High-voltage box and energy storage system

Abstract

Disclosed in the present application are a high-voltage box and an energy storage system. The high-voltage box comprises a box body, in which a battery management system and an electrical module are detachably installed, wherein the battery management system and the electrical module are arranged adjacent to each other and connected to each other; and the electrical module comprises a substrate and a plurality of electrical elements, the substrate is provided with a plurality of installation areas, the electrical elements are installed in the installation areas, the substrate is further provided with an adapter, the adapter is provided with a plurality of interfaces, and the interfaces are configured to be connected to the electrical elements and an external battery system.

Description

High-voltage box and energy storage system

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on March 14, 2024, application number 202420499394.9, and the entire contents of the above application are incorporated by reference into this application.

[0002] Technical Field

[0003] This application relates to the field of energy storage technology, and specifically to a high-voltage box and an energy storage system.

[0004] Background Art

[0005] The high-voltage box of the energy storage system is mainly configured to control the connection or disconnection of the main electrical circuit of the battery system, realize pre-charging, charging and discharging according to demand, and monitor the status of the battery system voltage, current, switches, contactors, etc. in real time.

[0006] Technical issues

[0007] The high-voltage box of the related technology has a battery management system and multiple electrical components installed inside. The battery management system and the multiple electrical components are connected by wiring harnesses or copper bars. However, due to the lack of effective division of the internal area of ​​the high-voltage box and the lack of modular design, the electrical components in the high-voltage box are arranged in a chaotic manner. During subsequent maintenance, a large number of wiring harnesses or devices need to be removed, which makes the operation cumbersome and inconvenient to repair.

[0008] Technical Solutions

[0009] In the first aspect, an embodiment of the present application provides a high-voltage box, comprising a box body, in which a battery management system and an electrical module are detachably installed, the battery management system and the electrical module are adjacently arranged and connected, the electrical module comprises a substrate and a plurality of electrical components, the substrate having a plurality of mounting areas, the mounting areas being installed with the electrical components, the substrate also being provided with an adapter connected to the battery management system, the adapter being provided with a plurality of interfaces, the plurality of interfaces being configured to be connected to the electrical components and an external battery system.

[0010] In a second aspect, an embodiment of the present application provides an energy storage system, comprising a battery system and the high-voltage box described above, wherein the battery system is connected to the high-voltage box.

[0011] Beneficial effects

[0012] The high-voltage box provided in this application integrates electrical components onto a baseboard to form a module that can be removably installed within the box. The adapter interface allows for quick connection between the electrical components and the external battery system and battery management system signals, enabling rapid installation and removal of the electrical module and facilitating replacement of the entire module. Furthermore, the baseboard divides the electrical components into multiple areas, enabling the positioning and installation of each component. This allows for a neat and reasonable arrangement of the electrical components, facilitates wiring and unwiring between them, and facilitates the replacement and maintenance of individual electrical components.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG1 is a partial schematic diagram of a high-voltage box according to an embodiment of the present application.

[0015] FIG2 is an exploded view of the assembly of the electrical module according to an embodiment of the present application.

[0016] FIG3 is a first perspective schematic diagram of a substrate according to an embodiment of the present application.

[0017] FIG4 is a second perspective schematic diagram of the substrate according to the embodiment of the present application.

[0018] In the picture:

[0019] 1. Box body; 11. Bottom plate;

[0020] 2. Electrical module; 21. Baseboard; 211. Mounting slot; 212. Reduction slot; 213. Glue overflow slot; 22. Electrical components; 221. Shunt; 222. First fuse; 223. Second fuse; 224. First high-voltage contactor; 225. Second high-voltage contactor; 226. Balancing relay; 227. Balancing resistor; 228. Adapter; 23. Liquid cooling plate; 24. Heat conducting plate; 25. Thermal insulation; 26. Temperature sensor; 27. Fixing parts; 28. Connecting parts.

[0021] Modes for Carrying Out the Invention

[0022] In the description of this application, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and can refer to internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0023] 1 and 2 , the present application provides a high-voltage box, comprising a box body 1, in which a battery management system and an electrical module 2 are detachably mounted. The battery management system and the electrical module 2 are adjacently arranged and connected. The electrical module 2 comprises a substrate 21 and a plurality of electrical components 22. The substrate 21 has a plurality of mounting areas. The upper surface of the substrate 21 is provided with a plurality of mounting areas, and the mounting areas are provided with electrical components 22 (in this embodiment, each mounting area is provided with an electrical component 22. In other embodiments, some mounting areas may be provided with electrical components 22, and some mounting areas may be used as spare areas for mounting other components without electrical components 22 mounted thereon). The substrate 21 is also provided with an adapter 228 for signal connection with the battery management system. The adapter 228 may be a terminal block. The adapter 228 is provided with interfaces, which are respectively configured to connect to the electrical components 22 and the external battery system. This design integrates electrical components 22 onto a substrate 21 to form an electrical module 2, and connects the electrical components 22 and the external battery system to the battery management system signals through an adapter 228, thereby enabling the battery management system to monitor the electrical components 22 and the external battery system in real time and control the power on and off of the electrical components 22 and the external battery system for protection. This design integrates electrical components 22 onto a substrate 21 to form an electrical module 2, and enables the electrical components 22 and the external battery system to be quickly connected to the battery management system signals through the interface of the adapter 228, which facilitates the installation and removal of the electrical module 2 and facilitates the replacement of the electrical module 2. In addition, the substrate 21 divides the electrical components 22 into multiple areas, which can be positioned and installed. On the one hand, it can arrange the electrical components 22 neatly and reasonably, facilitate the wiring and disconnection between the electrical components 22, and thus facilitate the replacement and maintenance of individual electrical components 22.

[0024] Exemplarily, referring to Figure 1, multiple electrical components 22 include a shunt 221, a first fuse 222, a second fuse 223, a first high-voltage contactor 224, and a second high-voltage contactor 225. The control circuit includes a positive circuit and a negative circuit. The negative circuit is connected to the negative terminal on the side wall of the high-voltage box, and the negative terminal is configured to be connected to the negative pole of the external battery system. The shunt 221, the first fuse 222 and the first high-voltage contactor 224 are connected in sequence to form a negative circuit. The second fuse 223 and the second high-voltage contactor 225 are connected in sequence to form a positive circuit. The positive circuit is connected to the positive terminal on the side wall of the high-voltage box, and the positive terminal is configured to be connected to the positive pole of the external battery system, so as to realize the electrical connection between the electrical module 2 and the external battery system.

[0025] In an optional embodiment, the electrical component 22 further includes a balancing relay 226 and a balancing resistor 227. The balancing relay 226 and the balancing resistor 227 are connected to form a balancing circuit, which is connected in parallel with the positive circuit. Exemplarily, the balancing circuit is connected in parallel with the second high-voltage contactor 225. During the charging and discharging process of the battery system, differences between individual cells can easily cause imbalances, seriously affecting the performance and service life of the battery system. By providing a balancing circuit, the balancing resistor 227 can be used to discharge the higher-voltage cells, releasing electricity as heat, thereby buying more charging time for other cells, thereby balancing the entire battery system.

[0026] Because the first fuse 222, the second fuse 223, and the balancing resistor 227 generate a significant amount of heat during normal use, temperature sensors 26 are optionally provided on the substrate 21 adjacent to the first fuse 222, adjacent to the second fuse 223, and adjacent to the balancing resistor 227. Temperature sensors 26, which may be thermistors, are connected to the battery management system. Temperature sensors 26 monitor temperature changes in the surrounding environment of the first fuse 222, the second fuse 223, and the balancing resistor 227, and transmit these temperature changes to the battery management system, enabling the battery management system to control the start and stop of the electrical module 2 based on the collected temperature changes.

[0027] 1 , to more clearly illustrate the connection between the electrical component 22 and the adapter 228, the bold dashed line in FIG1 represents the wiring path of the electrical component 22 and the adapter 228. Specifically, the temperature sensor 26, the first fuse 222, the second fuse 223, the first high-voltage contactor 224, the second high-voltage contactor 225, and the external battery system can be connected to the interface of the adapter 228 via signal lines, so that the battery management system can receive feedback signals from the temperature sensor 26, the first fuse 222, the second fuse 223, the first high-voltage contactor 224, the second high-voltage contactor 225, and the external battery system through the adapter 228, and send control signals to them.

[0028] Optionally, first connection holes are provided at intervals around the periphery of the substrate 21, and fixing nuts are welded to the bottom plate 11 of the box body 1. Fasteners pass through the first connection holes and are connected to the nuts to lock the substrate 21 in the box body 1, thereby realizing the detachable installation of the electrical module 2 in the box body 1.

[0029] Exemplarily, the substrate 21 is made of an insulating thermally conductive material, such as plastic, alumina ceramic, etc., to prevent short circuits between the electrical components 22. Exemplarily, the substrate 21 is integrally formed by plastic injection molding.

[0030] In an optional embodiment, referring to Figures 2 to 4 , each mounting area is provided with a mounting slot 211, and an electrical component 22 is disposed in each mounting slot 211. The mounting slots 211 can insulate and separate the electrical components 22 to prevent short circuits between the multiple electrical components 22 or provide better insulation for the electrical components 22.

[0031] Of course, in other optional embodiments, the upper surface of the substrate 21 is provided with multiple positioning marks (e.g., scribed lines) that divide the mounting surface of the substrate 21 into multiple mounting areas. This design, through the scribed lines, allows the mounting areas to be formed on the substrate 21 without increasing the thickness of the substrate 21, thereby reducing the volume of the electrical module 2 and improving the space utilization of the housing 1.

[0032] In an optional embodiment, referring to FIG3 , the base plate 21 is provided with a material reduction groove 212, which is spaced apart from the mounting groove 211. The provision of the material reduction groove 212 can reduce the material used in the base plate 21 to reduce costs, and can also reduce the weight of the base plate 21, thereby reducing the overall weight of the high-voltage box.

[0033] Furthermore, when the substrate 21 is injection molded from plastic and formed with multiple mounting grooves 211, if the groove wall thickness of the mounting grooves 211 is too large, during injection molding, the outer surface of the groove wall of the mounting groove 211 cools faster, while the center portion of the groove wall of the mounting groove 211 cools slower. Consequently, as cooling proceeds, the plastic in the center portion of the groove wall of the mounting groove 211 shrinks while expanding toward the outer surface, causing the center portion to be underfilled, thereby generating vacuum bubbles. This design, by providing the reduction grooves 212, helps reduce the thickness of the groove wall of the mounting groove 211, thereby reducing the occurrence of vacuum bubbles during the injection molding of the substrate 21, improving the injection molding quality while reducing the manufacturing difficulty.

[0034] Optionally, the material reduction trough 212 is provided with a fixing member 27, and the plurality of electrical components 22 are connected by a connector 28, which includes but is not limited to a copper bus, a wiring harness, etc., and the connector 28 is snapped onto the fixing member 27. Exemplarily, the fixing member 27 can be a wiring harness buckle, and the connector 28 can be a wiring harness. The wiring harness buckle can be snapped to limit the wiring harness to prevent the wiring harness from moving during vibration, causing friction between the connector 28 and the outer wall of the electrical component 22, or even damage.

[0035] For example, in this embodiment, high-voltage connections are achieved between the plurality of electrical components 22 through copper busbars, and low-voltage connections and signal connections are achieved between the plurality of electrical components 22 through wiring harnesses.

[0036] Because the electrical components 22 generate a large amount of heat during operation, the base plate 21 is further provided with a liquid cooling plate 23 and a heat conductor, as shown in FIG2 . The liquid cooling plate 23 is provided on the side of the base plate 21 facing away from the electrical components 22. In this embodiment, the liquid cooling plate 23 is provided on the lower surface of the base plate 21, and the heat conductor is connected to the electrical components 22 and the liquid cooling plate 23, respectively. The heat conductor can quickly transfer the heat generated by the electrical components 22 to the liquid cooling plate 23, and quickly dissipate the heat through the liquid cooling plate 23, preventing heat accumulation in the box body 1, helping to extend the service life of the electrical components 22 and ensure the stability and reliability of the high-voltage box.

[0037] Exemplarily, the heat conducting member includes a heat conducting plate 24 and an insulating thermally conductive adhesive. The heat conducting plate 24 can be a metal heat conducting plate 24. The heat conducting plate 24 is disposed between the liquid cooling plate 23 and the base plate 21 and is sealed in the notch of the mounting slot 211 near the liquid cooling plate 23. The mounting slot 211 passes through the base plate 21, and the electrical component 22 is spaced apart from the slot wall of the mounting slot 211. The insulating thermally conductive adhesive is filled between the electrical component 22 and the slot wall of the mounting slot 211 and is connected to the heat conducting plate 24. The heat generated by the electrical component 22 can first be transferred to the heat conducting plate 24 through the insulating thermally conductive adhesive, and then quickly transferred to the liquid cooling plate 23 through the thermally conductive adhesive. This design of insulating thermally conductive adhesive can not only provide good insulation protection for the electrical component 22, but also stabilize the electrical component 22 in the mounting slot 211 and transfer the heat generated by the electrical component 22. However, due to the low thermal conductivity of the insulating thermally conductive adhesive, the heat conduction effect is poor. However, the thermal conductivity of the heat conducting plate 24 is higher, and the heat conduction effect is better, which helps to improve the overall heat transfer efficiency, thereby improving the cooling effect inside the box 1. In addition, the heat conducting plate 24 can also block the notch of the mounting groove 211 adjacent to the liquid cooling plate 23, so as to prevent the adhesive from overflowing when pouring the insulating thermally conductive adhesive.

[0038] In an optional embodiment, referring to FIG4 , a side of the base plate 21 facing the heat transfer member is recessed to provide a glue overflow groove 213 that communicates with the mounting groove 211. The heat transfer plate 24 is sealed within the opening of the glue overflow groove 213. When the insulating thermally conductive adhesive is poured, some of the adhesive can overflow into the glue overflow groove 213, thereby increasing the contact area between the insulating thermally conductive adhesive and the heat transfer plate 24 and improving heat transfer efficiency.

[0039] Continuing with Figure 2 , a heat insulator 25 is provided on the side of the liquid cooling plate 23 facing away from the base plate 21, and is disposed between the housing 1 and the liquid cooling plate 23. The heat insulator 25 prevents heat from being transferred from the outside of the housing 1 to the liquid cooling plate 23, thereby preventing the cooling effect of the liquid cooling plate 23 from being reduced.

[0040] The present application also provides an energy storage system, comprising a battery system and a high-voltage box according to any of the above embodiments, wherein the battery system is connected to the high-voltage box. The energy storage system of the present application adopts a modular design, which is easy to install and disassemble and convenient to maintain.

[0041] In the description herein, it should be understood that the terms "upper," "lower," "left," "right," and other orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely for ease of description and simplified operation. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and do not have any special meaning.

[0042] Throughout this specification, references to terms such as "an embodiment" or "example" indicate that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example.

[0043] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

Claims

1. A high-voltage box, comprising a box body, in which a battery management system and an electrical module are detachably installed, the battery management system and the electrical module are adjacently arranged and connected, the electrical module comprises a substrate and a plurality of electrical components, the substrate has a plurality of mounting areas, the electrical components are mounted in the mounting areas, an adapter connected to the battery management system is further arranged on the substrate, the adapter is provided with a plurality of interfaces, and the plurality of interfaces are respectively arranged to be connected to the electrical components and external battery system signals.

2. The high-voltage box according to claim 1, wherein: Each of the installation areas is provided with an installation slot, and each of the installation slots is provided with one of the electrical components.

3. The high-voltage box according to claim 2, wherein: The substrate is provided with a material reduction groove, the material reduction groove is spaced apart from the mounting groove, the material reduction groove is provided with a fixing piece, a plurality of the electrical components are connected by a connecting piece, and the connecting piece is clamped on the fixing piece.

4. The high-voltage box according to any one of claims 2 to 3, wherein: The base plate is further provided with a liquid cooling plate and a heat conducting member. The liquid cooling plate is arranged on the side of the base plate away from the electrical component. The heat conducting member is connected to the electrical component and the liquid cooling plate respectively.

5. The high-voltage box according to claim 4, wherein: The heat-conducting member includes a heat-conducting plate and an insulating heat-conducting adhesive. The heat-conducting plate is arranged between the liquid cooling plate and the substrate. The mounting groove passes through the substrate. The insulating heat-conducting adhesive is filled between the electrical component and the groove wall of the mounting groove and is connected to the heat-conducting plate.

6. The high-voltage box according to claim 5, wherein: The side of the substrate facing the heat conducting member is recessed to be provided with a glue overflow groove communicated with the mounting groove, and the heat conducting plate is sealed at the notch of the glue overflow groove.

7. The high-voltage box according to claim 4, wherein: A heat insulating member is arranged on a side of the liquid cooling plate away from the base plate, and the heat insulating member is arranged between the box body and the liquid cooling plate.

8. The high-voltage box according to any one of claims 1 to 3, wherein: The plurality of electrical components include a shunt, a first fuse, a second fuse, a first high-voltage contactor, and a second high-voltage contactor. The control circuit includes a positive circuit and a negative circuit. The shunt, the first fuse, and the first high-voltage contactor are sequentially connected to form a negative circuit. The second fuse and the second high-voltage contactor are sequentially connected to form a positive circuit. The negative circuit is configured to connect to the negative electrode of the external battery system, and the positive circuit is configured to connect to the positive electrode of the external battery system. The electrical component further includes a balancing relay and a balancing resistor. The balancing relay and the balancing resistor are connected to form a balancing loop. The balancing loop is connected in parallel with the positive pole loop.

9. The high-voltage box according to claim 8, wherein: Temperature sensors are disposed at positions of the substrate adjacent to the first fuse and the second fuse, and the temperature sensors are connected to the battery management system.

10. An energy storage system, comprising a battery system and the high-voltage box according to any one of claims 1 to 9, wherein the battery system is connected to the high-voltage box.

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