Integrated battery packs and electric vehicles

Abstract

To provide an integrated battery pack which increases the structural strength and rigidity of the entire integrated battery pack, prevents deformation and twisting of a vehicle, reduces the thermal effect on the top of a case, and prevents a passenger cabin from being thermally affected by a high-temperature substance. [Solution] The present application provides an integrated battery pack and an electric vehicle, the integrated battery pack comprising a case with a storage chamber inside, a battery module 2 mounted in the storage chamber and having a pressure relief valve on the top, and a plurality of support members 3 spaced apart on the top of the battery module 2 and interposed between the battery module 2 and the case, with at least a portion of the support member 3 covering the pressure relief valve, and a pressure relief passage is enclosed between the support member 3 located at the pressure relief valve and the battery module 2.

Description

Technical Field

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

Background Art

[0002] With the rapid development of new energy vehicles and the iterative improvement of technologies, in the industry, the weight reduction, safety, and manufacturing cost of vehicles are demanded to be higher. Therefore, the Cell To Chassis (CTC) / Cell To Vehicle (CTV) technology emerges in response to the trend, and by integrating and designing the vehicle, it meets the market demand of reducing the types of components and the manufacturing cost of the vehicle.

Summary of the Invention

Problems to be Solved by the Invention

[0003] In the CTB electric vehicle in the related art, since the chassis of the vehicle and the case of the battery pack are integrally integrated, the structure of the vehicle is greatly simplified. However, since the weight of the seat and passengers in the passenger cabin directly acts on the battery pack, the battery modules in the battery pack are deformed or damaged under the pressure from the passenger cabin, affecting the safe operation of the battery pack. At the same time, when the battery module undergoes thermal runaway, the high-temperature substances discharged from the pressure relief valve spread to the bottom of the passenger cabin, directly affecting the passenger cabin thermally.

Means for Solving the Problems

[0004] The integrated battery pack according to this application includes a case with an accommodation chamber therein, a battery module mounted in the accommodation chamber and having a pressure relief valve at the top, and a plurality of support members provided at an interval above the top of the battery module and intervening between the battery module and the case, with at least a part being covered by the pressure relief valve. A pressure relief passage is surrounded between the support member located at the pressure relief valve and the battery module.

[0005] The present invention further provides an electric vehicle comprising a vehicle body, a seat, and an integrated battery pack attached to the vehicle body, with the seat attached to its case. [Effects of the Invention]

[0006] The beneficial effects of this application are as follows: Multiple support members are provided between the battery module and the top of the case. These support members provide support to the case, allowing the weight of the seat and occupant to be uniformly distributed throughout the battery module. This prevents the weight of the seat and occupant from concentrating at the connection point between the seat and the case or in the occupant's foot area. Providing support members enhances the structural strength and rigidity of the entire integrated battery pack, which is advantageous in preventing deformation and twisting of the vehicle. At the same time, the support members cover the pressure relief valve of the battery module, providing isolation from high-temperature materials in the event of thermal runaway of the battery module. This reduces the thermal impact on the top of the case, which is advantageous in preventing the occupant cabin from being affected by the heat of high-temperature materials. [Brief explanation of the drawing]

[0007] [Figure 1] This is an exploded view of an integrated battery pack relating to several realization forms of the present invention. [Figure 2] This is a cross-sectional view of an integrated battery pack according to one of the realization embodiments of the present invention, after a sheet has been attached. [Figure 3] This is a partial cross-sectional view of an integrated battery pack according to one of the realization embodiments of the present invention, after a sheet has been attached. [Figure 4] This is a magnified view of area A in Figure 3. [Figure 5] This is a schematic diagram showing a case lid with a sheet attached, according to several realization forms of the present invention. [Figure 6] This is a schematic diagram of a battery module relating to several realization forms of the present invention. [Figure 7] This is a magnified view of area B in Figure 6. [Figure 8]This is an exploded view of a battery module relating to several realization forms of the present invention. [Figure 9] This is a cross-sectional view of a first support member relating to several realization embodiments of the present invention. [Figure 10] This is a cross-sectional view of a second support member relating to several realization embodiments of the present invention. [Figure 11] This is a schematic diagram of a third support member relating to several realization forms of the present invention. [Figure 12] This is a schematic diagram of a temperature sensor according to several realization embodiments of the present invention. [Modes for carrying out the invention]

[0008] The technical proposal of this application will be described below with reference to the drawings, illustrating specific embodiments.

[0009] As shown in Figures 1 to 5, the integrated battery pack according to the present invention comprises a case 1, a battery module 2, and support members 3. The case 1 has a rectangular parallelepiped structure, with its length in the illustrated X direction, its width in the illustrated Y direction, and its height in the illustrated Z direction. The case 1 has a hollow structure and contains a housing chamber inside. The battery module 2 is installed in the housing chamber and has a pressure relief valve 26 at its top. If the battery module 2 experiences thermal runaway, the pressure relief valve 26 opens, releasing high-temperature gas and other substances (e.g., electrolyte) from inside the battery module 2. There are multiple support members 3, which are spaced apart at the top of the battery module 2 and interposed between the battery module 2 and the case 1. The support members 3 may be understood as having a first surface in contact with the battery module 2 and a second surface in contact with the top chamber wall of the housing chamber. At least a portion of the support member 3 covers the pressure relief valve 26; that is, a 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 surrounds the space between the support member 3 located at the pressure relief valve 26 and the battery module 2. If the battery module 2 experiences thermal runaway, high-temperature gases 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] The integrated battery pack is applied to CTV electric vehicles, meaning the vehicle adopts an integrated design, and the top of case 1 is used as the bottom of the vehicle's passenger cabin. The weight of the seat 7 and the passenger in the passenger cabin acts directly on case 1. Multiple support members 3 are provided between the battery module 2 and the top of case 1, and the support members 3 provide support to case 1. As a result, the gravity of the seat 7 and the passenger can be uniformly transmitted to the entire battery module 2 by the support members 3, preventing the gravity of the seat 7 and the passenger from concentrating at the connection point between the seat 7 and case 1 or in the passenger's foot area. Providing the support members 3 increases the structural strength and rigidity of the entire integrated battery pack, which is advantageous in preventing deformation and twisting of the vehicle. At the same time, the support members 3 cover the pressure relief valve 26 of the battery module 2, and in the event of thermal runaway of the battery module 2, they provide isolation from high-temperature materials, thereby reducing the thermal impact on the top of case 1 and preventing the passenger cabin from being affected by the heat of high-temperature materials.

[0011] Case 1 comprises a case bottom 11 and a case lid 12. To increase the overall structural strength of Case 1, the case bottom 11 and the case lid 12 are press-molded as a single unit. 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 its periphery. The first folded-up structure 112 surrounds the groove 111 and is flush with the groove opening of the groove 111. The case lid 12 comprises a lid body 121 and a mounting bracket 123. The lid body 121 has a structure similar to that of the case bottom 11, and a second folded-up structure 122 formed around its periphery that fits into the first folded-up structure 112. The lid body 121 and the case bottom 11 are placed together and connected and fixed with fastening members (e.g., screws, bolts, rivets, etc.). The fastening members are inserted into the first folded-up structure 112 and the second folded-up structure 122. A housing chamber is formed between the lid body 121 and the case bottom 11, configured for mounting the battery module 2. The mounting brackets 123 are configured for mounting the seat 7 and there are multiple brackets, and to accommodate the structural dimensions and mounting position of the seat 7, the multiple mounting brackets 123 may include at least two mounting brackets 123 with different shapes and dimensions. The multiple mounting brackets 123 are provided on one side of the lid body 121 that is separated from the case bottom 11, i.e., the mounting brackets 123 are provided at the top of the case 1. In this embodiment, the mounting brackets 123 and the lid body 121 are press-molded integrally. It can be understood that the case lid 12 of the case 1 forms the bottom of the occupant cabin, and gravity from both the seat 7 and the occupant 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 evenly distributes the gravitational force from the seat 7 and the occupant to the entire integrated battery pack, thereby preventing deformation, twisting, and other problems of the integrated battery pack caused by the concentration of localized forces.

[0012] The integrated battery pack further includes a liquid cooling plate 6. The liquid cooling plate 6 may employ a liquid cooling plate from related technologies, and can dissipate heat from the battery module 2 by a cooling liquid that circulates and flows inside. The liquid cooling plate 6 is provided at the bottom of the housing chamber, that is, it is attached to the bottom of the groove 111 of the case bottom 11. The battery module 2 is attached to the liquid cooling plate 6, and heat exchange is possible between the two. A foamed adhesive layer 4 is formed by filling the space between the side wall of the battery module 2 and the chamber wall of the housing chamber. A foamed adhesive layer 5 is formed by filling the space between the liquid cooling plate 6 and the bottom of the housing chamber. The side foamed adhesive layer 4 and the bottom foamed adhesive layer 5 act as buffers and absorb energy, preventing damage to the battery module 2 and liquid cooling plate 6 from collisions that occur when the bottom of the electric vehicle is in motion. At the same time, by filling with foam adhesive, the gaps between the battery module 2 and the case 1, and between the liquid cooling plate 6 and the case 1 are eliminated, forming the entire integrated battery pack as a single unit and increasing the overall strength and rigidity of the integrated battery pack. In some embodiments, 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] Preferably, as shown in Figure 12, a plurality of temperature sensors 10 are provided at intervals between the battery module 2 and the liquid cooling plate 6, and the temperature sensors 10 are configured to detect the temperature of the battery module 2. The temperature sensors 10 monitor the temperature change of the battery module 2 to intervene in a timely manner when the temperature of the battery module 2 is abnormal and to ensure the safety of the integrated battery pack.

[0014] Preferably, the integrated battery pack further comprises a Battery Management System (BMS) component 8. The BMS component 8 is provided on the battery module 2 and is 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 the relevant technology and be configured to provide the battery module 2 with protection such as undervoltage protection, temperature anomaly protection, and charge / discharge overcurrent protection.

[0015] Referring to Figures 6 to 8, the battery module 2 comprises a plurality of battery sets arranged sequentially along a first direction (the Y direction shown), and each battery set comprises a plurality of single cells 21 arranged sequentially along a second direction (the X direction shown). The first direction is perpendicular to the second direction, and in this embodiment, the plurality of battery sets are arranged sequentially along the width direction of the case 1, and the plurality of single cells 21 in each battery set are arranged sequentially along the length direction of the case 1. The single cells 21 are prismatic batteries with their thickness direction in the X direction shown. The plurality of support members 3 are distributed parallel to each other and spaced apart, and their length direction is parallel to the length direction of the case 1, so that one of the support members 3 can uniformly distribute the gravity from the seat 7 and the occupant to the plurality of single cells 21. Structural adhesive 9 is filled between two adjacent single cells 21. By filling with structural adhesive 9, the gaps between adjacent cell units 21 are eliminated, and all cell units 21 can be formed into a single integrated unit, thereby increasing the overall structural strength of the battery module 2 and ensuring that the entire battery module 2 is used to withstand the pressure from the case lid 12.

[0016] Inside Case 1, a plurality of battery modules 2 are sequentially arranged along the width direction of Case 1. In this embodiment, the number of battery modules 2 is two, and the two battery modules 2 are provided at intervals along the width direction of Case 1, and a structural adhesive 9 is filled 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. Among them, the CCS component 22 is connected to the electrode post of the single cell 21 and is configured to collect data such as the voltage and temperature of the single cell 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 to perform an insulating and protecting function. Two end plates 24 are provided corresponding to each battery pack, and the two end plates 24 are distributed at intervals along the length direction of Case 1, and the plurality of single cells 21 in the battery pack are interposed between the two end plates 24. A buffer sheet 25 is interposed between the end plate 24 and the inner wall of Case 1. The buffer sheet 25 is made of foam and serves to buffer and absorb energy. The CCS component 22 includes a plurality of terminal blocks. At the top of the entire battery module 2, a plurality of rows of positive electrode posts and negative electrode posts are distributed. One terminal block is provided corresponding to each row of positive electrode posts or each row of negative electrode posts. The terminal block is connected to the corresponding positive electrode post or negative electrode post. The plurality of terminal blocks are arranged at intervals along the width direction of Case 1, and there is a gap between two adjacent terminal blocks.

[0017] Since the top of the battery module 2 has a different structure depending on its position / area, the multiple support members 3 are also made with correspondingly different structures to adapt to the mounting space. One side of the support member 3 facing the battery module 2 is provided with a housing groove configured to accommodate the CCS component 22. The CCS component 22 is located within the housing groove of the support member 3, thereby preventing the top of the case 1 from being directly pressed against the CCS component 22 and further ensuring a secure connection between the CCS component 22 and the pole column. In this embodiment, the support member 3 comprises a first support member 31, a second support member 32, and a third support member 33. Of these, the first support member 31 is provided at both ends along the first direction (width direction of the case 1) of the battery module 2. The second support member 32 is provided above the pressure relief valve 26. The third support member 33 is provided at adjacent locations of two adjacent battery sets. To ensure the robustness of the mounting of the support member 3, the second and first surfaces of the support member 3 are adhesively fixed to the case 1 and the battery module 2, respectively. Specifically, 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 structural adhesive 9, and the second surface is adhesively fixed to the inner wall of the case lid 12 with structural adhesive 9.

[0018] Referring to what is shown in FIG. 9, the first support member 31 includes a main support block 311 and a sub-support block 312. The corresponding accommodation groove in the first support member is the first accommodation groove 313. On one side of the main support block 311 facing the battery module 2, a first adhesive groove 314 is provided. The sub-support block 312 is provided on one side of the main support block 311 away from the battery module 2. The sub-support block 312 has a first end connected to the main support block 311 and a second end that is a free end, and the free end extends in a direction away from the main support block 311 along the first direction. The sub-support block 312 is provided perpendicular to the main support block 311, and the first accommodation groove 313 is surrounded between the main support block 311 and the sub-support block 312, and it may be understood that the first accommodation groove 313 is configured to accommodate the CCS component 22 and the insulating plate 23. During installation, the side of the main support block 311 having the first adhesive groove 314 abuts against the shell of the single battery 21 and is adhesively fixed by the structural adhesive 9. The second surface of the main support block 311 and / or the second surface of the sub-support block 312 abut against the inner wall of the case lid 12 and are adhesively fixed by the structural adhesive 9. The first accommodation groove 313 is configured to avoid the CCS component 22 and the insulating plate 23 close to the first support member 31. In this embodiment, since the CCS component is located below the sub-support block 312, it is possible to avoid the pressure from the case lid 12 directly acting on the CCS component 22 and the pole post, and further avoid the circuit connection area of the battery module 2 being broken or deformed by an external force. In some embodiments, the main support block 311 may be higher than the sub-support block 312, or the main support block 311 may be lower than the sub-support block 312. With this structure, the main support block 311 and the sub-support block 312 are not located in the same plane, whereby a gap for accommodating a sufficient amount of the structural adhesive 9 is formed between the main support block 311 or the sub-support block 312 and the case lid 12, and the adhesive strength between the first support member 31 and the case lid 12 is increased.

[0019] Referring to Figure 10, the second support member 32 comprises a first support block 321 and two second support blocks 322. The corresponding accommodating groove in the second support member 32 is the second accommodating 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, and the second adhesive groove 325 is configured to accommodate structural adhesive 9, thereby firmly bonding the second support member 32 and the case lid 12. Along the width direction of the second support blocks 322 (i.e., the width direction of the case 1), the two second support blocks 322 are spaced apart on one side of the first support block 321 facing the battery module 2. Furthermore, the second support blocks 322 are spaced apart from the end of the first support block 321 along the width direction. A pressure relief passage 323 is enclosed between the first support block 321 and the two second support blocks 322. A second housing groove 324 is enclosed between the first support block 321 and each of the two second support blocks 322, and the second housing groove 324 is configured to accommodate the CCS component 22 and the insulating plate 23. When installed, one side 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 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 enclosed between the first support block 321, the two second support blocks 322 and the cell 21. The second housing groove 324 is configured to retract the CCS component 22 and the insulating plate 23 that are closer to the second support member 32. In this embodiment, since the CCS component 22 is located below the first support block 321, pressure from the case lid 12 is prevented from directly acting on the CCS component 22 and the pole column, and furthermore, the circuit connection area of ​​the battery module 2 is prevented from being subjected to external forces, preventing it from breaking or deforming.

[0020] Referring to Figure 11, the third support member 33 comprises a third support block 331 and a fourth support block 332. The corresponding receiving groove in the third support member 33 is the 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, configured to contain structural adhesive 9, thereby firmly bonding the third support block 331 to 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 may be provided on one side of the fourth support block 332 that is separated from the third support block 331, for containing a sufficient amount of structural adhesive 9. Along the width direction of the third support block 331 (i.e., the width direction of the case 1), the fourth support block 332 is positioned in the middle of the third support block 331 and spaced apart from the end of the third support block 331 along its width direction. A third housing groove 333 is enclosed between the ends of the third support block 331 along its width direction (first direction) and the fourth support block 332. The third housing groove 333 is configured to accommodate the CCS component 22 and insulating plate 23 that are close to the third support member 33. In this embodiment, the third support member 33 is attached to the connection point of two adjacent battery sets. When attached, one side of the third support block 331 having the third adhesive groove is bonded to the inner wall of the case lid 12, and the fourth support block 332 abuts against and is bonded to the shells of the single 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 directly acting on the CCS component 22 and the pole column, and furthermore, the circuit connection area of ​​the battery module 2 is prevented from being subjected to external forces and breaking or deforming.

[0021] In actual applications, the number and position of the support members 3 can be rationally selected according to the specific structural dimensions of the single cell 21.

[0022] As shown in Figures 1, 2, and 5, an electric vehicle comprising a vehicle body, a seat 7, and an integrated battery pack is further provided. The vehicle structure is simplified because the integrated battery pack is mounted on the vehicle body, and the top of its case 1 (i.e., the case lid 12) is simultaneously used as the bottom of the passenger cabin of the vehicle body. The seat 7 is attached to mounting brackets 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 is equipped with a support member 3, and the pressure from the case lid 12 is uniformly distributed throughout the integrated battery pack by the support member 3, thereby avoiding deformation, twisting, etc. of the integrated battery pack due to the concentration of applied force, and improving the safety performance of the integrated battery pack.

[0023] In this embodiment, multiple support members 3 are provided between the battery module 2 and the top of the case 1. The support members 3 provide support to the case 1, allowing the gravity of the seat 7 and the occupant to be uniformly transmitted to the entire battery module 2 by the support members 3. This prevents the gravity of the seat 7 and the occupant from concentrating at the connection point between the seat 7 and the case 1 or in the occupant's foot area. Providing the support members 3 enhances the structural strength and rigidity of the entire integrated battery pack, which is advantageous in preventing deformation and twisting of the vehicle. At the same time, the support members 3 cover the pressure relief valve 26 of the battery module 2, and in the event of thermal runaway of the battery module 2, they provide isolation from high-temperature materials. This reduces the thermal impact on the top of the case 1, which is advantageous in preventing the occupant cabin from being affected by the thermal impact of high-temperature materials. [Explanation of symbols]

[0024] 1 case 11. Case bottom 111... recessed groove 112...First folding structure 12...Case lid 121...Lid body 122...Second folding structure 123... Mounting bracket 2. Battery Module 21... Single cell 22.. CCS Components 23...Insulating board 24...end plate 25... cushioning sheet 26. Pressure relief valve 3. Support member 31. First support member 311... Main support block 312... Auxiliary support block 313...First storage trench 314...First adhesive groove 32...Second support member 321...First support block 322...Second support block 323... Pressure relief passage 324...Second storage trench 325...Second adhesive groove 33. Third support member 331...Third support block 332...4th support block 333...Third containment trench 4. Side foam adhesive layer 5. Bottom foam adhesive layer 6...liquid cooling plate 7 seats 8. BMS Component 9. Structural adhesives 10. Temperature sensor

Claims

1. The device comprises a case with an internal housing chamber, a battery module installed in the housing chamber and having a pressure relief valve at its top, and a plurality of support members spaced apart at the top of the battery module and interposed between the battery module and the case, wherein at least some of the support members cover the pressure relief valve, and a pressure relief passage is formed so as to be surrounded by the support members located at the pressure relief valve and the battery module. The battery module comprises a plurality of battery sets arranged sequentially along a first direction, and each of the battery sets comprises a plurality of single cells arranged sequentially along a second direction perpendicular to the first direction. The support member comprises a second support member, the second support member covering the pressure relief valve, the second support member comprising a first support block connected to the case, and two second support blocks spaced apart on one side of the first support block facing the battery module and connected to the battery module, the pressure relief passage is formed so as to be surrounded by the first support block, the two second support blocks and the single cell, and a second housing groove is formed so as to be surrounded by both ends of the first support block along the first direction and each of the two second support blocks, The battery module further comprises a cell contact system (CCS) component, and the second housing groove is configured to house the CCS component. Integrated battery pack.

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

3. The support members are configured in at least one of the following cases: when the support members are provided at both ends of the battery module along the first direction, and when the support members are provided at adjacent locations of two adjacent battery sets. The integrated battery pack according to claim 1.

4. The CCS component is connected to the pole of the single cell, The integrated battery pack according to claim 3.

5. When the support members are provided at both ends of the battery module along the first direction, the plurality of support members further comprises first support members provided at both ends of the battery module along the first direction, the first support member comprising a main support block and a sub-support block provided on one side of the main support block away from the battery module, and whose free end extends in a direction away from the main support block along the first direction, and a first housing groove is formed so as to be surrounded by the main support block and the sub-support block. The integrated battery pack according to claim 4.

6. When the plurality of support members are provided at adjacent locations of two adjacent battery assemblies, the plurality of support members further comprises a third support member provided at the connection location of the two adjacent battery assemblies, the third support member comprising 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, the third housing groove formed at both ends of the third support block along the first direction so as to be surrounded by the fourth support block. The integrated battery pack according to claim 4.

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

8. The housing chamber is further provided with a liquid cooling plate at the bottom to which the battery module is attached, and at least one of the following is filled with foam adhesive: between the battery module and the chamber wall of the housing chamber, and between the liquid cooling plate and the bottom of the housing chamber. An integrated battery pack according to any one of claims 1 to 7.

9. Multiple temperature sensors, configured to detect the temperature of the battery module, are provided at intervals between the battery module and the liquid cooling plate. The integrated battery pack according to claim 8.

10. The top of the case is provided with a mounting bracket configured to attach a seat. The integrated battery pack according to claim 1.

11. The vehicle comprises a vehicle body, a seat, and an integrated battery pack according to claim 1, which is attached to the vehicle body and has the seat attached to its case. Electric vehicle.

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