A drone battery swapping pack

Abstract

This utility model discloses a battery pack for drones, including a shell, a module stacking structure, a heat dissipation system, an electrical connection structure, and a battery management system. The shell consists of an aluminum top cover, aluminum side plates, and a base, secured with stepped screws. The module stacking structure is located inside the shell and includes several battery cell modules, with heat conduction between the modules via aluminum plates. The heat dissipation system includes heat sinks installed inside the modules, air vents on the shell, and honeycomb-shaped airflow channels between the battery cells, achieving a combination of passive and active heat dissipation. The battery management system is connected to the battery cell modules and can monitor voltage, current, and temperature in real time, triggering power-off protection in abnormal conditions. This utility model improves battery safety, reliability, and heat dissipation performance through structural optimization and heat dissipation design, while facilitating rapid battery replacement and making it suitable for various drone operation scenarios.

Description

Technical Field

[0001] This utility model relates to a battery pack, specifically a battery pack for swapping batteries for drones. Background Technology

[0002] As an emerging intelligent equipment, drones have been widely used in agricultural plant protection, power line inspection, logistics transportation, emergency rescue, and aerial surveying. However, the battery, as the core power source of drones, directly affects flight endurance and operational efficiency. Current drone batteries commonly suffer from the following problems:

[0003] First, the flight time is limited. Most consumer-grade drone batteries only support a flight time of ten to twenty minutes, and the coverage area of ​​a single operation for industrial-grade drones is also very limited. This short flight time means that users need to change batteries frequently, which not only increases the burden of operation but also affects the efficiency of continuous operation in scenarios such as agricultural plant protection or power line inspection. It may even affect the quality of the operation due to battery replacement midway.

[0004] Secondly, compatibility and safety are insufficient. Different brands or models of drones often have different battery specifications, requiring users to equip themselves with multiple batteries, increasing cost and management complexity. Some inferior batteries are prone to overheating or even catching fire when overcharged, over-discharged, or short-circuited, posing serious safety hazards. In addition, frequent plugging and unplugging can easily cause wear and tear on the battery interface, reducing reliability over long-term use.

[0005] Secondly, its heat dissipation and environmental adaptability are poor. During drone flight, the battery operates at high power output for extended periods, easily leading to overheating of the battery cells. Existing batteries often rely on traditional heat dissipation methods such as silicone padding, which have limited cooling efficiency. In high-temperature environments, the battery is prone to bulging and capacity degradation; in low-temperature or high-altitude environments, battery performance declines rapidly, making normal operation difficult and severely limiting the drone's ability to operate in complex environments.

[0006] In addition, unreasonable structural design is also a major problem with existing technologies. Some batteries have messy internal wiring layouts, unclear current conduction paths, low integration of heat sinks and modules, and insufficient overall assembly reliability, affecting battery stability and ease of maintenance. Furthermore, the quick-replacement design of traditional batteries is flawed, often requiring users to spend considerable time disassembling and reassembling them during operation, reducing the continuity and efficiency of drone operations. Summary of the Invention

[0007] To address the aforementioned problems, this invention provides a battery pack for drones that effectively overcomes the shortcomings of existing technologies.

[0008] This utility model is achieved through the following technical solution: a drone battery swapping pack, comprising:

[0009] The housing consists of an aluminum top cover, aluminum side plates and a base. The housing is fixed by stepped screws and waterproof rubber strips are provided at the joints of the housing to achieve waterproof sealing.

[0010] The module stacking structure is located inside the housing and includes several battery cell modules. Aluminum plates are placed between the battery cell modules to achieve heat conduction.

[0011] The heat dissipation system includes a heat sink installed inside the module, air vents on the housing, and honeycomb air channels located between the battery cells;

[0012] The electrical connection structure includes an output flexible copper busbar and a wire positioning hole. The output flexible copper busbar is electrically connected to the battery cell module and led out through the wire positioning hole.

[0013] The battery management system, connected to the cell module, is used to monitor the voltage, current, and temperature status of the battery pack and to provide power-off protection in case of abnormalities.

[0014] As a preferred technical solution, a quick battery swapping structure is also included, with a pin slot on the outside of the housing to enable quick installation and removal of the battery pack.

[0015] As a preferred technical solution, the housing includes two aluminum side plates, two aluminum top covers, and a base. The aluminum side plates are located on both sides of the base, and the two aluminum top covers cover the upper and lower surfaces of the aluminum side plates.

[0016] As a preferred technical solution, the honeycomb airflow channel is embedded with a phase change heat dissipation mechanism.

[0017] As a preferred technical solution, the honeycomb airflow channels have a spacing of 3mm, which is used to achieve active heat dissipation and air convection between the battery cells.

[0018] As a preferred technical solution, the battery management system includes a main control module and a power module, and adopts a separate architecture.

[0019] As a preferred technical solution, the housing is made of 6061 series aluminum profile.

[0020] As a preferred technical solution, the splicing position of the shell is also provided with a waterproof adhesive strip.

[0021] The beneficial effects of this invention are as follows: First, it achieves higher safety and stability. This invention adopts a separate design of "main control module + power module" and sets waterproof adhesive strips at the shell connection, which can effectively improve the battery's protection capability in different environments. The battery management system can monitor the battery's voltage, current, and temperature in real time and automatically trigger power-off protection when abnormalities occur, avoiding safety accidents caused by overcharging, over-discharging, or short circuits, thus fundamentally improving the safety of battery use.

[0022] Secondly, heat dissipation performance is significantly improved. This invention features honeycomb-shaped airflow channels between the battery cells and embeds a phase-change heat dissipation mechanism on the outside of the cells. During high-power discharge, it can absorb and release heat, forming a composite heat dissipation system combined with the heat sink and air vents. Compared with traditional heat dissipation methods that rely on silicone filling, this invention can reduce the cell temperature by more than ten degrees Celsius under high-rate discharge scenarios, thereby effectively delaying the degradation process under high-temperature environments and significantly extending the battery cycle life.

[0023] Furthermore, it improves assembly reliability and overall integrity. The housing of this invention consists of an aluminum top cover, aluminum side plates, and a base, which are machined using CNC milling and secured with stepped screws, ensuring the housing's precision and strength. Internal modules utilize aluminum plates for heat conduction and structural fixation, avoiding issues such as messy wiring harnesses and unstable assembly, thus enhancing the overall integrity and durability of the battery module.

[0024] In addition, it features a quick battery swapping function. This invention incorporates a locking pin on the outside of the battery casing, allowing users to quickly install and remove the battery through a simple plugging and unplugging action. This significantly reduces the time required for battery replacement during drone operations, thereby ensuring the stability and efficiency of continuous operations such as agricultural plant protection and power line inspection. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0027] Figure 2 This is a schematic diagram of the internal structure of the present invention after the heat sink has been removed;

[0028] Figure 3 This is a schematic diagram of the internal structure of the present invention;

[0029] Explanation of reference numerals in the attached figures:

[0030] 3. Aluminum top cover; 2. Aluminum side panel; 1. Base; 4. Waterproof adhesive strip position; 9. Aluminum plate; 6. Heat sink; 5. Air duct; 7. Cable hole; 8. Pin holder. Detailed Implementation

[0031] All features disclosed in this specification, or all steps in all disclosed methods or processes, may be combined in any way, except for mutually exclusive features and / or steps.

[0032] Any feature disclosed in this specification (including any appended claims, abstract, and drawings) may be replaced by other equivalent or similar features, unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is merely one example of a series of equivalent or similar features.

[0033] like Figures 1-3 As shown, this utility model provides a battery pack for drones. In a specific embodiment, the overall structure and various functional modules of the battery pack have been optimized to meet the operational needs of drones under long-term, high-intensity, and complex environments. The battery pack includes a shell, which consists of an aluminum top cover 3, aluminum side plates 2, and a base 1. The aluminum top cover 3 and aluminum side plates 2 are locked and fixed to the base 1 by stepped screws. This stepped screw connection can ensure the fastening force while improving the overall assembly accuracy and structural stability, and avoiding loosening caused by long-term vibration.

[0034] At the joints of the casing, there are dedicated waterproof sealing strips 4, which can be filled with silicone or rubber seals during use, giving the battery pack excellent waterproof and moisture-proof capabilities, ensuring stable operation even in rainy, foggy, or humid environments. To further balance lightweight and strength, the outer surface of the casing can be covered with PC / ABS composite material, which reduces the overall weight of the battery pack while improving impact resistance and high-temperature resistance. In practice, the casing uses two aluminum side plates 2 located on both sides of the base 1, and two aluminum top covers 3 covering the upper and lower surfaces of the side plates, forming a complete internal cavity to accommodate the battery cell module and other components.

[0035] An internal modular stacking structure is incorporated within the housing. This structure comprises several battery cell modules, which are stacked sequentially to form a complete power supply unit. To improve heat conduction between the battery cells, an aluminum plate 9 is placed between each battery cell module. Utilizing the excellent thermal conductivity of aluminum, the heat generated by the battery cell during operation can be quickly conducted outwards, preventing cell degradation or safety hazards caused by localized overheating. The battery cell modules are fixed together through the stacking structure, which not only improves the overall assembly integrity but also reduces wiring harness crossover, thereby enhancing the stability of current transmission.

[0036] To further improve heat dissipation performance, a heat dissipation system is also installed inside the battery pack. This system includes a heat sink 6 installed inside the module, air vents 5 located on the casing, and honeycomb-shaped airflow channels positioned between the battery cells. The heat sink 6 is directly attached to the surface of the battery cell to quickly absorb heat generated during discharge. The air vents 5 connect to the outside air, allowing cool air to enter the internal cavity and create air convection, thereby carrying away the heat generated by the battery cells. The honeycomb-shaped airflow channels are arranged between the battery cells, with each channel spaced 3mm apart. This structure provides a path for airflow and enhances the structural stability of the module. More importantly, a phase change cooling mechanism is embedded within the honeycomb flow channel. This mechanism operates on a principle similar to an evaporator, switching between different melting point states of the same substance to achieve heat absorption and dissipation. In actual products, this might be achieved simply by using thermally conductive silicone pads and thermally conductive gel to manage the transient high temperatures at the tab's power discharge point. When the battery is under high-current discharge, as the cell temperature rises to the phase change temperature, the phase change mechanism absorbs a significant amount of heat and releases it as the temperature drops, thus passively regulating heat. Through the synergistic effect of passive phase change cooling and active air convection cooling, the battery can maintain a reasonable temperature range even during prolonged high-rate discharge, significantly improving cycle life and reliability.

[0037] In terms of electrical connections, the battery pack features an electrical connection structure including an output flexible copper busbar and a wire positioning hole 7. The output flexible copper busbar is used to aggregate and output the electrical energy from multiple battery cell modules. One end of the busbar connects to the battery cell module, and the other end is led out to an external interface through the wire positioning hole 7. The flexible copper busbar design maintains conductivity while providing good flexibility, preventing breakage or loose connections due to vibration or frequent plugging and unplugging. The wire positioning hole 7 serves as the lead-out channel between the copper busbar and the external interface. It is reinforced to prevent wear or displacement due to long-term use, thereby improving the reliability and stability of the electrical connection.

[0038] The battery pack also integrates a battery management system (BMS) for monitoring and controlling the battery's operating status. This system is electrically connected to the cell modules and can detect voltage, current, and temperature parameters in real time. In case of abnormal conditions such as overcharging, over-discharging, overcurrent, or overtemperature, it promptly triggers power-off protection to ensure battery safety. The BMS adopts a separate design architecture for the main control module and the power module. The main control module is used for data acquisition and logic judgment, while the power module is responsible for high-current switching and protection actions. This separate configuration effectively avoids the risk of the entire system failing due to the failure of a single component, thereby enhancing the safety and reliability of the battery pack.

[0039] During use, this battery pack can also be used with a quick-swap mechanism. A latch 8 is located on the outside of the casing; when the user needs to replace the battery, they can quickly remove or install the battery pack from the drone's battery compartment by simply unlocking the latch. Compared to traditional methods relying on screws or clips for disassembly and assembly, this quick-swap mechanism significantly reduces replacement time and improves the efficiency of the drone in continuous operation scenarios. For example, in agricultural plant protection operations, operators can complete battery replacement in seconds, ensuring uninterrupted operation.

[0040] This specific implementation achieves a comprehensive improvement in the drone battery's waterproofness, moisture resistance, heat dissipation, safety, and operational convenience by optimizing the shell structure design, introducing a honeycomb flow channel and phase change heat dissipation composite structure, adopting a separate battery management system, and a fast battery swapping structure. This ensures that the battery pack can still operate stably and reliably under complex and changing environmental conditions and meet the requirements for long-term, high-efficiency use.

[0041] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any changes or substitutions conceived without inventive effort should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope defined in the claims.

Claims

1. A battery pack for swapping batteries in unmanned aerial vehicles, characterized in that, include: The housing is composed of an aluminum top cover (3), an aluminum side plate (2) and a base (1). The housing is fixed by step screws and a waterproof rubber strip (4) is provided at the connection of the housing to achieve waterproof sealing. The module stacking structure is located inside the housing and includes several battery cell modules. An aluminum plate (9) is provided between the battery cell modules to achieve heat conduction. The heat dissipation system includes a heat sink (6) installed inside the module, air vents (5) provided on the housing, and honeycomb air channels located between the cells; The electrical connection structure includes an output flexible copper busbar and a wire hole (7), wherein the output flexible copper busbar is electrically connected to the battery cell module and led out through the wire hole (7); The battery management system, connected to the cell module, is used to monitor the voltage, current, and temperature status of the battery pack and to provide power-off protection in case of abnormalities.

2. The UAV battery swapping pack according to claim 1, characterized in that: It also includes a quick battery swapping structure with a pin slot (8) on the outside of the housing to enable quick installation and removal of the battery pack.

3. The UAV battery swapping pack according to claim 1, characterized in that: The housing includes two aluminum side plates (2), two aluminum top covers (3) and a base (1). The aluminum side plates (2) are located on both sides of the base (1), and the two aluminum top covers (3) cover the upper and lower surfaces of the aluminum side plates (2).

4. The UAV battery swapping pack according to claim 1, characterized in that: The honeycomb-shaped airflow channel is embedded with a phase change heat dissipation mechanism.

5. The UAV battery swapping pack according to claim 1, characterized in that: The honeycomb-shaped airflow channels are spaced 3mm apart, which is used to achieve active heat dissipation and air convection between the battery cells.

6. The UAV battery swapping pack according to claim 1, characterized in that: The battery management system includes a main control module and a power module, and adopts a separate architecture.

7. The UAV battery swapping pack according to claim 1, characterized in that: The housing is made of 6061 series aluminum profiles.

8. The UAV battery swapping pack according to claim 3, characterized in that: The splicing position of the shell is also provided with a waterproof adhesive strip (4).

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