liquid cooling system. The battery cover (13) is located at the opening of the battery box (11) and has a mounting hole (101). The DC charging aluminum busbar (2) extends through the mounting hole (101) into the battery box (11) and is electrically connected to the output end of the battery module; The insulating structure (3) covers the surface of the DC charging aluminum busbar (2) and is interference-fitted with the mounting hole (101); The heat-conducting structure (4) is located in the section of the DC charging aluminum busbar (2) inside the battery box (11) and is in contact with the cold plate (12).

2. A battery pack integrating a DC charging aluminum busbar according to claim 1, characterized in that, The insulation structure (3) includes an insulating covering layer (31) and a sealing block (32). The insulating coating layer (31) covers the outer surface of the DC charging aluminum busbar (2); The sealing insert (32) is provided at the mounting hole (101) to fill and seal the mounting hole (101).

3. A battery pack integrating a DC charging aluminum busbar according to claim 2, characterized in that, The insulating structure (3) also includes a sealing skirt (33); The sealing skirt (33) is located at the end of the sealing insert (32) on the outside of the battery cover (13) and extends to the periphery; The top surface of the battery cover (13) is provided with a sealing groove (102) corresponding to the position of the sealing skirt (33), and the sealing skirt (33) can be embedded in the sealing groove (102).

4. A battery pack integrating a DC charging aluminum busbar according to claim 2, characterized in that, The insulating covering layer (31) and the sealing insert (32) are integrally injection molded structures.

5. A battery pack integrating a DC charging aluminum busbar according to claim 1, characterized in that, The thermally conductive structure (4) includes a thermally conductive element (41) and an insulating thermally conductive pad (42), wherein, The heat-conducting component (41) is fixedly installed in the section of the DC charging aluminum busbar (2) located inside the battery box (11); The insulating thermal pad (42) is sandwiched between the thermal conductive element (41) and the cold plate (12) to achieve electrical insulation when conducting heat.

6. A battery pack integrating a DC charging aluminum busbar according to claim 5, characterized in that, The heat-conducting component (41) includes a heat-conducting vertical plate (411) and a heat-conducting contact plate (412), wherein, The heat-conducting vertical plate (411) is fixed to the end of the DC charging aluminum busbar (2); The thermally conductive contact plate (412) is fixedly disposed at one end of the thermally conductive vertical plate (411) away from the DC charging aluminum busbar (2) and is in contact with the insulating thermally conductive pad (42).

7. A battery pack integrating a DC charging aluminum busbar according to claim 6, characterized in that, The heat-conducting component (41) also includes heat dissipation fins (413). The heat dissipation fins (413) include a plurality of fins, which are uniformly disposed on the outer surface of the heat-conducting vertical plate (411).

8. A battery pack integrating a DC charging aluminum busbar according to claim 6, characterized in that, The insulating thermal pad (42) has a thermal groove (401) corresponding to the thermal contact plate (412), and the thermal contact plate (412) is accommodated in the thermal groove (401).

9. A battery pack integrating a DC charging aluminum busbar according to claim 5, characterized in that, The insulating thermal pad (42) is made of silicone-based thermally conductive material.

10. A car, characterized in that, The battery pack comprising any one of claims 1-9, which integrates a DC charging aluminum busbar.

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