High-efficiency battery module protection frame

Abstract

This invention proposes a high-efficiency battery module protection frame for housing a battery module, and the protection frame has good heat dissipation and insulation characteristics. The protection frame includes: a vertical frame, wherein the vertical frame forms a shape that surrounds the battery module on its sides in the longitudinal direction; an upper partition is disposed above the vertical frame; and a lower partition is disposed below the vertical frame; wherein the vertical frame, the upper partition, and the lower partition form a box including the sides and top and bottom edges for accommodating the battery module. The vertical frame includes a front panel, a rear panel, a left panel, and a right panel; these panels are connected to form a rectangular vertical frame; wherein the left panel and the right panel have ventilation holes, allowing air to enter through the ventilation holes of one panel and exit through the ventilation holes of the other panel.

Description

High-efficiency battery module protection frame Technical Field

[0001] This work relates to battery protection frames, especially a high-efficiency battery module protection frame. Prior Technology

[0002] Existing battery module protective frames are mostly made of metal or single resin materials to provide structural support and insulation. However, while metal materials have good thermal conductivity, they are prone to localized overheating or short circuits in battery module applications. Furthermore, metal is difficult to process and heavy, making it unsuitable for portable or automotive applications. Resin or plastic materials, while possessing insulation and corrosion resistance, generally have low thermal conductivity, causing heat buildup in battery modules during prolonged operation, thus affecting lifespan and safety. Since traditional frame materials are mostly single-component, it is difficult to balance high strength, insulation, and heat dissipation performance. For example, while epoxy resin is commonly used in battery encapsulation, its poor thermal conductivity and flammability make it insufficient for the safety requirements of high-power-density modules. Moreover, if a metal frame is chosen to improve heat dissipation, it inevitably increases the module weight, forcing a trade-off between lightweight design and structural strength, making it impossible to achieve both simultaneously. In summary, existing technologies still have shortcomings in material selection and heat dissipation structure design, failing to simultaneously meet the requirements of efficient heat dissipation, lightweight, insulation, and safety, and urgently need improvement.

[0003] Based on its extensive experience with battery module materials, the applicant in this case aims to propose a novel battery module protection frame design with excellent heat dissipation and insulation properties, ensuring the stable and safe operation of the battery modules housed within. Summary of the Invention

[0004] Therefore, the purpose of this application is to solve the aforementioned problems in the prior art. This application proposes a high-efficiency battery module protective frame made of a composite material formed from epoxy resin, graphene, and boron nitride. This material possesses high mechanical strength, good insulation, and excellent thermal conductivity, overcoming the shortcomings of insufficient thermal conductivity in traditional resin materials and avoiding safety concerns caused by the excessive weight and electrical conductivity of metal frames. Furthermore, this application incorporates numerous regularly arranged protruding parts and recessed air channels on the inner surface of the frame, effectively increasing the contact area and guiding airflow. Combined with a fan located on the outside of the frame, this forms a highly efficient heat dissipation channel, significantly improving the heat dissipation speed and ensuring the battery module remains stable during long-term operation. In addition, the upper and lower separators are made of aerogel and graphene composite materials, which are not only lightweight and resistant to deformation but also further enhance heat dissipation performance. This simultaneously meets the requirements for heat dissipation, insulation, lightweighting, and structural strength, demonstrating a significant improvement over existing technologies and effectively enhancing the safety and reliability of the battery module.

[0005] To achieve the above objectives, this invention proposes a high-efficiency battery module protection frame for housing a battery module, and the protection frame has good heat dissipation and insulation characteristics. The protection frame includes: a vertical frame, wherein the vertical frame forms a shape that surrounds the battery module on its sides in the longitudinal direction; an upper partition is disposed above the vertical frame; and a lower partition is disposed below the vertical frame; wherein the vertical frame, the upper partition, and the lower partition form a box including the sides and the top and bottom edges for accommodating the battery module. The vertical frame includes a front panel, a rear panel, a left panel, and a right panel; these panels are connected to form a rectangular vertical frame; wherein the left panel and the right panel have ventilation holes, allowing air to enter through the ventilation holes of one panel and exit through the ventilation openings of the other panel.

[0006] The features and advantages of this case will be further understood from the following description; please refer to the accompanying drawings while reading. Simple Explanation of the Diagram

[0007] Figure 1 shows the structure of the protective frame and the battery module in this case.

[0008] Figure 2 shows the configuration of the inner protrusion and air duct on the inner surface of the vertical frame and the outer protrusion and air duct on the outer surface of the vertical frame in this case.

[0009] Figure 3 shows the asymmetrical cross-section of the inner protrusion and the outer protrusion of a panel of the vertical frame in this case.

[0010] Figure 4 shows that the multiple fans in this case are arranged on the left and right sides of the protective frame.

[0011] Figure 5 shows that the front panel and the rear panel of this case have ventilation holes.

[0012] Figure 6 shows the structure and leads of the battery module in this case.

[0013] Figure 7 shows a schematic diagram of the connection between the BMS module and the inverter in this case.

[0014] Figure 8 shows a cross-section of a panel of the vertical frame in this case coated with the heat-dissipating adhesive. Implementation

[0015] The following is a detailed description of a preferred embodiment of this invention, including its structural components, effects, and advantages, with reference to the accompanying drawings. The scale of the drawings is for illustrative purposes only and is not intended to limit the scope of this invention.

[0016] This invention proposes a protective frame 100 for a high-efficiency battery module, used to house a battery module 30. The protective frame 100 possesses excellent heat dissipation and insulation characteristics, ensuring the stable and safe operation of the battery module 30 housed within. As shown in Figure 1, the protective frame 100 includes the following components:

[0017] A vertical frame 10 is formed, which longitudinally surrounds the battery module 30 on its sides, for enclosing the internal battery module 30. In this case, the vertical frame 10 includes a front panel 12, a rear panel 14, a left panel 16, and a right panel 18; these panels are connected to form a rectangular vertical frame. The left panel 16 and the right panel 18 have ventilation holes, allowing air to enter through the ventilation holes of one panel and exit through the ventilation holes of the other panel.

[0018] The vertical frame 10 is made of a mixture of epoxy resin, graphene, and boron nitride. Epoxy resin is a thermosetting plastic with good mechanical properties, electrical insulation, corrosion resistance, and dimensional stability. However, epoxy resin itself has poor thermal conductivity and is easily flammable. Boron nitride has excellent thermal conductivity, electrical insulation, and high-temperature stability. In addition, graphene is a two-dimensional material with extremely high thermal and electrical conductivity. Therefore, the mixture formed by adding boron nitride and graphene to epoxy resin improves its thermal conductivity, enhances its mechanical properties, and also has good high-temperature thermal conductivity, comparable to that of aluminum. The weight ratio of epoxy resin to graphene to boron nitride is 85~90:1~3:7~9.

[0019] Preferably, at least one inner surface of the vertical frame 10 forms a plurality of inner protrusions A, the purpose of which is that the inner protrusions A on the inner surface can contact the battery module 30 and the mounting components of the battery module 30 installed inside, so as to achieve rapid heat dissipation.

[0020] Preferably, the inner protrusions A on at least one inner surface of the vertical frame 10 form a regular pattern, such as a honeycomb shape, and the inner recesses B between the inner protrusions A form air ducts (Fig. 2). These air ducts extend from the left side to the right side of the inner surface, thus guiding the air from the left side to the right side, which helps with the overall heat dissipation.

[0021] Preferably, at least one outer surface of the vertical frame 10 forms a plurality of protruding portions C, the purpose of which is that the protruding portions C on the inner surface can contact the battery housing installed on the outside, so as to achieve the purpose of rapid heat dissipation.

[0022] Preferably, the protruding portions C on at least one outer surface of the vertical frame 10 form a regular pattern, such as a honeycomb shape, and the recessed portions D between the protruding portions C form air ducts (Fig. 2). These air ducts extend from the left side to the right side of the outer surface, thus guiding the air from the left side to the right side, which helps with the overall heat dissipation.

[0023] Preferably, at least one inner surface of the vertical frame 10 forms a plurality of inner protrusions A and at least one outer surface of the vertical frame 10 forms an outer protrusion C, forming an asymmetrical shape to increase the heat dissipation effect of the vertical frame 10. Please refer to Figure 3 for a cross-section of one panel of the vertical frame 10.

[0024] An upper partition 22 is positioned above the vertical frame 10 (Figure 1).

[0025] A partition 24 is positioned below the vertical frame 10 (Figure 1).

[0026] The upper partition 22 and lower partition 24 are constructed using a mixture of aerogel and graphene, thus achieving excellent heat dissipation. Aerogel is a highly porous and extremely low-density solid material with very low thermal conductivity, making it commonly used for thermal insulation. However, when aerogel is combined with graphene, which has extremely high thermal conductivity, the graphene forms a continuous network of heat-conducting channels within the aerogel structure, significantly improving the overall thermal conductivity. Simultaneously, the high porosity of the aerogel itself promotes air convection and heat release, resulting in a composite material that not only has excellent thermal conductivity but also possesses the advantages of being lightweight and resistant to deformation, making it a highly efficient heat dissipation material. The weight ratio of the aerogel to the graphene is between 8:1 and 15:1.

[0027] The vertical frame 10, the upper partition 22, and the lower partition 24 form a box including the sides and the top and bottom edges, which is used to house the battery module 30 and serve as the encapsulation of the battery module 30.

[0028] This invention also includes multiple fans 40 for battery cooling. These fans 40 are respectively located on the left and right sides of the protective frame 100 (Figure 4), thus guiding airflow 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. This configuration forms the airflow channel shown in Figure 1. Furthermore, the protruding portions on the vertical frame 10 effectively conduct the heat dissipated by the battery in the battery module 30 away.

[0029] Preferably, ventilation holes are formed on the front panel 12 and the rear panel 14 (Figure 5), so that some air can also flow out through the ventilation holes on the front panel 12 and the rear panel 14, thus increasing the overall heat dissipation effect.

[0030] Figure 6 shows the configuration of the battery module 30, which consists of two battery layers arranged in an array. Each layer forms a 6x8 configuration, with six batteries connected in series as a unit. The positive and negative leads of each battery unit are then extended, and all positive and negative leads of these battery units are connected in series to the next-level device. The positive and negative leads from each battery can be designed in different shapes to meet the needs of the external application and are routed to the next-level device using a ribbon cable configuration.

[0031] This case also includes a BMS (Battery Management System) module 50, which is used to connect to the positive and negative terminals of the battery installed inside the protective frame 100, and then perform necessary processing on the current and voltage from the battery to achieve the effect of controlling each battery.

[0032] Figure 6 shows the connection of the positive and negative leads from the battery module 30 to the input terminal of the BMS module 50.

[0033] As shown in Figure 7, in this case, an inverter 60 can be connected in series at the back end of the BMS module 50 as needed to convert the current from the BMS module 50 to AC and transmit the power from the battery to the rear components in AC form; or to convert the external power to DC and convert the external AC power to DC power to charge the battery module 30.

[0034] Preferably, at least one surface of the vertical frame 10 is coated with a thermal colloid 70 to increase heat dissipation and prevent electromagnetic interference. Refer to Figure 8 for a cross-section of one panel of the vertical frame 10 coated with the thermal colloid 70. Preferably, all surfaces of the vertical frame 10 are coated with the thermal colloid 70.

[0035] Preferably, at least one surface of the vertical frame 10, the upper partition 22, and the lower partition 24 is coated with the thermal colloid 70 for heat dissipation and prevention of electromagnetic interference (EMI). Preferably, all surfaces of the vertical frame 10, the upper partition 22, and the lower partition 24 are coated with the thermal colloid 70.

[0036] The heat dissipation colloid 70 is a mixture of deionized water, ethanol, propylene glycol, N-methylpyrrolidone (NMP), polyurethane (PU), polyvinylpyrrolidone (PVP), graphene, boron nitride, alumina (Al2O3), lanthanum phosphate (LaPO4), and lanthanum phosphate coated with PDMS (PDMS@LaPO4).

[0037] In this application, deionized water, ethanol, propylene glycol, NMP, PU, ​​and PVP are first mixed to form a colloidal matrix. Then, a solid mixture of graphene, boron nitride, aluminum oxide, LaPO4, and PDMS@LaPO4 is dispersed in the colloidal matrix to form a solution, which is then sprayed onto a portion of at least one side of the vertical frame 10, the upper partition 22, and the lower partition 24. After drying, most of the components of the solution evaporate, leaving the heat-dissipating colloid 70 formed by the solid mixture. Preferably, the thickness of the remaining heat-dissipating colloid 70 is between 1 and 5 μm.

[0038] The solid component constitutes 0.5–2.2 wt% of the solution.

[0039] The weight ratio of the deionized water to the ethanol is 1:3 to 1:7.

[0040] The weight ratio of the deionized water to the propylene glycol is 1:0.1 to 1:0.3.

[0041] The weight ratio of the deionized water to the NMP is 2:1 to 3:1;

[0042] The weight ratio of the PVP to the PU is 1:1 to 1:5;

[0043] The total weight of the PVP and PU accounts for 1-5 wt% of the solution.

[0044] The graphene accounts for 0.2~0.7 wt% of the weight of the solution;

[0045] The weight ratio of graphene to boron nitride is 1:2~8;

[0046] The weight ratio of the graphene to the total weight of LaPO4 and PDMS@LaPO4 is 1:2~10;

[0047] The weight ratio of the total weight of LaPO4 and PDMS@LaPO4 to the weight of alumina is 5:2~5;

[0048] The weight ratio of LaPO4 to PDMS@LaPO4 is 1:3~5.

[0049] The LaPO4 particles in the LaPO4 have a size of 20 to 150 nanometers; the LaPO4 particles in the PDMS@LaPO4 have a size of 20 to 150 nanometers, and the thickness of the PDMS surrounding the LaPO4 is less than 10 nanometers; the alumina particles in the alumina have a size of 20 to 50 nanometers.

[0050] In this heat-dissipating colloid 70, the PU is a polymer matrix that provides 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 overall coating.

[0051] The PVP is an interface modifier with high polarity and good solubility. It can promote the uniform dispersion of alumina, boron nitride and graphene in PU, and improve the structural uniformity and overall thermal and electrical conductivity stability.

[0052] This graphene is both a conductive and thermally conductive material, playing a crucial role in both EMI suppression and thermal conduction. Graphene possesses extremely high electron mobility and conductivity, and can reflect and absorb incident electromagnetic waves, thereby reducing EMI interference. Simultaneously, its high thermal conductivity allows it to rapidly conduct heat generated by electromagnetic absorption or component operation along a planar direction.

[0053] The alumina is a thermally conductive material with good thermal conductivity and electrical insulation. It is responsible for connecting the graphene to form a continuous thermally conductive path, thereby effectively improving the overall thermal conductivity. Preferably, the alumina is γ-alumina (γ-Al2O3), which has high thermal conductivity and dispersion stability.

[0054] Boron nitride, a thermally conductive material, is dispersed within the colloidal matrix, further improving overall thermal conductivity and heat distribution uniformity. This boron nitride exhibits high thermal conductivity and excellent chemical stability, forming multidirectional thermal conduction channels within the PU layer to facilitate rapid heat transfer from the interior to the outer surface.

[0055] The LaPO4 and LaPO4@PDMS are thermally radiative materials that enhance the far-infrared radiation capability of their surfaces, dissipating heat conducted to them through radiation and thus improving overall heat dissipation efficiency. The LaPO4 particles effectively absorb and radiate heat; the outer PDMS coating protects the LaPO4 from reaction with alkaline solvents and prevents the nanoparticles from agglomerating in high pH environments. Due to cost considerations, PDMS coating can significantly improve dispersibility and stability by coating only a portion of the particles. While LaPO4 itself does not generate heat, when external heat is transferred to its surface via thermally conductive materials, it effectively releases heat to the outside through radiation, achieving highly efficient heat dissipation.

[0056] The advantages of this design lie in the fact that the high-efficiency battery module protective frame is made of a composite material formed from epoxy resin, graphene, and boron nitride. This material possesses high mechanical strength, good insulation, and excellent thermal conductivity, overcoming the shortcomings of insufficient thermal conductivity in traditional resin materials and avoiding safety concerns caused by the excessive weight and electrical conductivity of metal frames. Furthermore, this design incorporates numerous regularly arranged protruding parts and recessed air channels on the inner surface of the frame, effectively increasing the contact area and guiding airflow. Combined with a fan located on the outside of the frame, this forms a highly efficient heat dissipation channel, significantly improving the heat dissipation speed and ensuring the battery module remains stable during long-term operation. In addition, the upper and lower separators are made of aerogel and graphene composite materials, which are not only lightweight and resistant to deformation but also further enhance heat dissipation performance. This simultaneously meets the requirements for heat dissipation, insulation, lightweighting, and structural strength, representing a significant improvement over existing technologies and effectively enhancing the safety and reliability of the battery module.

[0057] In conclusion, the human-centered and considerate design of this case is highly in line with actual needs. Its specific improvements over existing deficiencies represent a significant breakthrough compared to prior art, offering genuine functional enhancements that are not easily achieved. Furthermore, since this case has not been publicly disclosed or revealed in domestic or international literature or markets, it complies with patent law requirements. The above detailed description is a specific description of one feasible embodiment of this case. However, this embodiment is not intended to limit the scope of the patent in this case. All equivalent implementations or modifications that do not depart from the spirit of the technology in this case should be included in the scope of the patent in this case.

[0058] 10: Vertical frame

[0059] 12: Front Panel

[0060] 14: Rear Panel

[0061] 16: Left panel

[0062] 18: Right panel

[0063] 22: Upper partition

[0064] 24: Lower partition

[0065] 30: Battery Module

[0066] 40: Fan

[0067] 50: BMS (Battery Management System) Module

[0068] 60: Inverter

[0069] 70: Thermal colloid

[0070] 100: Protection Frame

[0071] A: Protruding part

[0072] B: Concave area

[0073] C: Protruding part

[0074] D: Outer concave part

Claims

1. A high-efficiency battery module protection frame for housing a battery module, wherein the protection frame has good heat dissipation and insulation characteristics; the protection frame comprises: a vertical frame, wherein the vertical frame forms a shape in which the sides surround the battery module in the longitudinal direction; an upper partition disposed above the vertical frame; and a lower partition disposed below the vertical frame; wherein the vertical frame, the upper partition, and the lower partition form a box including the sides and the upper and lower sides for accommodating the battery module.

2. The high-efficiency battery module protection frame as described in claim 1, wherein the vertical frame includes a front panel, a rear panel, a left panel and a right panel; these panels are connected to form a rectangular vertical frame; wherein the left panel and the right panel have ventilation holes, allowing air to enter through the ventilation holes of one panel and exit through the ventilation openings of the other panel.

3. The high-efficiency battery module protection frame as described in claim 1, wherein at least one inner surface of the vertical frame forms a plurality of protruding portions, the purpose of which is that the protruding portions of the inner surface can contact the battery module and the mounting components of the battery module installed inside, so as to achieve rapid heat dissipation; wherein the recessed portions between the protruding portions form air ducts, which extend from the left side to the right side of the inner surface, thus guiding the air from the left side to the right side, which helps the overall heat dissipation effect.

4. The high-efficiency battery module protection frame as described in claim 1, wherein at least one outer surface of the vertical frame forms a plurality of protruding portions; wherein the recessed portions between the protruding portions form air ducts that extend from the left side to the right side of the outer surface, thereby guiding the air from the left side to the right side, which helps the overall heat dissipation.

5. The high-efficiency battery module protection frame as described in claim 3, wherein the inner protrusion of at least one inner surface of the vertical frame is configured in a honeycomb shape.

6. The high-efficiency battery module protection frame as described in claim 4, wherein the protruding portion of at least one outer surface of the vertical frame is configured in a honeycomb shape.

7. The high-efficiency battery module protection frame as described in claim 3, wherein at least one outer surface of the vertical frame forms a plurality of protruding portions; the plurality of inner protruding portions on at least one inner surface of the vertical frame and the plurality of protruding portions on the outer surface form an asymmetrical shape to increase the heat dissipation effect of the vertical frame.

8. The high-efficiency battery module protection frame as described in claim 2, further comprising a plurality of fans for battery heat dissipation; the plurality of fans are respectively disposed on the left and right sides outside the protection frame.

9. The high-efficiency battery module protection frame as described in claim 1 further comprises: a BMS (Battery Management System) module for connecting the positive and negative terminals of the battery installed inside the protection frame; and an inverter connected to the BMS module for converting the current from the BMS module from DC to AC.

10. The high-efficiency battery module protection frame as described in claim 1, wherein at least one surface of the vertical frame, the upper separator, and the lower separator is coated with a heat-dissipating colloid, which increases heat dissipation capacity by means of thermal conduction and radiation.

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