Integrated battery pack and electric vehicle

Abstract

To provide an integrated battery pack in which structural strength and rigidity of the whole integrated battery pack are enhanced, occurrence of deformation and torsion of a vehicle is avoided, thermal influence on a top part of a case is reduced, and thermal influence of a high temperature substance on an occupant cabin is avoided.SOLUTION: The present application provides an integrated battery pack and an electric vehicle, the integrated battery pack includes a case having an accommodating cavity therein, a battery module 2 mounted in the accommodating cavity and having a pressure relief valve at a top of the battery module 2, and a plurality of support components 3 arranged at intervals at the top of the battery module 2 and interposed between the battery module 2 and the case, at least a part of the support components 3 covering the pressure relief valve, and a pressure relief passage is enclosed between the support component 3 located at the pressure relief valve and the battery module 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This application relates to the technical field of battery manufacturing, for example, to integrated battery packs and electric vehicles. [Background technology]

[0002] With the rapid development of new energy vehicles and the continuous improvement of technology, the industry is placing greater demands on vehicle weight reduction, safety, and manufacturing costs. Therefore, Cell To Chassis (CTC) / Cell To Vehicle (CTV) technology has emerged in response to the times, meeting the market demand for integrated vehicle design, reducing the number of parts and lowering vehicle manufacturing costs. Summary of the Invention [Problem to be solved by the invention]

[0003] In related art CTB electric vehicles, the vehicle chassis and the battery pack case are integrated into one unit, greatly simplifying the vehicle structure. However, the weight of the seats and passengers in the passenger cabin directly acts on the battery pack, so the battery modules in the battery pack may be deformed or damaged by pressure from the passenger cabin, affecting the safe operation of the battery pack. At the same time, if the battery module experiences thermal runaway, high-temperature material is discharged from the pressure relief valve and spreads to the bottom of the passenger cabin, directly affecting the passenger cabin. [Means for solving the problem]

[0004] The integrated battery pack according to the present application comprises a case having a storage chamber therein, a battery module mounted in the storage chamber and having a pressure relief valve at its top, and a plurality of support members spaced apart from one another on the top of the battery module, interposed between the battery module and the case, with at least a portion of the support members covering the pressure relief valve, and a pressure relief passage is enclosed between the support members located at the pressure relief valve and the battery module.

[0005] The present application further provides an electric vehicle comprising a vehicle body, a seat, and an integrated battery pack attached to the vehicle body and having a case to which the seat is attached. [Effects of the Invention]

[0006] The beneficial effects of the present invention are as follows: A plurality of support members are provided between the battery modules and the top of the case. The support members support the case, allowing the weight of the seat and occupant to be evenly distributed throughout the battery modules and preventing the weight of the seat and occupant from concentrating on the connection points between the seat and the case or on the occupant's foot area. The support members increase the structural strength and rigidity of the integrated battery pack as a whole, which is beneficial for preventing deformation and twisting of the vehicle. At the same time, the support members cover the pressure relief valves of the battery modules, providing isolation against high-temperature materials in the event of thermal runaway of the battery modules. This reduces the thermal impact on the top of the case and is beneficial for preventing the passenger cabin from being thermally affected by high-temperature materials. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is an exploded view of an integrated battery pack according to some implementations of the present application. [Figure 2] 1 is a cross-sectional view of an integrated battery pack according to some implementations of the present application after a sheet has been attached to the battery pack; [Figure 3] FIG. 10 is a partial cross-sectional view of an integrated battery pack according to some implementations of the present application after a sheet has been attached to the battery pack. [Figure 4] FIG. 4 is an enlarged view of a portion A in FIG. [Figure 5] FIG. 10 is a schematic diagram of a case lid according to some implementations of the present application after a sheet has been attached to the lid. [Figure 6] 1 is a schematic diagram of a battery module according to some implementations of the present application; [Figure 7] FIG. 7 is an enlarged view of a portion B in FIG. [Figure 8]FIG. 2 is an exploded view of a battery module according to some implementations of the present application. [Figure 9] FIG. 2 is a cross-sectional view of a first support member according to some implementations of the present application. [Figure 10] FIG. 2 is a cross-sectional view of a second support member according to some implementations of the present application. [Figure 11] FIG. 10 is a partial schematic view of a third support member according to some implementations of the present application. [Figure 12] FIG. 1 is a schematic diagram of a temperature sensor according to some implementations of the present application. DETAILED DESCRIPTION OF THE INVENTION

[0008] Hereinafter, the technical solution of the present application will be described through specific embodiments with reference to the drawings.

[0009] As shown in FIGS. 1 to 5 , the integrated battery pack according to the present application includes a case 1, a battery module 2, and a support member 3. The case 1 has a rectangular parallelepiped structure, with its length direction corresponding to the X direction, its width direction corresponding to the Y direction, and its height direction corresponding to the Z direction. The case 1 has a hollow structure and an accommodation chamber therein. The battery module 2 is mounted in the accommodation chamber, and a pressure relief valve 26 is provided at the top thereof. In the event of thermal runaway of the battery module 2, the pressure relief valve 26 opens to release high-temperature gas and other substances (e.g., electrolyte) inside the battery module 2. There are multiple support members 3, which are spaced apart from each other on the top of the battery module 2 and are interposed between the battery module 2 and the case 1. The support member 3 may be understood to have a first surface abutting the battery module 2 and a second surface abutting the top chamber wall of the accommodation chamber. At least a portion of the support member 3 is covered by the pressure relief valve 26, i.e., the support member 3 is provided at a position corresponding to the pressure relief valve 26 of the battery module 2. A pressure relief passage 323 is surrounded between the support member 3 located at the pressure relief valve 26 and the battery module 2. When the battery module 2 experiences thermal runaway, high-temperature gas and other substances pass through the pressure relief valve 26 and are released into the pressure relief passage 323, where they are dispersed and discharged to the outside of the case 1.

[0010] This integrated battery pack is applied to a CTV electric vehicle, i.e., the vehicle adopts an integrated design, and the top of the case 1 serves as the bottom of the vehicle passenger cabin. The weight of the seat 7 and passengers in the passenger cabin acts directly on the case 1. A plurality of support members 3 are provided between the battery module 2 and the top of the case 1 to support the case 1. This allows the weight of the seat 7 and passengers to be evenly distributed throughout the battery module 2, preventing the weight from concentrating on the connection point between the seat 7 and the case 1 or on the passenger's foot area. The support members 3 enhance the structural strength and rigidity of the integrated battery pack as a whole, thereby preventing deformation and twisting of the vehicle. At the same time, the support members 3 cover the pressure relief valves 26 of the battery modules 2, providing isolation against high-temperature materials in the event of thermal runaway of the battery module 2. This reduces the thermal impact on the top of the case 1 and advantageously prevents the passenger cabin from being affected by the thermal impact of high-temperature materials.

[0011] The case 1 includes a case bottom 11 and a case lid 12. The case bottom 11 and the case lid 12 are integrally press-formed to enhance the overall structural strength of the case 1. The case bottom 11 has a groove 111 formed on the side facing the case lid 12, and a first folded-up structure 112 formed around the periphery. The first folded-up structure 112 is surrounded by the groove 111 and is flush with the opening of the groove 111. The case lid 12 includes a lid main body 121 and a mounting bracket 123. The lid main body 121 has a structure similar to that of the case bottom 11, and has a second folded-up structure 122 formed around the periphery that fits into the first folded-up structure 112. The lid main body 121 and the case bottom 11 are fitted together and connected and fixed with fasteners (e.g., screws, bolts, rivets, etc.). The fasteners are inserted into the first folded-up structure 112 and the second folded-up structure 122. Between the lid body 121 and the case bottom 11, an accommodation chamber configured to mount the battery module 2 is formed. The mounting brackets 123 are configured to mount the seat 7, and are provided in plurality. The plurality of mounting brackets 123 may include at least two mounting brackets 123 with different shapes and dimensions to suit the structural dimensions and mounting position of the seat 7. The plurality of mounting brackets 123 are provided on one side of the lid body 121 that is away from the case bottom 11, i.e., the mounting brackets 123 are provided on the top of the case 1. In this embodiment, the mounting brackets 123 and the lid body 121 are integrally press-formed. It can be understood that the case lid 12 of the case 1 forms the bottom of the passenger cabin, and that gravity from both the seat 7 and the passenger is applied to the case lid 12. Since the second surface of the support member 3 is connected to the inner wall of the case lid 12, the support member 3 distributes the gravity from the seat 7 and the occupant evenly to the entire integrated battery pack, preventing deformation, twisting, etc. of the integrated battery pack due to the concentration of force received in a local area.

[0012] The integrated battery pack further includes a liquid cooling plate 6. The liquid cooling plate 6 may be a liquid cooling plate used in the related art, and the cooling liquid circulating inside can dissipate heat from the battery module 2. The liquid cooling plate 6 is located at the bottom of the housing chamber, i.e., attached to the bottom of the groove 111 in the case bottom 11. The battery module 2 is attached to the liquid cooling plate 6, allowing heat exchange between them. A foam adhesive is filled between the side wall of the battery module 2 and the wall of the housing chamber to form a side foam adhesive layer 4. A foam adhesive is also filled between the liquid cooling plate 6 and the bottom of the housing chamber to form a bottom foam adhesive layer 5. The side foam adhesive layer 4 and the bottom foam adhesive layer 5 act as buffers and absorb energy, preventing damage to the battery module 2 and the liquid cooling plate 6 from being caused by a bottom collision while the electric vehicle is running. At the same time, by filling the foam adhesive, gaps between the battery module 2 and the case 1 and between the liquid cooling plate 6 and the case 1 are eliminated, the entire integrated battery pack is formed as a single unit, and the strength and rigidity of the entire integrated battery pack can be increased. In some embodiments, the foam adhesive may be filled only between the battery module 2 and the case 1, or only between the liquid cooling plate 6 and the case 1.

[0013] 12, a plurality of temperature sensors 10 are preferably provided at intervals between the battery modules 2 and the liquid cooling plate 6, and the temperature sensors 10 are configured to detect the temperature of the battery modules 2. The temperature sensors 10 monitor the temperature changes of the battery modules 2 so as to intervene in a timely manner when the temperature of the battery modules 2 is abnormal, thereby ensuring the safety of the integrated battery pack.

[0014] Preferably, the integrated battery pack further includes a battery management system (BMS) component 8. The BMS component 8 is provided in the battery module 2 and electrically connected to the battery module 2. The temperature sensor 10 is electrically connected to the BMS component 8. The BMS component 8 may employ components of related art and be configured to provide low voltage protection, abnormal temperature protection, charge / discharge overcurrent protection, etc. to the battery module 2.

[0015] 6 to 8, the battery module 2 includes a plurality of battery groups arranged sequentially along a first direction (the Y direction in the drawings), and each battery group includes a plurality of unit cells 21 arranged sequentially along a second direction (the X direction in the drawings). The first direction is perpendicular to the second direction. In this embodiment, the battery groups are arranged sequentially along the width direction of the case 1, and the unit cells 21 in each battery group are arranged sequentially along the length direction of the case 1. The unit cells 21 are prismatic cells whose thickness direction is the X direction in the drawings. The multiple support members 3 are parallel and spaced apart, and their length direction is parallel to the length direction of the case 1. Therefore, each support member 3 can uniformly distribute the weight of the seat 7 and the occupant to the multiple unit cells 21. A structural adhesive 9 is filled between two adjacent unit cells 21. By filling the structural adhesive 9, gaps between adjacent cells 21 are eliminated and all cells 21 can be formed into a single, integrated unit, thereby increasing the structural strength of the entire battery module 2 and allowing the entire battery module 2 to be used to bear pressure from the case lid 12.

[0016] A plurality of battery modules 2 are mounted within the case 1 and arranged in sequence along the width direction of the case 1. In this embodiment, there are two battery modules 2, which are spaced apart along the width direction of the case 1 and have a structural adhesive 9 between them. The battery module 2 further includes a cell contact system (CCS) component 22, an insulating plate 23, an end plate 24, and a buffer sheet 25. The CCS component 22 is connected to the poles of the cells 21 and is configured to collect data such as the voltage and temperature of the cells 21. The CCS component 22 is located at the top of the battery module 2, and the insulating plate 23 covers the CCS component 22 for insulation protection. Two end plates 24 are provided corresponding to each battery group, and are spaced apart along the length direction of the case 1. The cells 21 in each battery group are sandwiched between the two end plates 24. A buffer sheet 25 is interposed between the end plate 24 and the inner wall of the case 1. The buffer sheet 25 is made of foam and functions to buffer and absorb energy. The CCS component 22 includes a plurality of terminal blocks. Multiple rows of positive and negative poles are distributed at the top of the entire battery module 2, with one terminal block corresponding to each row of positive poles or each row of negative poles. The terminal block is connected to the corresponding positive pole or negative pole. The multiple terminal blocks are arranged at intervals along the width direction of the case 1, with a gap between two adjacent terminal blocks.

[0017] Because the top of the battery module 2 has different structures depending on the position / area, the multiple support members 3 also have correspondingly different structures to accommodate the installation space. One side of the support member 3 facing the battery module 2 is provided with an accommodation groove configured to accommodate the CCS component 22. The CCS component 22 is positioned within the accommodation groove of the support member 3, thereby preventing the top of the case 1 from being directly pressed against the CCS component 22 and ensuring a reliable connection between the CCS component 22 and the terminal post. In this embodiment, the support member 3 includes a first support member 31, a second support member 32, and a third support member 33. The first support member 31 is provided at both ends of the battery module 2 in the first direction (the width direction of the case 1). The second support member 32 is provided above the pressure relief valve 26. The third support member 33 is provided at the adjacent location of two adjacent battery groups. To ensure that the support member 3 is firmly attached, the second and first surfaces of the support member 3 are adhesively fixed to the case 1 and the battery module 2, respectively. That is, along the height direction of the case 1, the first surface of the support member 3 is adhesively fixed to the battery module 2 with a structural adhesive 9, and the second surface is adhesively fixed to the inner wall of the case lid 12 with the structural adhesive 9.

[0018] Referring to FIG. 9 , the first support member 31 includes a main support block 311 and a sub-support block 312. The corresponding accommodating groove in the first support member 31 is a first accommodating groove 313. A first adhesive groove 314 is provided on one surface of the main support block 311 facing the battery module 2. The sub-support block 312 is provided on one surface of the main support block 311 facing away from the battery module 2. A first end of the sub-support block 312 is connected to the main support block 311, and a second end is a free end that extends in a first direction away from the main support block 311. The sub-support block 312 is provided perpendicular to the main support block 311, and a first accommodating groove 313 is defined between the main support block 311 and the sub-support block 312. The first accommodating groove 313 may be understood to be configured to accommodate the CCS component 22 and the insulating plate 23. During installation, the surface of the main support block 311 having the first adhesive groove 314 abuts against the shell of the cell 21 and is adhesively fixed thereto with the structural adhesive 9. The second surface of the main support block 311 and / or the second surface of the sub-support block 312 abuts against the inner wall of the case lid 12 and is adhesively fixed thereto with the structural adhesive 9. The first housing groove 313 is configured to accommodate the CCS component 22 and insulating plate 23 that are close to the first support member 31. In this embodiment, the CCS component 22 is located below the sub-support block 312, which prevents pressure from the case lid 12 from directly acting on the CCS component 22 and the terminal posts and further prevents the circuit connection area of ​​the battery module 2 from being broken or deformed by external force. In some embodiments, the main support block 311 may be higher or lower than the sub-support block 312. This structure means that the main support block 311 and the secondary support block 312 are not positioned on the same plane, which creates a gap between the main support block 311 or the secondary support block 312 and the case lid 12 to accommodate a sufficient amount of structural adhesive 9, thereby increasing the adhesive strength between the first support member 31 and the case lid 12.

[0019] Referring to FIG. 10 , the second support member 32 includes a first support block 321 and two second support blocks 322. The corresponding groove in the second support member 32 is a second groove 324. A second adhesive groove 325 is provided on one side of the first support block 321 facing the inner wall of the case lid 12. The second adhesive groove 325 is configured to receive a structural adhesive 9, thereby firmly bonding the second support member 32 to the case lid 12. The two second support blocks 322 are spaced apart along the width direction of the second support block 322 (i.e., the width direction of the case 1) on one side of the first support block 321 facing the battery module 2. The second support blocks 322 are also spaced apart from the end of the first support block 321 along the width direction. A pressure relief passage 323 is defined between the first support block 321 and the two second support blocks 322. Second accommodating grooves 324 are defined between both ends of the first support block 321 in the first direction and each of the two second support blocks 322, and the second accommodating grooves 324 are configured to accommodate the CCS component 22 and the insulating plate 23. During installation, one surface of the first support block 321 having the second adhesive groove 325 abuts against the inner wall of the case lid 12 and is bonded and fixed with the structural adhesive 9. By abutting the second support block 322 against the shell of the cell 21 and positioning the pressure relief valve 26 between the two second support blocks 322, a pressure relief passage 323 is defined between the first support block 321, the two second support blocks 322, and the cell 21. The second accommodating grooves 324 are configured to accommodate the CCS component 22 and the insulating plate 23 that are close to the second support member 32. In this embodiment, the CCS component 22 is located below the first support block 321, which prevents pressure from the case lid 12 from acting directly on the CCS component 22 and the poles, and also prevents the circuit connection area of ​​the battery module 2 from being broken or deformed by external force.

[0020] Referring to FIG. 11 , the third support member 33 includes a third support block 331 and a fourth support block 332. The corresponding receiving groove in the third support member 33 is a third receiving groove 333. The third support block 331 is connected to the case lid 12 of the case 1, and a third adhesive groove is provided on one side facing the case lid 12. The third adhesive groove is configured to receive structural adhesive 9, thereby firmly bonding the third support block 331 and the case lid 12. The fourth support block 332 is provided on one side of the third support block 331 facing the battery module 2, and is connected to the battery module 2. To ensure the strength of the bond of the fourth support block 332, a third adhesive groove for receiving a sufficient amount of structural adhesive 9 may be provided on one side of the fourth support block 332 away from the third support block 331. The fourth support block 332 is located at the center of the third support block 331 along the width direction (i.e., the width direction of the case 1) and is spaced apart from the widthwise ends of the third support block 331. A third accommodating groove 333 is defined between the fourth support block 332 and both ends of the third support block 331 along its width direction (first direction). The third accommodating groove 333 is configured to accommodate the CCS component 22 and insulating plate 23 near the third support member 33. In this embodiment, the third support member 33 is attached to the connection points of two adjacent battery sets. During attachment, one side of the third support block 331 having the third adhesive groove is adhesively fixed to the inner wall of the case lid 12, and the fourth support block 332 abuts and adhesively fixed to the shells of the cells 21 in the two adjacent battery sets. Since the CCS component 22 is located below the third support block 331, pressure from the case lid 12 is prevented from acting directly on the CCS component 22 and the poles, and furthermore, the circuit connection area of ​​the battery module 2 is prevented from being broken or deformed by external force.

[0021] In practical application, the number and positions of the support members 3 can be reasonably selected according to the specific structural dimensions of the cells 21 .

[0022] As shown in Figures 1, 2 and 5, an electric vehicle is provided that includes a vehicle body, a seat 7, and an integrated battery pack. The integrated battery pack is attached to the vehicle body, and the top of its case 1 (i.e., case lid 12) also serves as the bottom of the passenger cabin of the vehicle body, thereby simplifying the vehicle structure. The seat 7 is attached to a mounting bracket 123 on the case lid 12. The weight of the seat 7 and the passenger acts directly on the case lid 12. The integrated battery pack includes a support member 3, and pressure from the case lid 12 is uniformly distributed over the entire integrated battery pack by the support member 3, thereby preventing deformation or twisting of the integrated battery pack due to concentrated force and improving the safety performance of the integrated battery pack.

[0023] In this embodiment, multiple support members 3 are provided between the battery modules 2 and the top of the case 1. The support members 3 support the case 1, allowing the weight of the seat 7 and occupant to be evenly distributed throughout the battery modules 2 and preventing the weight from concentrating on the connection between the seat 7 and the case 1 or on the area where the occupant steps. The support members 3 increase the structural strength and rigidity of the integrated battery pack as a whole, which is beneficial for preventing deformation and twisting of the vehicle. At the same time, the support members 3 cover the pressure relief valves 26 of the battery modules 2, providing isolation against high-temperature materials in the event of thermal runaway of the battery modules 2. This reduces the thermal impact on the top of the case 1 and is beneficial for preventing the passenger cabin from being thermally affected by high-temperature materials. [Explanation of symbols]

[0024] 1. Case 11. Bottom of the case 111···Groove 112···First folding structure 12. Case lid 121...Lid body 122...Second fold-up structure 123 Mounting bracket 2. Battery module 21. Cell 22 CCS Components 23 Insulating plate 24...end plate 25. Cushioning sheet 26 Pressure relief valve 3. Support member 31 First support member 311 Main support block 312 Secondary support block 313···First receiving groove 314···First adhesive groove 32... Second support member 321···First support block 322 Second support block 323 Pressure relief passage 324···Second receiving groove 325···Second adhesive groove 33 Third support member 331 Third support block 332···Fourth support block 333···Third storage groove 4. Side foam adhesive layer 5 Bottom foam adhesive layer 6...liquid cooling plate 7 seats 8. BMS Components 9. Structural adhesives 10. Temperature sensor

Claims

1. a case having a storage chamber therein; a battery module attached to the storage chamber and having a pressure relief valve at its top; and a plurality of support members provided at intervals on the top of the battery module between the battery module and the case, at least a portion of which is covered by the pressure relief valve, wherein a pressure relief passage is enclosed between the support member located at the pressure relief valve and the battery module. Integrated battery pack.

2. the opposing surfaces of the support member are adhesively fixed to the case and the battery module, respectively; The integrated battery pack according to claim 1 .

3. the battery module includes a plurality of battery groups sequentially arranged along a first direction, and each battery group includes a plurality of unit cells sequentially arranged along a second direction perpendicular to the first direction; The support members are configured in at least one of a case where the support members are provided at both ends of the battery module along the first direction and a case where the support members are provided at adjacent locations of two adjacent battery sets. The integrated battery pack according to claim 1 .

4. the battery module further includes a cell contact system (CCS) component connected to a pole of the battery cell, and the support member is provided with an accommodation groove configured to accommodate the CCS component. The integrated battery pack according to claim 3 .

5. When the support members are provided on both ends of the battery module in the first direction, the support members include first support members provided on both ends of the battery module in the first direction, the first support members include a main support block and a sub-support block provided on one side of the main support block that is separated from the battery module and whose free end extends in a direction that is separated from the main support block along the first direction, and the accommodating groove is surrounded between the main support block and the sub-support block. The integrated battery pack according to claim 4 .

6. the support member includes a second support member that covers the pressure relief valve, the second support member including a first support block connected to the case, and two second support blocks that are spaced apart on one side of the first support block facing the battery module and connected to the battery module, the pressure relief passage being surrounded between the first support block, the two second support blocks, and the battery cells, and the accommodating groove being surrounded between both ends of the first support block in the first direction and each of the two second support blocks. The integrated battery pack according to claim 4 .

7. When the support member is provided at a location adjacent to two adjacent battery sets, the support member includes a third support member provided at a connection location of the two adjacent battery sets, the third support member includes a third support block connected to the case, and a fourth support block provided on one side of the third support block facing the battery module and connected to the battery module, and the accommodating groove is surrounded by both ends of the third support block along the first direction between the third support block and the fourth support block. The integrated battery pack according to claim 4 .

8. A structural adhesive is filled between two adjacent cells. The integrated battery pack according to claim 3 .

9. The battery pack further includes a liquid cooling plate provided at the bottom of the storage chamber and to which the battery module is attached, and a foam adhesive is filled between at least one of the space between the battery module and a chamber wall of the storage chamber and the space between the liquid cooling plate and a chamber bottom of the storage chamber.

2. The integrated battery pack according to claim 1.

10. a plurality of temperature sensors configured to detect temperatures of the battery modules are provided at intervals between the battery modules and the liquid cooling plate; The integrated battery pack according to claim 9 .

11. A mounting bracket is provided on the top of the case to which a seat is attached.

2. The integrated battery pack according to claim 1.

12. A vehicle comprising: a vehicle body; a seat; and the integrated battery pack according to any one of claims 1 to 11, which is attached to the vehicle body and has a case to which the seat is attached. Electric car.

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