A battery pack

Abstract

The utility model provides a kind of battery pack, belong to battery technical field.Battery pack includes control cabinet and with control cabinet upper and lower superposition at least one module box, module box includes module box and battery module, control cabinet includes control cabinet and the controller of being connected with corresponding battery module by conductor, control cabinet and module box are all the box of upper end opening and with bottom wall, the topmost box in each box is fixed with upper cover by bolt, the bottom wall of the remaining box except the bottommost box is all provided with through hole that is through for corresponding conductor by bolt connection between upper and lower adjacent box.This utility model can realize the extension of output electric quantity, compatibility is relatively high, the original control cabinet and module box can continue to use, need not redevelop a brand-new battery pack, and for battery manufacturer, according to the demand of different customer, realize quick production, greatly shorten production cycle, reduce production cost.

Description

Technical Field

[0001] This utility model relates to a battery pack and belongs to the field of battery technology. Background Technology

[0002] Existing battery packs typically include a housing, battery modules housed within the housing, and controllers for controlling the charging and discharging of the battery modules. For example, Chinese utility model patent CN222673139U discloses a double-layer battery pack. This double-layer battery pack includes a housing structure, a lower battery module, an upper battery module, and a battery control module. It also includes a master control acquisition board and two slave control acquisition boards. One slave control acquisition board is electrically connected to the lower battery module and is used to collect data from it. The other slave control acquisition board is electrically connected to the upper battery module and is used to collect data from it. The two slave control acquisition boards are each electrically connected to the master control acquisition board. The battery control module is also electrically connected to the master control acquisition board, enabling it to receive data collected by the master control acquisition board. Furthermore, the battery control module is electrically connected to both the upper and lower battery modules, allowing it to control the charging or discharging of the upper and lower battery modules based on the data collected by the master control acquisition board, thereby improving the safety of the battery pack.

[0003] However, existing battery packs have a limited number of battery modules and cannot expand their output capacity. When the power consumption of external devices increases, they cannot be quickly compatible because the volume of the enclosure is fixed. New battery modules cannot be directly added to the enclosure, so new battery packs must be developed, which has a long development cycle and high cost.

[0004] Meanwhile, for battery manufacturers, different users have different power requirements. Existing battery packs put the battery control module, acquisition board and other control devices and battery modules in a box. Obviously, battery packs with different output power require different box specifications, which increases production costs and makes it impossible to quickly schedule production according to the needs of different customers, resulting in a long production cycle. Utility Model Content

[0005] The purpose of this utility model is to provide a battery pack that solves the problem that the output power of existing battery packs cannot be expanded, and that new battery packs must be developed when power consumption increases, resulting in long cycles and high costs. It also solves the problem that battery manufacturers cannot quickly schedule production according to different customer needs, resulting in long production cycles and high costs.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A battery pack includes a control box and at least one module box stacked vertically above the control box. The module box includes a module box body and battery modules disposed within the module box body. The control box includes a control box body and a control device disposed within the control box body and connected to the corresponding battery modules via conductors. Both the control box body and the module box body are boxes with an open top and a bottom wall. The topmost box body is fixed with a top cover by bolts. The adjacent boxes are connected by bolts. The bottom walls of the remaining boxes, except for the bottommost box body, are provided with through holes that allow the corresponding conductors to pass through.

[0007] The beneficial effects of the above technical solution are as follows: This utility model is a pioneering invention. The battery pack provided includes a control box and at least one module box stacked on top of the control box. The module box includes a module box body and a battery module disposed in the module box body. The control box includes a control box body and a control device disposed in the control box body and connected to the corresponding battery module through a conductor. The battery module and the control device are arranged in different boxes. One battery pack can be equipped with one control box and one or more module boxes.

[0008] Since both the control box and the module box are open at the top and have a bottom wall, all boxes except the bottom one have through holes on their bottom walls to allow conductors to pass through, thus accommodating conductor arrangement. The top box is bolted to a cover, and adjacent boxes are bolted together. This allows for the addition of more than one new module box when power consumption increases. The new module box can be stacked on top, requiring the original cover to be removed and fixed to the new box. The bottom wall of the new module box also needs through holes to allow for rewiring between the new and existing battery modules, and between the new battery modules and the control devices. Alternatively, the new module box can be stacked below the top box or above the bottom box; simply unscrewing the bolts between adjacent boxes and rewiring is sufficient. In short, the original control box and module box can be reused, eliminating the need to develop a completely new battery pack, thus shortening the development cycle and reducing costs.

[0009] For battery manufacturers, module boxes and control boxes can be mass-produced, with one control box for each battery pack. Then, the corresponding number of module boxes can be configured according to the needs of different customers, which can achieve rapid production scheduling, greatly shorten the production cycle, and reduce production costs.

[0010] Furthermore, the control device includes a data acquisition board and a battery control module connected to the data acquisition board. The conductor includes a data acquisition harness connected between the data acquisition board and the corresponding battery module, and a conductive busbar connected between the battery control module and the corresponding battery module. The through hole includes a data acquisition harness through hole for the data acquisition harness to pass through and a conductive busbar through hole for the conductive busbar to pass through.

[0011] Furthermore, each enclosure is a cuboid structure, with the wiring harness through-hole and the conductive busbar through-hole located at both ends of the length of the bottom wall of the corresponding enclosure.

[0012] Furthermore, the battery module includes multiple cells arranged in a row, two end plates located at both ends of the row of cells, and cable ties that bind and fix the row of cells and the two end plates together. The bottom wall of the module housing has protrusions extending in the width direction at both ends along the length direction. The end plates at both ends of the battery module are supported and fixed on the corresponding protrusions. Wiring harness through holes and conductive busbar through holes are respectively set on the two protrusions on the bottom wall of the corresponding module housing.

[0013] Furthermore, each individual housing has only one wire harness through hole and one conductor bar through hole, and both are elongated.

[0014] Furthermore, the height of the control box is less than the height of the module box.

[0015] Furthermore, the control box is the topmost box, and at least one module box is provided below the control box. New module boxes can be installed between the control box and the adjacent module box below it or between the adjacent module boxes above and below it.

[0016] Furthermore, foam is filled between the conductive busbar and the battery module, and between the conductive busbar and the side wall of the corresponding housing.

[0017] Furthermore, the control box and each module box are provided with outwardly extending flanges at their upper and lower ends, and the flanges are provided with bolt holes for the corresponding bolts to pass through.

[0018] Furthermore, each module enclosure is made of die-cast aluminum alloy. Attached Figure Description

[0019] Figure 1 This is a perspective view of embodiment 1 of the battery pack of this utility model; Figure 2 This is an exploded view of embodiment 1 of the battery pack of this utility model; Figure 3 This is a perspective view of the lower module box in Embodiment 1 of the battery pack of this utility model; Figure 4 This is a perspective view of the lower module housing in Embodiment 1 of the battery pack of this utility model; Figure 5 This is a perspective view of the lower battery module in Embodiment 1 of the battery pack of this utility model; Figure 6 This is a perspective view of the intermediate layer module box in Embodiment 1 of the battery pack of this utility model; Figure 7 This is a perspective view of the intermediate layer module housing in Embodiment 1 of the battery pack of this utility model; Figure 8 This is a perspective view of the control box in Embodiment 1 of the battery pack of this utility model; Figure 9 This is a perspective view of the control box in Embodiment 1 of the battery pack of this utility model; Figure 10 This is a perspective view of the battery control module in Embodiment 1 of the battery pack of this utility model; Figure 11 This is a perspective view of embodiment 2 of the battery pack of this utility model.

[0020] In the diagram: 10. Control box; 11. Control box body; 111. Upper layer through hole; 12. Battery control module; 121. Positive terminal connection; 122. Negative terminal connection; 13. BMS main control acquisition board; 14. BMS slave control acquisition board; 15. Electrical connector; 20. Top cover; 30. Middle layer module box; 31. Middle layer module body; 311. Middle layer protrusion; 3111. Middle layer through hole; 32. Middle layer battery module; 33. Middle layer inner connecting copper busbar; 34. Negative terminal connecting copper busbar; 35. Middle layer foam; 40. Lower layer module box; 41. Lower layer module body; 411. Lower layer protrusion; 42. Lower layer battery module; 43. Lower layer inner connecting copper busbar; 44. Positive terminal connecting copper busbar; 45. Upper and lower layer connecting copper busbar; 46. Lower layer foam; 50. Upper layer module box; 60. Sealing strip. Detailed Implementation

[0021] To address the technical problems existing in the prior art, the basic concept of this utility model is to modularize the battery module and the control device separately. The battery module is set in a module box, and the control device is set in a control box. The control box and the module box are stacked one on top of the other, and each box has an opening at the top and a bottom wall. Except for the bottom box, the bottom walls of the other boxes are provided with through holes for conductors between the control device and the corresponding battery module to pass through. At the same time, the top box is fixed with a top cover by bolts, and adjacent boxes are connected by bolts. This allows new module boxes to be added above the top box and between adjacent boxes, realizing the expansion of power capacity. In other words, the number of module boxes can be flexibly configured according to customer needs, enabling rapid production scheduling, shortening the production cycle, and reducing production costs.

[0022] The features and performance of this utility model will be further described in detail below with reference to the embodiments.

[0023] The implementation method of the battery pack in this utility model is as follows: like Figure 1 As shown, the battery pack includes a control box 10 and at least one module box stacked on top of the control box 10. In this embodiment, there are two module boxes, namely a middle layer module box 30 and a lower layer module box 40. The control box 10 is located above the middle layer module box 30 and the lower layer module box 40. The battery pack has a three-layer structure.

[0024] The two module boxes have similar structures, both including a module box body and battery modules housed within the box body. (Specifically, in combination...) Figure 2 and Figure 3 As shown, the lower module box 40 includes a lower module box body 41 and lower battery modules 42 disposed inside the lower module box body 41. Two sets of lower battery modules 42 are arranged in parallel. The two sets of lower battery modules 42 are connected in series through a lower inner connecting copper busbar 43 at one end. That is, the two ends of the lower inner connecting copper busbar 43 are respectively connected to the two sets of lower battery modules 42.

[0025] The two lower battery modules 42 have the same structure, such as Figure 5 As shown, the lower battery module 42 includes multiple battery cells 421 arranged in a row and connected in series, two end plates 422 located at both ends of the row of battery cells 421, and cable ties 423 that bind and fix the row of battery cells 421 and the two end plates 422 together. The cable ties 423 are stainless steel strips, and the end plates 422 are aluminum end plates. The height of the end plates 422 is less than the height of the battery cells 421, and the bottom surfaces of each battery cell 421 are flush. The bottom surfaces of the end plates 422 and the battery cells 421 are not flush, so that the bottom of both ends of the module forms a stepped structure.

[0026] like Figure 4 As shown, the lower module housing 41 is a rectangular box. The bottom wall of the lower module housing 41 has lower protrusions 411 extending in the width direction at both ends in the length direction. The end plates 422 at both ends of the lower battery module 42 are respectively supported and fixed on the corresponding lower protrusions 411. The specific fixing method is bolt fixing. Therefore, the end plates 422 are provided with bolt holes, and the lower protrusions 411 are provided with corresponding threaded holes.

[0027] The area between the two lower protrusions 411 is the installation area for the lower battery module 42, which serves as a limiting point during installation. Specifically, when assembling the lower module box 40, multiple cells 421 and end plates 422 are first bundled together using cable ties 423 to form the lower battery module 42. The bundled lower battery module 42 is then installed inside the lower module box 41 using thermally conductive adhesive. The end plates 422 at both ends are supported on the lower protrusions 411, and finally, the end plates 422 are fixed to the lower protrusions 411 using bolts. The two sets of lower battery modules 42 are then connected in series via lower internal connecting copper busbars 43. The combined effect of the thermally conductive adhesive and bolts ensures the secure fixing of each cell 421 within the lower battery module 42, preventing it from bouncing due to battery pack vibrations.

[0028] Combination Figure 2 , Figure 6 and Figure 7 As shown, the intermediate layer module box 30 includes an intermediate layer module box body 31 and intermediate layer battery modules 32 disposed in the intermediate layer module box body 31. Two sets of intermediate layer battery modules 32 are also arranged in parallel. The two sets of intermediate layer battery modules 32 are connected in series through an intermediate layer internal connecting copper busbar 33 at one end. That is, the two ends of the intermediate layer internal connecting copper busbar 33 are respectively connected to the two sets of intermediate layer battery modules 32.

[0029] The two intermediate battery modules 32 have the same structure, and in fact, they have the same structure as the lower battery module 42. They also include multiple cells arranged in a row and connected in series, two end plates located at both ends of the row of cells, and cable ties that bind the row of cells and the two end plates together. The height of the end plates is less than the height of the cells, and the bottom surfaces of each cell are flush. The bottom surfaces of the end plates and cells are not flush, so that the bottom of both ends of the module forms a stepped structure.

[0030] Similarly, the intermediate layer module housing 31 is also a rectangular box structure. The bottom wall of the intermediate layer module housing 31 has intermediate layer protrusions 311 extending in the width direction at both ends in the length direction. The end plates at both ends of the intermediate layer battery module 32 are supported and fixed on the corresponding intermediate layer protrusions 311. The specific fixing method is also bolt fixing. Therefore, bolt through holes are provided on the end plates, and corresponding threaded holes are provided on the intermediate layer protrusions 311.

[0031] Similarly, the area between the two intermediate layer protrusions 311 is the installation area for the intermediate layer battery module 32, which serves as a limiting point during installation. Specifically, when assembling the intermediate layer module box 30, multiple cells and end plates are first bundled together with cable ties to form the intermediate layer battery module 32. The bundled intermediate layer battery module 32 is then installed inside the intermediate layer module box 31 using thermally conductive structural adhesive. The end plates at both ends are supported on the intermediate layer protrusions 311, and finally, the end plates are fixed to the intermediate layer protrusions 311 with bolts. The two sets of intermediate layer battery modules 32 are then connected in series via the intermediate layer internal connecting copper busbar 33. Through the combined effect of the thermally conductive structural adhesive and bolt connections, the secure fixing of each cell in the intermediate layer battery module 32 is ensured, preventing it from bouncing due to battery pack vibration.

[0032] In other embodiments, the intermediate battery module 32 and the lower battery module 42 can also be installed in the corresponding housing simply by thermally conductive structural adhesive. That is, the end plate in the battery module is no longer fixed to the protrusion by bolts. Therefore, there is no need to provide threaded holes on the protrusion and no need to provide bolt holes on the end plate.

[0033] In this embodiment, both the middle module housing 31 and the lower module housing 41 are die-cast aluminum alloy housings. These housings have excellent thermal conductivity, allowing heat generated by the battery module to be conducted to the housing and then into the air for natural heat dissipation. The structure is simple and the manufacturing cost is low. In other embodiments, the module housing can also be made of steel. In this case, to ensure effective heat dissipation, an additional cooling system is required, such as a liquid cooling plate at the bottom of the battery module.

[0034] Combination Figure 2 , Figure 8 , Figure 9 and Figure 10 As shown, the control box 10 includes a control box body 11 and a control device disposed inside the control box body 11 and connected to the corresponding battery module through a conductor. In this embodiment, the control device includes a battery control module 12 (i.e., a battery disconnection unit BDU, whose core functions include connecting / disconnecting the high voltage circuit, precharging, energy distribution, overload / short circuit protection, etc.), a BMS master control acquisition board 13, and two BMS slave control acquisition boards 14. Therefore, the conductors include the acquisition harness connected between the acquisition board and the corresponding battery module and the conductive busbar connected between the battery control module 12 and the corresponding battery module.

[0035] The system includes two BMS slave acquisition boards 14. One BMS slave acquisition board 14 is connected to the intermediate layer battery module 32 via an acquisition harness to collect data information from each cell in the intermediate layer battery module 32, thereby monitoring the status of the intermediate layer battery module 32 and preventing overcharging or over-discharging. The other BMS slave acquisition board 14 is connected to the lower layer battery module 42 via an acquisition harness to collect data information from each cell in the lower layer battery module 42, thereby monitoring the status of the lower layer battery module 42 and preventing overcharging or over-discharging.

[0036] Two BMS slave acquisition boards 14 are electrically connected to the BMS master acquisition board 13 via wiring harnesses. The two slave acquisition boards 14 and the master acquisition board 13 are arranged in layers, with the master acquisition board 13 mounted above the slave acquisition boards 14, saving space and improving the space utilization within the control box 11. In other embodiments, if space permits, the master acquisition board and slave acquisition boards can be located at the same height, without being arranged in layers.

[0037] The battery control module 12 and the BMS main control acquisition board 13 are electrically connected via a wiring harness. At the same time, the battery control module 12 is electrically connected to the lower battery module 42 via a positive terminal copper busbar 44, and to the middle battery module 32 via a negative terminal copper busbar 34. It is also electrically connected to the electrical connector 15 installed on the side wall of the control box 11 via a copper busbar or wiring harness. This allows the battery control module 12 to receive data information collected by the BMS main control acquisition board 13 and to control the charging or discharging of the battery module based on the data information collected by the BMS main control acquisition board 13, thereby improving the safety of battery use.

[0038] like Figure 8 and Figure 10 As shown, the battery control module 12 includes a positive terminal connection part 121 and a negative terminal connection part 122. The positive terminal connection part 121 is used to connect to the positive terminal connection copper busbar 44, and the negative terminal connection part 122 is used to connect to the negative terminal connection copper busbar 34.

[0039] Combination Figure 2 , Figure 3 and Figure 6 As shown, the intermediate layer battery module 32 and the lower layer battery module 42 are connected in series by an interlayer connecting copper busbar 45. The bottom of the interlayer connecting copper busbar 45 is connected to one of the lower layer battery modules 42 in the lower layer module housing 41, and the top passes through the bottom wall of the intermediate layer module housing 31 and is connected to one of the intermediate layer battery modules 32 in the intermediate layer module housing 31.

[0040] Another lower battery module 42 inside the lower module housing 41 is connected to a positive terminal connecting copper busbar 44. The bottom of the positive terminal connecting copper busbar 44 is connected to the lower battery module 42, and the top passes through the bottom wall of the middle module housing 31 and the bottom wall of the control housing 11 and extends into the control housing 11, where it is fixedly connected to the positive terminal connecting part 121.

[0041] like Figure 3 As shown, since one end of the two lower battery modules 42 is connected in series through the lower inner connecting copper busbar 43, the upper and lower connecting copper busbar 45 and the positive terminal connecting copper busbar 44 are both located at the other end.

[0042] Combination Figure 2 and Figure 6 As shown, one of the intermediate layer battery modules 32 inside the intermediate layer module housing 31 is connected to the upper and lower layer connecting copper busbar 45 mentioned above, and the other intermediate layer battery module 32 is connected to the negative terminal connecting copper busbar 34. The bottom of the negative terminal connecting copper busbar 34 is connected to the intermediate layer battery module 32, and the top extends through the bottom wall of the control housing 11 into the control housing 11 and is fixedly connected to the negative terminal connection part 122.

[0043] Since one end of the two intermediate layer battery modules 32 is connected in series through the intermediate layer internal connecting copper busbar 33, the negative terminal connecting copper busbar 34 is located at the other end, and the upper and lower layer connecting copper busbar 45 extending into the intermediate layer module housing 31 is also located at the other end.

[0044] And, as Figure 2 As shown, the positive connection copper busbar 44, the inter-layer connection copper busbar 45, and the negative connection copper busbar 34, which need to pass through the bottom wall of other enclosures, are located at the same end along the length of the enclosure to facilitate the unified routing of the copper busbars.

[0045] Specifically, such as Figure 7 As shown, there are two intermediate layer protrusions 311 ( Figure 7 Due to the viewing angle, only one intermediate layer protrusion 311 is visible. It has through-holes 3111 on both sides, and the through-holes 3111 on both sides are elongated and extend along the width of the housing. One of the intermediate layer protrusions 3111's through-holes allows the positive electrode connecting copper busbar 44 and the upper / lower layer connecting copper busbar 45 to pass through. The other intermediate layer protrusion 311's through-hole allows the acquisition harness between the BMS slave acquisition board 14 and the lower battery module 42 to pass through, thus separating the copper busbar and the acquisition harness.

[0046] like Figure 8 and Figure 9As shown, upper-level through holes 111 are provided on the bottom wall of the control box 11 at both ends along its length. Both upper-level through holes 111 are elongated and extend along the width of the box. The battery control module 12 and the BMS main control acquisition board 13 are not arranged to cover the upper-level through holes 111. One upper-level through hole 111 allows the positive terminal connecting copper busbar 44 and the negative terminal connecting copper busbar 34 to pass through, while the other upper-level through hole 111 allows the acquisition wiring harness between the BMS slave control acquisition board 14 and the lower battery module 42, and between the BMS slave control acquisition board 14 and the middle battery module 32 to pass through, thus separating the copper busbars and acquisition wiring harnesses.

[0047] That is, except for the lower module housing 41, both the control housing 11 and the intermediate module housing 31 are provided with through holes. The through holes on a single housing are divided into two types: wire harness through holes and conductive busbar through holes. Each housing has only one wire harness through hole and one conductive busbar through hole, both of which are elongated and located at both ends of the length of the housing's bottom wall. In other embodiments, depending on the specific number of copper busbars and acquisition wire harnesses, each copper busbar and each acquisition wire harness can be equipped with a separate through hole, and the through hole does not need to be elongated; for example, it can be circular or square. In other embodiments, the through holes are not limited to being located at both ends of the housing's length; for example, they can be located at both ends of the width, or partly located at one or both ends of the length and partly located at one or both ends of the width.

[0048] In the above embodiments, the intermediate layer through hole 3111 is disposed on the intermediate layer protrusion 311. In other embodiments, if the end plate of the intermediate layer battery module is flush with the bottom surface of each cell, and the end plate and each cell are directly supported on the bottom wall of the housing, there is no intermediate layer protrusion 311. In this case, the intermediate layer through hole 3111 is directly opened on the bottom wall of the intermediate layer module housing 31. Alternatively, in other embodiments, even if there is an intermediate layer protrusion 311, the intermediate layer through hole 3111 is not disposed on the intermediate layer protrusion 311, but is disposed on the flat bottom wall of the intermediate layer module housing 31, avoiding the intermediate layer protrusion 311.

[0049] In addition, both the negative electrode connecting copper busbar 34 and the positive electrode connecting copper busbar 44 include horizontally extending connecting portions located at the upper and lower ends, as well as an extension portion located between the two connecting portions. Meanwhile, the connection position of the negative electrode connecting copper busbar 34 to the corresponding intermediate layer battery module 32 is directly above the connection position of the positive electrode connecting copper busbar 44 to the corresponding lower layer battery module 42. Therefore, to avoid interference between the positive electrode connecting copper busbar 44 and the negative electrode connecting copper busbar 34, and to ensure that the two copper busbars can be fixed to the positive electrode connecting portion 121 and the negative electrode connecting portion 122 respectively, the extension portion of the negative electrode connecting copper busbar 34 is designed to extend vertically. Figure 6 As shown), the extension of the positive electrode connecting copper busbar 44 is bent into a Z-shape. Figure 3 As shown), so that the upper connecting part transitions towards the positive electrode connecting part 121.

[0050] In addition, the connecting copper busbar 45 between the upper and lower layers also includes horizontally extending connecting portions at the upper and lower ends, and an extension portion between the two connecting portions, with the extension portion extending vertically. The lower layer inner connecting copper busbar 43 and the middle layer inner connecting copper busbar 33 have the same structure. Defining the length direction of the battery module or the length direction of the housing as the left-right direction, and arranging the two battery modules in each layer in a front-to-back configuration, both the lower layer inner connecting copper busbar 43 and the middle layer inner connecting copper busbar 33 include horizontally extending connecting portions at the front and rear ends, and an extension portion between the two connecting portions. The main body of the extension portion extends along the front-to-back direction, while the thickness direction is the left-to-right direction. Both the front and rear ends of the extension portion are bent to be integrally connected with the connecting portions at the front and rear ends. Therefore, after the lower layer inner connecting copper busbar 43 and the middle layer inner connecting copper busbar 33 respectively realize the series connection of the corresponding two sets of battery modules, their extension portions are located on one side of the end plate of the corresponding battery module.

[0051] During use, the copper busbars may sway due to vibration of the battery pack. To avoid this, such as... Figure 3 As shown, lower layer foam 46 is filled between the lower inner connecting copper busbar 43 and the end plate of the lower battery module 42, and between the lower inner connecting copper busbar 43 and the side wall of the lower module housing 41, so as to clamp the extension of the lower inner connecting copper busbar 43 in the middle and prevent the lower inner connecting copper busbar 43 from shaking.

[0052] like Figure 6 As shown, intermediate layer foam 35 is filled between the end plate of the intermediate layer connecting copper busbar 33 and the intermediate layer battery module 32, and between the intermediate layer connecting copper busbar 33 and the side wall of the intermediate layer module housing 31, so as to clamp the extension of the intermediate layer connecting copper busbar 33 in the middle and prevent the intermediate layer connecting copper busbar 33 from shaking.

[0053] Meanwhile, since the upper and lower layer connecting copper busbar 45 extends into the middle layer module housing 31, middle layer foam 35 is filled between the upper and lower layer connecting copper busbar 45 and the end plate of the middle layer battery module 32, and between the upper and lower layer connecting copper busbar 45 and the side wall of the middle layer module housing 31, thereby clamping the extension of the upper and lower layer connecting copper busbar 45 in the middle and preventing the upper and lower layer connecting copper busbar 45 from shaking.

[0054] Meanwhile, since the positive electrode connecting copper busbar 44 passes completely through the intermediate layer module housing 31, intermediate layer foam 35 is filled between the positive electrode connecting copper busbar 44 and the end plate of the intermediate layer battery module 32, and between the positive electrode connecting copper busbar 44 and the side wall of the intermediate layer module housing 31, thereby clamping the extension of the positive electrode connecting copper busbar 44 in the middle and preventing the positive electrode connecting copper busbar 44 from shaking.

[0055] Of course, since part of the connecting copper busbar 45 between the upper and lower layers and the positive connecting copper busbar 44 are located inside the lower module housing 41, foam can also be installed between the connecting copper busbar 45 between the upper and lower layers and the positive connecting copper busbar 44 and the side wall of the lower module housing 41 to improve the fixing and protection effect.

[0056] The foam mentioned above can be CR foam, silicone foam, EVA foam, etc.

[0057] The above embodiments use copper busbars as conductive busbars. Aluminum busbars can also be used in other embodiments, but both copper and aluminum busbars are prone to deformation. The foam padding ensures the conductive busbars do not wobble, preventing short circuits, open circuits, or the casing becoming electrified, and even serious consequences such as battery pack combustion. In other embodiments, an insulating support can be installed inside the housing to fix the conductive busbars to the support, improving their stability. In other embodiments, when the conductive busbars are sufficiently rigid, the insulating support and foam padding can be omitted.

[0058] In other embodiments, if the current flow requirements can be met, the busbar can also be replaced with a wire harness, in which case all the through holes are wire harness through holes.

[0059] Combination Figure 2 , Figure 4 , Figure 7 and Figure 9 As shown, the control box 11 and each module box are all boxes with an open top and a bottom wall. Since the control box 11 is located at the top in this embodiment, a top cover 20 is fixed to the control box 11, and the top cover 20 is fixed to the control box 11 by bolts. Other adjacent boxes are connected by bolts, that is, the control box 11 is connected to the middle layer module box 31 by bolts, and the middle layer module box 31 is connected to the lower layer module box 41 by bolts.

[0060] For users, when the power consumption of external electrical equipment increases, one or more new module boxes (including the box body and the battery modules set inside the box body, which is also a box body with an open top and a bottom wall) can be added. The new module boxes can be stacked on top. At this time, the original top cover 20 needs to be removed and fixed on the new module box. At the same time, a corresponding number of slave control acquisition boards need to be added in the control box 11 and connected to the master control acquisition board. The newly added slave control acquisition boards are connected to the new battery modules through acquisition wire harnesses. The new battery modules are connected in series with the original battery modules through conductive busbars. The bottom wall of the new module box also needs to be provided with through holes to meet the rewiring between the new battery modules and the original battery modules, and between the new battery modules and the control devices.

[0061] Of course, the new module box can also be stacked below the control box 11 (e.g., Figure 11 As shown, an upper module box 50 can be added between the control box 10 and the intermediate module box 30, or stacked on top of the bottom box. This can be achieved simply by removing the bolts between the adjacent boxes, adding a BMS slave acquisition board inside the control box 11, and making new wiring. In short, the original control box 10 and module box can continue to be used without the need to develop a completely new battery pack, thus shortening the cycle and reducing costs.

[0062] For battery manufacturers, module boxes and control boxes can be mass-produced, with one control box per battery pack. Then, the corresponding number of module boxes can be configured according to the needs of different customers, which can achieve rapid production scheduling, greatly shorten the production cycle, and reduce production costs.

[0063] like Figure 2 As shown, to facilitate the fixing of the upper cover 20 and the control box 11, the control box 11 and the intermediate module box 31, and the intermediate module box 31 and the lower module box 41, outwardly extending flanges are provided at the upper and lower ends of the control box 11 and each module box, respectively. The flanges have bolt holes for corresponding bolts to pass through. In other embodiments, when the thickness of the box sidewall is suitable, threaded holes can be directly machined on the box sidewall without the need for flanges.

[0064] In addition, to ensure the battery pack's airtightness, sealing strips 60 are respectively installed between the top cover 20 and the control box 11, between the control box 11 and the middle module box 31, and between the middle module box 31 and the lower module box 41. The battery pack adopts a three-layer assembly structure, making it very convenient and quick to replace battery modules and perform maintenance. After assembly, the overall stability is high, the sealing is good, and it can adapt to various complex working conditions and harsh environments. At the same time, it can realize capacity expansion, has high compatibility, and can greatly reduce product development costs and cycles.

[0065] like Figure 1 , Figure 2 and Figure 11 As shown, the control box 11, the intermediate module box 31, and the lower module box 41 have the same length and width, and the height of each module box is the same. However, the height of the control box 11 is less than the height of the module boxes. This minimizes the volume of the control box 11 while ensuring that the control components can be arranged, thereby reducing the overall volume of the battery pack. In other embodiments, the height of the control box 11 can also be equal to the height of the module boxes.

[0066] The control devices in the above embodiments include the battery control module (BDU), the BMS master control acquisition board, and the BMS slave control acquisition board, which are installed in the control box. In other embodiments, the BMS slave control acquisition board can also be arranged in each module box and is part of the module box. The control devices such as the battery control module (BDU) and the BMS master control acquisition board are still arranged in the control box. In this case, when expanding the charging capacity, only the module box needs to be added, and it is not necessary to add a BMS slave control acquisition board in the control box.

[0067] The controller in the above embodiments includes a separately arranged battery control module (BDU), a BMS main control acquisition board, and a BMS slave control acquisition board. In other embodiments, the controller can also be an integrated BMS motherboard, where all voltage and temperature acquisition circuits and main control logic are integrated on a single circuit board to form an all-in-one controller. In this case, the controller is a single device.

[0068] In other embodiments, a PDU (Power Distribution Unit) can be used instead of a BDU. The PDU's functions cover and exceed those of the BDU. It can not only complete the battery-side power distribution and switching tasks of the BDU, but also usually integrates functions such as DC fast charging, slow charging, and DC / DC conversion.

[0069] In other embodiments, the battery pack may consist of only a control box and a module box.

[0070] In other embodiments, regardless of the number of module boxes, the control box does not necessarily have to be at the top. For example, when there is only one module box, the control box can be below the module box; when there are two module boxes, the control box can be below the two module boxes or between the two module boxes; similarly, when there are three module boxes, the control box can be below the three module boxes, or on the second or third layer. Furthermore, regardless of the number of module boxes or how the control box is arranged, newly added module boxes can be placed at the top, between the control box and a module box adjacent to the control box, or between two adjacent module boxes. In short, the bottom wall of the newly added module box must have a through hole to meet the needs of conductor passage. Therefore, it is required that the bottom walls of all boxes except the bottom box have through holes that allow the corresponding conductors to pass through.

[0071] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. The patent protection scope of the present utility model shall be determined by the claims. Similarly, any equivalent structural changes made based on the description and drawings of the present utility model shall also be included within the protection scope of the present utility model.

Claims

1. A battery pack, characterized in that, The system includes a control box and at least one module box stacked on top of the control box. The module box includes a module box body and a battery module disposed within the module box body. The control box includes a control box body and a control device disposed within the control box body and connected to the corresponding battery module via a conductor. Both the control box body and the module box body are boxes with an open top and a bottom wall. The topmost box body is fixed with a top cover by bolts. The adjacent boxes body are connected by bolts. Except for the bottommost box body, the bottom walls of the remaining boxes body are provided with through holes that allow the corresponding conductors to pass through.

2. The battery pack according to claim 1, characterized in that, The control device includes a data acquisition board and a battery control module connected to the data acquisition board. The conductor includes a data acquisition harness connected between the data acquisition board and the corresponding battery module, and a conductive busbar connected between the battery control module and the corresponding battery module. The through holes include a data acquisition harness through hole for the data acquisition harness to pass through and a conductive busbar through hole for the conductive busbar to pass through.

3. The battery pack according to claim 2, characterized in that, Each enclosure is a rectangular box, with the wiring harness through-hole and the conductor bar through-hole located at both ends of the length of the bottom wall of the corresponding enclosure.

4. The battery pack according to claim 3, characterized in that, The battery module includes multiple cells arranged in a row, two end plates located at both ends of the row of cells, and cable ties that bind and fix the row of cells and the two end plates together. The bottom wall of the module housing has protrusions extending in the width direction at both ends along the length direction. The end plates at both ends of the battery module are supported and fixed on the corresponding protrusions. Wiring harness through holes and conductive busbar through holes are respectively set on the two protrusions on the bottom wall of the corresponding module housing.

5. The battery pack according to any one of claims 2 to 4, characterized in that, Each individual housing has only one wire harness through hole and one conductor bar through hole, and both are elongated.

6. The battery pack according to any one of claims 1 to 4, characterized in that, The height of the control box is less than the height of the module box.

7. The battery pack according to any one of claims 1 to 4, characterized in that, The control box is the topmost box, and at least one module box is located below the control box. New module boxes can be installed between the control box and the adjacent module box below it or between adjacent module boxes above and below it.

8. The battery pack according to any one of claims 2 to 4, characterized in that, Foam is filled between the conductive busbar and the battery module, and between the conductive busbar and the side wall of the corresponding housing.

9. The battery pack according to any one of claims 1 to 4, characterized in that, The control box and each module box are equipped with outwardly extending flanges at their upper and lower ends, and the flanges are provided with bolt holes for the corresponding bolts to pass through.

10. The battery pack according to any one of claims 1 to 4, characterized in that, Each module enclosure is made of die-cast aluminum alloy.

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