Protective frame for high-efficiency battery modules

Abstract

This invention provides a protective frame for high-efficiency battery modules that can effectively improve the safety and reliability of the battery module. [Solution] The protective frame 100 for high-efficiency battery modules according to the present invention is used to house a battery module 30, and the protective frame has heat dissipation and insulation properties. The protective frame comprises a vertical frame 10 consisting of side plates that surround the battery module in the vertical direction, an upper cover plate 22 positioned above the vertical frame, and a lower cover plate 24 positioned below the vertical frame. The vertical frame, the upper cover plate, and the lower cover plate form a box body for housing the battery module. The vertical frame comprises a front panel 12, a rear panel 14, a left panel 16, and a right panel 18. These panels are connected to each other to form a rectangular vertical frame.

Description

Technical Field

[0001] The present invention relates to a battery protection frame, and more particularly to a protection frame for a high-efficiency battery module.

Background Art

[0002] Many conventional protection frames for battery modules are made of metal or a single resin material, providing structural support and insulation effects.

Summary of the Invention

Problems to be Solved by the Invention

[0003] However, metal materials have good thermal conductivity, but there is a risk that some parts may overheat or short-circuit during the use of the battery module. Also, processing is inconvenient, the weight is heavy, and it is not suitable for portable or in-vehicle applications. Resin or plastic materials have insulation and corrosion resistance, but tend to have low thermal conduction performance. When the battery module is used for a long time, heat is likely to accumulate, affecting the service life and safety. Many of the conventional frame body materials have a single component and it is difficult to have both high strength, insulation, and heat dissipation performance. For example, common epoxy resins are often used in battery packages, but they have low thermal conductivity and are flammable, so the safety requirements for high-power density modules are insufficient. Also, when a metal frame body is selected to enhance heat dissipation, the weight of the module will increase, and it is necessary to make a trade-off between weight reduction and structural strength in the design, and it is impossible to have both. Summing up the above, the prior art has insufficient material selection and heat dissipation structure design, and cannot simultaneously meet the requirements of high-efficiency heat dissipation, weight reduction, insulation, and safety, and improvement is strongly desired.

[0004] Based on their many years of experience with battery module materials, the inventors recognized the need to provide a novel protective frame design for battery modules that offers good heat dissipation and insulation, ensures the stability of the battery modules housed within, and enables safe operation.

[0005] This invention was developed through diligent research by the inventor in view of the above-mentioned problems, and its purpose is to provide a protective frame for high-efficiency battery modules. [Means for solving the problem]

[0006] To achieve the above objective, a protective frame for a high-efficiency battery module, which is one aspect of the present invention, has heat dissipation and insulation properties. The protective frame comprises a vertical frame consisting of side plates that surround the battery module in the vertical direction, an upper cover plate positioned above the vertical frame, and a lower cover plate positioned below the vertical frame. The vertical frame, the upper cover plate, and the lower cover plate form a box body for housing the battery module. Furthermore, the present invention has multiple regularly arranged protrusions and recessed air ducts on the inner surface of the frame body, which effectively increases the contact area and guides the airflow. Combined with a fan positioned outside the frame, a highly efficient heat dissipation channel is formed, significantly improving the rate of heat discharge and enabling the battery module to maintain stability even during long-term operation. [Effects of the Invention]

[0007] According to this invention, there is a clear improvement effect, and the safety and reliability of the battery module can be effectively enhanced.

[0008] The following information will become clear from the description in the specification and drawings described later. [Brief explanation of the drawing]

[0009] [Figure 1]This is a schematic diagram showing a protective frame and battery module according to one embodiment of the present invention. [Figure 2] This diagram shows the arrangement of an inner protrusion on the inner surface of a vertical frame and an air duct, and an outer protrusion on the outer surface of a vertical frame and an air duct, according to one embodiment of the present invention. [Figure 3] This is an asymmetrical cross-sectional view showing the inner and outer protrusions of a vertical frame panel according to one embodiment of the present invention. [Figure 4] This is a schematic diagram showing the arrangement of multiple fans of the present invention on the left and right sides of the protective frame. [Figure 5] This is a schematic diagram showing that the front and rear panels of the present invention have ventilation holes. [Figure 6] This is a schematic diagram showing the structure and leads of the battery module of the present invention. [Figure 7] This is a schematic diagram showing the connection between the BMS module and the inverter of the present invention. [Figure 8] This is a cross-sectional view of a panel of a vertical frame according to one embodiment of the present invention, in which a heat dissipation layer is formed. [Modes for carrying out the invention]

[0010] The present invention will be described below through embodiments of the invention, but these embodiments are not intended to limit the scope of the invention covered by the utility model registration claims. Furthermore, not all combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0011] The high-efficiency battery module protection frame 100 according to the present invention is used to house a battery module 30, and the protection frame 100 has good heat dissipation and insulation properties, ensuring the stability of the battery module 30 housed inside and enabling safe operation.

[0012] The protective frame 100 includes the following configuration (see Figure 1). This will be described in detail below.

[0013] The vertical frame 10 has side panels (side walls) formed in the vertical direction that surround the battery module, and is used to house the internal battery module 30. In this embodiment, the vertical frame 10 comprises a front panel 12, a rear panel 14, a left panel 16, and a right panel 18. These panels are connected to each other to form a rectangular vertical frame. The left panel 16 and the right panel 18 have ventilation holes, and air enters through the ventilation holes of one panel and exits through the ventilation holes of the other panel.

[0014] The material of the vertical frame 10 is a composite (or mixed) material of epoxy resin, graphene, and boron nitride. Epoxy resin is a thermosetting plastic with good mechanical properties, electrical insulation properties, corrosion resistance, and sizing stability. However, because epoxy resin itself has low thermal conductivity, it is easily combustible. Boron nitride has excellent thermal conductivity, electrical insulation properties, and stability at high temperatures. Graphene is a two-dimensional material with extremely high thermal conductivity and electrical conductivity. Therefore, by adding boron nitride and graphene to epoxy resin, the composite material can be formed to improve its thermal conductivity and simultaneously enhance its mechanical properties. It also has good high-temperature thermal conductivity, which is preferably comparable to that of metallic aluminum. The weight ratio of the epoxy resin, the graphene, and the boron nitride is in the range of 85-90:1-3:7-9. Such composite materials of epoxy resin, graphene, and boron nitride combine high mechanical strength, good insulation, and excellent thermal conductivity, overcoming not only the drawback of insufficient thermal conductivity in conventional resin materials, but also safety concerns arising from the excessive weight and conductivity of metal frames.

[0015] Preferably, at least one inner surface of the vertical frame 10 has a plurality of inner protrusions A formed thereon, which allow the inner protrusions A of the inner surface to contact the battery module 30 and the mounting assembly member of the battery module 30 that are installed inside, thereby achieving high-speed heat dissipation.

[0016] Preferably, the plurality of inner protrusions A on at least one inner surface of the vertical frame 10 are arranged in a staggered pattern with a gap (preferably a constant gap) between them, forming a regular pattern (for example, a pattern in which substantially regular hexagonal columns are arranged regularly at a constant interval). An air duct (see FIG. 2) is formed in the inner recess B between the inner protrusions A. By extending these air ducts from the left side to the right side of the inner surface, the air on the left side can be guided to the right side to assist the overall heat dissipation effect. Incidentally, the inner protrusions A and the inner recesses B can also be arranged alternately in a honeycomb pattern.

[0017] Preferably, on at least one outer surface of the vertical frame 10, a plurality of outer protrusions C are formed to enable contact with a battery case attached externally and to promote heat dissipation (preferably to achieve high-speed heat dissipation).

[0018] Preferably, the plurality of outer protrusions C on at least one outer surface of the vertical frame 10 are arranged in a staggered pattern with a gap (preferably a constant gap) between them, forming a regular pattern (for example, a pattern in which substantially regular hexagonal columns are arranged regularly at a constant interval). An air duct (see FIG. 2) is formed in the outer recess D between the outer protrusions C. By extending these air ducts from the left side to the right side of the outer surface, the air on the left side can be guided to the right side to assist the overall heat dissipation effect.

[0019] Preferably, an asymmetric form is formed by the plurality of inner protrusions A formed on at least one inner surface of the vertical frame 10 and the outer protrusions C formed on at least one outer surface of the vertical frame 10, and the heat dissipation effect of the vertical frame 10 is enhanced. Refer to the cross-section of one panel of the vertical frame 10 shown in FIG. 3.

[0020] The upper cover plate 22 is disposed above the vertical frame 10 (see FIG. 1).

[0021] The lower cover 24 is disposed below the vertical frame 10 (see FIG. 1).

[0022] Since the upper cover plate 22 and the lower cover plate 24 are made of a composite material of aerogel and graphene, they have a suitable heat dissipation effect. Aerogel is an extremely low-density solid material with high porosity and is commonly used for heat insulation because of its extremely low thermal conductivity. However, after aerogel and graphene with extremely high thermal conductivity are combined, graphene forms a continuous heat conduction channel network in the aerogel structure, so that the overall heat conduction performance is greatly improved. In addition, the high porosity of the aerogel itself promotes the convection of air and the release of heat. Such a composite material not only has high heat conduction efficiency, but also has the advantages of being lightweight and difficult to deform, and becomes a high-efficiency heat dissipation material. The weight ratio of the aerogel to the graphene is in the range of 8:1 to 15:1. Thus, by using the composite material of aerogel and graphene, it is possible to further improve the heat dissipation performance while being lightweight and difficult to deform, and at the same time, it can meet the requirements of heat dissipation, insulation, weight reduction, and structural strength.

[0023] The vertical frame 10, the upper cover plate 22, and the lower cover plate 24 form a box body (box-shaped body) having side plates and upper and lower cover plates, which is used to accommodate the battery module 30 and serves as the package of the battery module 30.

[0024] The protective frame 100 of this invention further includes a plurality of fans 40 used for heat dissipation from the battery. The plurality of fans 40 are arranged on the left and right sides of the outside of the protective frame 100, respectively (see Figure 4), so that air can be guided from the left side, through the ventilation holes of the left panel 16 into the vertical frame 10, and out through the ventilation holes of the right panel 18. The above arrangement of this invention is applied to form a ventilation channel as shown in Figure 1. Furthermore, the protrusions on the vertical frame 10 of this invention can effectively guide the heat emitted from the battery of the battery module 30 to be released.

[0025] Preferably, ventilation holes are formed in the front panel 12 and the rear panel 14 (see Figure 5), and some of the air flows out through the ventilation holes in the front panel 12 and the rear panel 14, thereby enhancing the overall heat dissipation effect.

[0026] Figure 6 shows the arrangement of the battery module 30, which is divided into upper and lower battery layer sets and arranged in an array. Each layer of battery sets forms a 6x8 arrangement, and six batteries are connected in series to form one battery unit, with positive and negative lead wires drawn out from each battery unit, and the positive and negative lead wires of all the battery units are connected in series to a subsequent device. The positive and negative lead wires drawn out from each battery are connected to external equipment according to the application, are designed in different configurations and connected to the subsequent device using wiring methods.

[0027] This invention further includes a Battery Management System (BMS) module 50 used to connect to the positive and negative electrodes of the battery mounted inside the protective frame 100. Then, the necessary processing is performed based on the current and voltage from the battery, achieving a management effect for each battery.

[0028] As shown in Figure 6, the positive lead wire and the negative lead wire from the battery module 30 are connected to the input terminals of the BMS module 50.

[0029] In the example shown in Figure 7, the present invention has an inverter 60 connected in series to the rear end of the BMS module 50 to perform DC-AC conversion of the current from the BMS module 50, depending on the demand. Power from the battery is transmitted to the rear assembly member in AC form. Alternatively, AC-DC conversion of external power is performed, and the external AC current is converted to DC current to charge the battery module 30.

[0030] Preferably, a heat dissipation layer 70 is formed on at least a portion of the surface of the vertical frame 10 to enhance the heat dissipation energy force (heat dissipation capacity) and suppress electromagnetic radiation interference. Refer to the cross-section of one panel of the vertical frame 10 shown in Figure 8 in which the heat dissipation layer 70 is formed. Preferably, the heat dissipation layer 70 is formed on all surfaces of the vertical frame 10.

[0031] Preferably, the heat dissipation layer 70, used for heat dissipation and to suppress electromagnetic interference (EMI), is formed on at least one surface portion of the vertical frame 10, the upper cover plate 22, and the lower cover plate 24. Preferably, the heat dissipation layer 70 is formed on all surfaces of the vertical frame 10, the upper cover plate 22, and the lower cover plate 24.

[0032] The heat dissipation layer 70 can be formed from a heat dissipation gel composition. The heat dissipation gel composition is a mixture of deionized water, ethanol, propylene glycol, N-methylpyrrolidone (NMP), polyurethane (PU), polyvinylpyrrolidone (PVP), graphene, boron nitride, aluminum oxide (Al2O3), lanthanum phosphate (LaPO4), and lanthanum phosphate (LaPO4@PDMS) coated with PDMS (polydimethylsiloxane).

[0033] In a preferred embodiment of the present invention, first, deionized water, ethanol, propylene glycol, NMP, PU, ​​and PVP are mixed to form a colloidal substrate. Then, solid components formed from graphene, boron nitride, aluminum oxide, LaPO4, and LaPO4@PDMS are dispersed in the colloidal substrate to form a solution, which is sprayed or applied to a partial area of ​​at least one surface of the vertical frame 10, the upper cover plate 22, and the lower cover plate 24. Subsequently, by drying, at least a portion of the volatile components, including deionized water, ethanol, propylene glycol, and NMP, in the heat dissipation gel composition are removed (evaporated), and a heat dissipation layer 70 containing the solid components and the PU and PVP constituting the substrate is formed. Preferably, the thickness of the remaining heat dissipation layer 70 is in the range of 1 to 5 μm.

[0034] The weight ratio of the solid content in the solution is in the range of 0.5 to 2.2 wt%.

[0035] The ratio of the weight of deionized water to the weight of ethanol is in the range of 1:3 to 1:7.

[0036] The ratio of the weight of the deionized water to the weight of the propylene glycol is in the range of 1:0.1 to 1:0.3.

[0037] The ratio of the weight of the deionized water to the weight of the NMP is in the range of 2:1 to 3:1.

[0038] The ratio of the weight of the PVP to the weight of the PU is in the range of 1:1 to 1:5.

[0039] The weight ratio of "the sum of the weights of the PVP and the PU" in the solution is in the range of 1 to 5 wt%.

[0040] The weight ratio of the graphene to the solution is in the range of 0.2 to 0.7 wt%.

[0041] The ratio of the weight of graphene to the weight of boron nitride is in the range of 1:2 to 8.

[0042] The weight ratio of the graphene to the sum of the weights of LaPO4 and PDMS@LaPO4 is in the range of 1:2 to 10.

[0043] The ratio of the total weight of LaPO4 and PDMS@LaPO4 to the weight of aluminum oxide is in the range of 5:2 to 5.

[0044] The ratio of the weight of LaPO4 to the weight of PDMS@LaPO4 is in the range of 1:3 to 5.

[0045] The average particle size of the LaPO4 particles in the LaPO4 is in the range of 20 to 150 nm. The average particle size of the LaPO4 particles in the PDMS@LaPO4 is in the range of 20 to 150 nm, and the thickness of the PDMS surrounding the LaPO4 is less than 10 nm. The average particle size of each aluminum oxide particle in the aluminum oxide is in the range of 20 to 50 nm. In this specification, the average particle size can be measured by known methods such as image analysis using electron microscopy, dynamic light scattering, or laser diffraction / scattering.

[0046] The PU in the heat dissipation layer 70 is a polymer substrate, possessing good mechanical flexibility, adhesion, and film-forming properties, effectively supporting the dispersion of inorganic and conductive materials, while maintaining the flexibility and durability of the entire coating layer.

[0047] The PVP is an interface modifier that has high polarity and good solubility, promoting the uniform dispersion of the aluminum oxide, boron nitride, and graphene in the PU, thereby improving structural uniformity, overall thermal conductivity, and thermal conductivity stability.

[0048] The graphene is a conductive and thermally conductive material, playing a key role in both EMI resistance and thermal conductivity. The graphene has extremely high electron mobility and conductivity, and is capable of reflecting and absorbing incident electromagnetic waves, thereby reducing EMI interference. Furthermore, the high thermal conductivity of the graphene allows for rapid conduction of thermal energy generated by electromagnetic wave absorption or component movement along the planar direction.

[0049] The aluminum oxide is a thermally conductive material with good thermal conductivity and electrical insulation properties, and plays a role in bonding with the graphene to form a continuous thermal conduction channel, thereby increasing the overall thermal conduction efficiency. Preferably, the aluminum oxide is γ-aluminum oxide (γ-Al2O3), which has a high thermal conductivity coefficient and dispersion stability.

[0050] The boron nitride is a thermally conductive material that is dispersed in the colloidal substrate, further improving the overall thermal conductivity and uniformity of the heat distribution. The boron nitride has high thermal conductivity and excellent chemical stability, forming multi-directional thermal conduction channels within the PU, which helps to rapidly transfer thermal energy from the interior to the outer surface.

[0051] The LaPO4 and PDMS@LaPO4 are thermal radiation materials that enhance the far-infrared radiation capability of their surfaces, thereby dissipating the thermal energy conducted to their surface by radiation and improving the overall heat dissipation effect. The LaPO4 particles in the LaPO4 effectively absorb and radiate thermal energy. The outer PDMS coating layer protects the LaPO4 from reacting with alkaline solvents and prevents the aggregation of nanoparticles in high pH environments. Considering the cost of coating with PDMS, even coating only a portion of the particles can significantly improve dispersibility and stability. The LaPO4 itself does not generate thermal energy; however, when external heat is transferred to its surface by a thermally conductive material, it can effectively release thermal energy to the outside environment by radiation, achieving a highly efficient thermal energy dissipation effect.

[0052] Although embodiments of the present invention have been described in detail above with reference to the drawings, the specific configuration is not limited to these embodiments, and design modifications and the like are also included within the scope of the spirit of the present invention. [Explanation of Symbols]

[0053] 10 vertical frames 12 Front Panel 14. Rear panel 16 Left panel 18 Right panel 22 Upper cover plate 24 Lower cover plate 30 Battery Modules 40 Fans 50 BMS (Battery Management System) Modules 60 Inverter 70 Heat dissipation layer 100 protective frames A Inner protrusion B Inner recess C Outer protrusion D Outer recess

Claims

1. A protective frame for a high-efficiency battery module used to house a battery module, wherein the protective frame has heat dissipation and insulation properties, and the protective frame is A vertical frame comprising a vertical frame consisting of side plates that surround the battery module in the vertical direction, An upper cover plate positioned above the aforementioned vertical frame, It comprises a lower cover plate located below the vertical frame, A protective frame for a high-efficiency battery module, characterized in that the vertical frame, the upper cover plate, and the lower cover plate form a box body for housing the battery module, including side plates and upper and lower cover plates.

2. The vertical frame comprises a front panel, a rear panel, a left panel, and a right panel, and these panels are connected to each other to form a rectangular vertical frame, and the left panel and the right panel have ventilation holes, and air enters through the ventilation holes in one panel and exits through the ventilation holes in the other panel, characterized in that the protective frame for a high-efficiency battery module according to claim 1.

3. Multiple inner protrusions are formed on at least one inner surface of the vertical frame to allow contact with the battery module and the mounting assembly member for the battery module, thereby promoting heat dissipation. The protective frame for a high-efficiency battery module according to claim 1, characterized in that an air duct is formed in an inner recess between the inner protrusions, and these air ducts extend from the left to the right side of the inner surface, thereby guiding the air on the left side to the right side to assist in the overall heat dissipation.

4. Multiple outward protrusions are formed on at least one outer surface of the aforementioned vertical frame. The protective frame for a high-efficiency battery module according to claim 1, characterized in that air ducts are formed in the outer recesses between the outer protrusions, and these air ducts extend from the left to the right side of the outer surface, thereby guiding the air on the left side to the right side to assist in the overall heat dissipation.

5. The protective frame for a high-efficiency battery module according to claim 3, characterized in that the plurality of inner protrusions on at least one inner surface of the vertical frame are arranged in a staggered pattern with intervals between them.

6. The protective frame for a high-efficiency battery module according to claim 4, characterized in that the plurality of outer protrusions on at least one outer surface of the vertical frame are arranged in a staggered pattern with intervals between them.

7. The protective frame for a high-efficiency battery module according to claim 3, characterized in that a plurality of outer protrusions are formed on at least one outer surface of the vertical frame, and an asymmetrical shape is formed by the plurality of inner protrusions on at least one inner surface of the vertical frame and the plurality of outer protrusions on the outer surface, thereby enhancing the heat dissipation effect of the vertical frame.

8. The protective frame for a high-efficiency battery module according to claim 1, further comprising a plurality of fans used for heat dissipation of the battery, wherein the plurality of fans are arranged on the left and right sides of the outside of the protective frame, respectively.

9. A Battery Management System (BMS) module for connecting the positive and negative terminals of a battery, which is mounted inside the protective frame, The protective frame for a high-efficiency battery module according to claim 1, further comprising an inverter connected to the BMS module for performing DC-AC conversion of the current from the BMS module.

10. The protective frame for a high-efficiency battery module according to claim 1, characterized in that at least one surface portion of the vertical frame, the upper cover plate, and the lower cover plate is provided with a heat dissipation layer for enhancing heat dissipation and suppressing electromagnetic interference.

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