Battery system and assembly method

Abstract

A battery system (10) and an assembly method. The battery system comprises batteries (300) and a battery box. The battery box comprises a box body assembly (200) and a battery support frame (100). The battery box is provided with a plurality of battery slots for accommodating the batteries (300), and each battery slot comprises a first battery slot (101) and a second battery slot (201). The first battery slot (101) and the second battery slot (201) are arranged opposite one another. The first battery slot (101) is formed on the battery support frame (100), and the second battery slot (201) is formed on the box body assembly (200). The box body assembly (200) and the battery support frame (100) tightly sandwich the batteries (300).

Description

Battery system and assembly method

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on January 30, 2024, with application number 202410132738.7. The entire contents of the above application are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of battery technology, and in particular to a battery system and an assembly method. Background Art

[0003] With the rapid development of new energy, low-voltage batteries for vehicles face harsh environments. For example, driving at high speed on bumpy roads makes the batteries prone to strong vibrations and impacts, which can easily cause damage to the batteries. In severe cases, it may cause thermal runaway of the batteries and trigger safety accidents. SUMMARY OF THE INVENTION

[0004] Therefore, how to optimize the structure of the battery system and improve the stability of the battery system is a technical problem that needs to be solved urgently in the current field of battery technology.

[0005] The present application provides a battery system, comprising:

[0006] Battery;

[0007] A battery box for accommodating batteries, the battery box includes a box assembly and a battery holder installed in the box assembly, the battery box is provided with multiple battery slots for accommodating batteries, each battery slot includes a first battery slot and a second battery slot, the first battery slot and the second battery slot are arranged opposite to each other, the first battery slot is opened in the battery holder, and the second battery slot is opened in the box assembly, and structural adhesive for fixing the battery is provided in the battery slot.

[0008] The present application also provides a method for assembling a battery system, the method comprising:

[0009] A battery bracket is provided, wherein each first battery slot in the battery bracket is pre-set with a first arc-shaped rib and structural adhesive;

[0010] Install the battery in the first battery slot and connect the pre-installed BMS assembly and the battery.

[0011] A box assembly is provided, wherein each second battery slot in the box assembly is pre-set with a second arc-shaped rib and structural adhesive;

[0012] Assemble the battery bracket equipped with the battery and the box assembly;

[0013] Provide a cover assembly and cover the assembled box assembly. Beneficial effects

[0014] The battery system provided in the present application clamps the battery through the box assembly and the battery bracket, thereby limiting and fixing the battery, ensuring that the battery is fixed in the battery slot, preventing relative movement between the battery and the battery box, and improving the stability of the battery system. In addition, since the second battery slot is directly opened in the box assembly, compared with the combined structure of the independent mounting slot component and the box, the height of the box assembly is lower, saving height space. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG1 is a perspective schematic diagram of a battery system provided by some implementations of the present application from an oblique perspective;

[0016] FIG2 is an exploded schematic diagram of a battery system provided by some implementations of the present application;

[0017] FIG3 is a perspective diagram of a battery system provided by some implementations of the present application, viewed from a bottom perspective;

[0018] FIG4 is a perspective diagram of a battery holder provided by some implementations of the present application, viewed from a bottom perspective;

[0019] FIG5 is a perspective diagram of a battery holder with batteries installed thereon, as viewed from a bottom perspective, provided by some implementations of the present application;

[0020] FIG6 is a top view of a battery system with the upper cover removed, provided by some implementations of the present application;

[0021] FIG7 is a schematic cross-sectional view taken along AA of FIG6 provided in some implementations of the present application;

[0022] FIG8 is a flow chart of a battery system assembly method provided by some implementations of the present application.

[0023] Description of reference numerals:

[0024] Battery system 10, battery holder 100, box assembly 200, battery 300, structural adhesive 400, tab 500, BMS assembly 600, cover assembly 700;

[0025] First battery slot 101, first arc-shaped rib 102, first convex rib 103, bottom plate 104, third side plate 105, end plate 106, notch 107;

[0026] Second battery slot 201, second arc-shaped rib 202, second convex rib 203, first side plate 204, first pressure relief valve 205, second side plate 206, second pressure relief valve 207, first pressure relief channel 208, second pressure relief channel 209, reinforcing rib 210, connecting portion 211, pressure relief channel 212;

[0027] Explosion-proof valve 301. Modes for Carrying Out the Invention

[0028] It should be understood that the specific embodiments described herein are intended only to illustrate and explain the present application and are not intended to limit the present application. In this application, unless otherwise indicated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in actual use or operation, specifically the directions of the drawings in the accompanying drawings; while "inner" and "outer" refer to the outline of the device.

[0029] Since the low-voltage automotive batteries in the related art face harsh environments, such as driving at high speed on bumpy roads, the batteries are prone to strong vibrations and impacts, which can easily cause damage to the batteries. In severe cases, the batteries may experience thermal runaway and cause safety accidents. For this reason, the embodiments of the present application provide a battery system and an assembly method, which clamp the battery through a box assembly and a battery bracket to limit and fix the battery, ensure that the battery is fixed in the battery slot, prevent relative movement between the battery and the battery box, and improve the stability of the battery system. Since the second battery slot is directly opened in the box assembly, compared with the combined structure of the independent mounting slot component and the box, the height of the box assembly is lower, saving height space. For specific solutions, please refer to the specific description below.

[0030] It should be noted that, hereinafter, the terms "battery module", "battery", "battery element", "battery cell" and "battery pack" may be used interchangeably and may refer to any of a variety of rechargeable battery chemistries and configurations, including but not limited to lithium ion (e.g., lithium ion phosphate, lithium cobalt oxide, lithium iron phosphate, other lithium metal oxides, etc.), lithium ion polymer, nickel metal hydride, nickel cadmium, nickel metal hydride, nickel zinc, silver zinc or other battery types / configurations. The term "electric vehicle" is used herein to refer to a fully electric vehicle, also referred to as an EV, a plug-in hybrid vehicle, also referred to as a PHEV, or a hybrid electric vehicle (HEV), wherein the hybrid vehicle employs multiple propulsion sources, one of which is an electric drive system. It should be understood that the same reference numerals are used in multiple figures to refer to the same components or components with equivalent functions.

[0031] The embodiments of the present application are generally applicable to systems using electric motors, and more specifically, but not exclusively, to electric vehicles using multi-phase electric motors (e.g., inductive motors). Electric vehicles use one or more stored energy sources, such as battery packs, to provide electrical energy to the vehicle. This energy is at least partially used to propel the vehicle. The stored energy can also be used to provide energy required by other vehicle systems, such as vehicle lighting, partitionable heating, ventilation, and air conditioning (HVAC) systems, auxiliary control systems (e.g., sensors, displays, navigation systems, etc.), vehicle entertainment systems (e.g., radio, DVD, MP3, etc.), etc. Conventional electric vehicles include passenger vehicles and vehicles designed to transport goods, examples of which include passenger cars, trucks, electric bicycles, and recreational boats. Electric vehicles also include dedicated work vehicles and carts, some of which can be integrated with forklifts, scissor lifts, lifting and / or articulated boom aerial work platforms, street cleaning systems, conveyor belts, and flatbed transport platforms.

[0032] Specifically, please refer to Figures 1-8. Figure 1 is a stereoscopic schematic diagram of the battery system provided by an embodiment of the present application from an oblique perspective. The battery system 10 specifically includes a battery 300 and a battery box for accommodating the battery 300. The battery box includes a box assembly 200 and a battery holder 100 installed in the box assembly 200. The battery box is provided with a plurality of battery slots for accommodating the battery 300. Each battery slot includes a first battery slot 101 and a second battery slot 201. The first battery slot 101 and the second battery slot 201 are arranged relative to each other. The first battery slot 101 is opened in the battery holder 100, and the second battery slot 201 is opened in the box assembly 200. The box assembly 200 and the battery holder 100 clamp the battery 300.

[0033] The battery system 10 provided in this embodiment is a low-voltage battery system, whose voltage may specifically be 12V. The number of batteries 300 may be 4 or other numbers, which may be specifically set according to actual needs.

[0034] At the same time, with the development of the low-voltage battery system 10 in the future, its voltage can also be adjusted accordingly, for example, 48V, which can be set according to actual needs.

[0035] The cross-sectional shapes of the first battery slot 101 and the second battery slot 201 are both semicircular arcs that match the battery 300 .

[0036] In the embodiment of the present application, the battery 300 is clamped by the box assembly 200 and the battery holder 100, so as to limit and fix the battery 300, ensure that the battery 300 is fixed in the battery slot, prevent the battery 300 and the battery box from moving relative to each other, and improve the stability of the battery system 10. Since the second battery slot 201 is directly opened in the box assembly 200, compared with the combined structure of the independent mounting slot component and the box, the height of the box assembly 200 is lower, saving height space.

[0037] In order to improve the structural stability of the battery system 10 , as shown in FIG. 1 and FIG. 4 , in some embodiments of the present application, a first battery slot 101 is provided with a plurality of first arc-shaped ribs 102 abutting against the battery 300 on its wall.

[0038] In some embodiments of the present application, a plurality of second arc-shaped ribs 202 abutting against the batteries 300 are provided on the wall of the second battery slot 201 .

[0039] In some embodiments of the present application, the first battery slot 101 has a plurality of first arc-shaped ribs 102 disposed on its wall for contacting the battery 300 ; and the second battery slot 201 has a plurality of second arc-shaped ribs 202 disposed on its wall for contacting the battery 300 .

[0040] In the embodiment of the present application, a plurality of first arc-shaped ribs 102 are provided on the wall of the first battery slot 101, thereby effectively improving the structural strength of the battery holder 100; a plurality of second arc-shaped ribs 202 are provided on the wall of the second battery slot 201, thereby effectively improving the structural strength of the box assembly 200 and providing a positioning reference for the battery 300.

[0041] In some embodiments of the present application, a plurality of first arc-shaped ribs 102 are evenly spaced apart on the slot wall of the first battery slot 101, and structural adhesive 400 for fixing the battery 300 is provided between adjacent first arc-shaped ribs 102, and / or structural adhesive 400 for fixing the battery 300 is provided between both ends of the first arc-shaped ribs 102 and the first battery slot 101.

[0042] Multiple second arc-shaped ribs 202 are evenly spaced apart on the slot wall of the second battery slot 201, and structural adhesive 400 for fixing the battery 300 is arranged between adjacent second arc-shaped ribs 202, and / or structural adhesive 400 for fixing the battery 300 is arranged between the second arc-shaped ribs 202 and both ends of the second battery slot 201.

[0043] The thickness of the structural adhesive 400 may be equal to the thickness of the first arc-shaped rib 102 and / or the second arc-shaped rib 202 .

[0044] In the embodiment of the present application, by some implementation methods, the structural adhesive 400 and the setting of the first arc-shaped rib 102 can ensure the adhesive thickness of the battery 300, thereby ensuring the adhesive effect and durability of the battery 300 with the battery holder 100 and the box assembly 200, thereby improving the overall stability and safety of the battery system 10.

[0045] It should be noted that the structural adhesive 400 in FIG. 1 is for ease of viewing and is only a schematic illustration. The specific area and range of the structural adhesive 400 are as described in the following specific embodiment.

[0046] In some embodiments of the present application, first ribs 103 are provided between adjacent first battery slots 101 .

[0047] In some embodiments of the present application, second ribs 203 are provided between adjacent second battery slots 201 .

[0048] In some embodiments of the present application, first ribs 103 are provided between adjacent first battery slots 101 ; and second ribs 203 are provided between adjacent second battery slots 201 .

[0049] In the embodiment of the present application, by providing first ribs 103 between adjacent first battery slots 101 and / or providing second ribs 203 between adjacent second battery slots 201 , the overall structural strength and safety of the battery system 10 can be effectively improved.

[0050] To improve the safety of the battery system 10 and prevent thermal runaway of the battery 300 from causing safety accidents, in some embodiments of the present application, a pressure relief channel 212 is formed between the battery holder 100 and the box assembly 200. The pressure relief channel 212 is located between the end of the battery 300 and the side panel of the box assembly 200, and the explosion-proof valve 301 of the battery 300 is directly connected to the pressure relief channel 212. In this way, while the battery system 10 can cope with thermal runaway, its structure is simple to manufacture, reducing costs and increasing efficiency.

[0051] Optionally, the end plate 106 of the battery holder 100 is provided with a notch 107 to connect the explosion-proof valve 301 of the battery 300 with the pressure relief channel 212. This prevents the battery holder 100 from blocking the explosion-proof valve 301 of the battery 300, facilitating smooth pressure relief of the battery 300 in the event of thermal runaway.

[0052] Optionally, a pressure relief valve is installed on the side panel, and the pressure relief valve is connected to the pressure relief channel 212.

[0053] Specifically, a first pressure relief valve 205 is provided on the first side plate 204 of the box assembly 200 near the first end of the battery 300. This can achieve thermal runaway pressure relief on the first end of the battery 300, thereby improving the safety of the battery system 10.

[0054] Optionally, a second pressure relief valve 207 is provided on the second side plate 206 of the box assembly 200 near the second end of the battery 300. This can achieve thermal runaway pressure relief on the second end side of the battery 300, thereby improving the safety of the battery system 10.

[0055] A first pressure relief valve 205 is provided on a first side plate 204 of the box assembly 200, near the first end of the battery 300, and a second pressure relief valve 207 is provided on a second side plate 206 of the box assembly 200, near the second end of the battery 300. This allows simultaneous thermal runaway pressure relief at both ends of the battery 300, thereby improving the safety of the battery system 10.

[0056] In some embodiments of the present application, explosion-proof valves 301 are provided at both ends of the battery. The pressure relief channel 212 includes a first pressure relief channel 208 and a first pressure relief channel 209, respectively located on either side of the battery holder 100. The first pressure relief channel 208 is directly connected to the explosion-proof valve 301 at the first end of the battery 300, and the first pressure relief channel 209 is directly connected to the explosion-proof valve 301 at the second end of the battery 300. In this way, if thermal runaway occurs in the battery 300, both ends of the battery 300 can simultaneously perform explosion-proof pressure relief, thereby improving the explosion-proof pressure relief capability and enhancing the safety of the battery system 10.

[0057] In some embodiments of the present application, the battery system 10 further includes a BMS assembly 600 connected to the battery 300. The pressure relief channel 212 and the BMS assembly 600 are located on different sides of the battery holder 100. This isolates the flue gas from the BMS, preventing damage to the BMS and preventing it from generating a thermal warning signal.

[0058] The first pressure relief channel 208 and / or the first pressure relief channel 209 are both isolated from the BMS assembly 600 . For specific implementations, please refer to the following embodiments and will not be described in detail here.

[0059] In some embodiments of the present application, the battery holder 100 includes a base plate 104 located at the bottom of the first battery slot 101, the BMS assembly 600 is installed on the side of the base plate 104 facing away from the battery 300, and the end of the base plate 104 abuts against the side plate of the box assembly 200 to form the pressure relief channel 212 on the side of the base plate 104 close to the battery 300.

[0060] The embodiment of the present application provides a countermeasure for thermal runaway of the battery system 10, isolates the flue gas from the BMS assembly 600, avoids damage to the BMS and prevents the thermal runaway warning signal from being reported, and realizes directional exhaust, which can prevent the battery system 10 from exploding to a certain extent, thereby effectively improving the safety of the battery system 10.

[0061] In some embodiments of the present application, the battery holder 100 also includes a third side plate 105 connected to the side of the bottom plate 104 close to the battery 300, and the ends of the third side plate 105 are abutted against the side plates of the box assembly 200 to form a pressure relief channel 212 on the side close to the battery 300. The side of the third side plate 105 facing away from the pressure relief channel 212 is provided with a connection portion 211 for fixing the battery holder 100 to the box assembly 200.

[0062] In an embodiment of the present application, the ends of the third side panels 105 are abutted against the side panels of the box assembly 200 to form a pressure relief channel 212 on the side close to the battery 300, thereby isolating an installation position on the side of the non-pressure relief channel 212, thereby facilitating the installation of the battery holder 100 and the box assembly 200. The bottom plate 104, the two third side panels 105, the side panels of the box assembly 200, and the bottom guard plate of the box assembly 200 constitute the pressure relief channel 212.

[0063] In order to improve the structural strength of the battery holder 100, in an embodiment of the present application, reinforcing ribs 210 can be provided on the outer sides of the two third side panels 105, and a connecting portion 211 is provided at the end away from the bottom plate 104. The reinforcing ribs 210 are respectively connected to the third side panels 105 and the connecting portion 211, and the connecting portion 211 is used to fix the battery holder 100 on the box assembly 200.

[0064] In some embodiments of the present application, the battery system 10 further includes a tab 500 , which is disposed on the battery holder 100 and connected to the battery 300 .

[0065] In a specific embodiment of the present application, as shown in Figures 2, 4 and 5, the battery system 10 includes four batteries 300. From left to right, the outer end of the first battery is connected to a bar 500 for connecting an input or output line, and the inner end is connected to the inner end of the second battery through a bar 500 fixed on the battery holder 100, and the outer end of the second battery is connected to the outer end of the third battery through the bar 500, and the inner end of the third battery is connected to the inner end of the fourth battery through a bar 500 fixed on the battery holder 100, and the outer end of the fourth battery is connected to a bar 500 for connecting an output or input line.

[0066] In some embodiments of the present application, the battery system 10 further includes a BMS assembly 600 . The BMS assembly 600 is disposed on a side of the battery holder 100 away from the box assembly 200 and is connected to the battery 300 .

[0067] In some embodiments of the present application, the battery system 10 further includes a cover assembly 700 , which is disposed on the box assembly 200 . The cover assembly 700 is used to cover the box assembly 200 .

[0068] In addition, the present application also provides a battery system assembly method, as shown in FIG8 , which is a flow chart of the battery system assembly method provided in an embodiment of the present application. The method includes the following steps:

[0069] 801. Provide a battery bracket, wherein each first battery slot in the battery bracket is pre-set with a first arc-shaped rib and structural adhesive.

[0070] In addition, first ribs may be pre-arranged between adjacent first battery slots.

[0071] 802. Assemble the battery in the first battery slot using structural adhesive, and connect the pre-installed BMS assembly and tabs to the battery.

[0072] The process of assembling the battery in the first battery slot may include applying a tool to the first battery slot to assist in positioning and assembling the battery.

[0073] 803. Provide a box assembly, wherein each second battery slot in the box assembly is pre-set with a second arc-shaped rib and structural adhesive.

[0074] In addition, second ribs may be pre-arranged between adjacent second battery slots.

[0075] 804. Assemble the battery bracket equipped with the battery and the box assembly.

[0076] 805. Provide a cover assembly and cover the cover assembly with the assembled box assembly.

[0077] It should be noted that the specific structure of the battery system in the embodiments of the present application should refer to the description of some implementation embodiments.

[0078] In the embodiment of the present application, through the installation process of steps 801 to 805, since the first arc ribs and structural adhesive are pre-arranged in each first battery slot, after the tooling is applied to the first battery slot for auxiliary positioning to complete the assembly, the next process (welding the battery and the series aluminum bar) can be immediately carried out without other auxiliary positioning or continuing to maintain the original auxiliary positioning, thereby shortening the production cycle and improving efficiency.

Claims

1. A battery system comprising: Battery; A battery box is configured to accommodate the battery, the battery box includes a box assembly and a battery holder installed in the box assembly, the battery box is provided with a plurality of battery slots configured to accommodate the battery, each of the battery slots includes a first battery slot and a second battery slot, the first battery slot and the second battery slot are arranged opposite to each other, the first battery slot is opened in the battery holder, the second battery slot is opened in the box assembly, and the box assembly and the battery holder clamp the battery.

2. The battery system according to claim 1, wherein: The wall of the first battery slot is provided with a plurality of first arc-shaped ribs abutting against the battery; And / or, the wall of the second battery slot is provided with a plurality of second arc-shaped ribs abutting against the battery.

3. The battery system according to claim 2, wherein: A plurality of the first arc-shaped ribs are evenly spaced apart on the slot wall of the first battery slot, and structural adhesive for fixing the battery is provided between adjacent first arc-shaped ribs; And / or, structural adhesive for fixing the battery is provided between the first arc-shaped rib and both ends of the first battery slot.

4. The battery system according to claim 2, wherein: A plurality of the second arc-shaped ribs are evenly spaced apart on the slot wall of the second battery slot, and structural glue for fixing the battery is provided between adjacent second arc-shaped ribs. And / or, structural adhesive for fixing the battery is provided between the second arc-shaped rib and both ends of the second battery slot.

5. The battery system according to claim 1, wherein: A first rib is provided between adjacent first battery slots; And / or, second ribs are provided between adjacent second battery slots.

6. The battery system according to claim 1, wherein: The cross-sectional shapes of the first battery slot and the second battery slot are both arc-shaped to match the batteries.

7. The battery system according to claim 1, wherein: A pressure relief channel is formed between the battery bracket and the box assembly, and the explosion-proof valve of the battery is communicated with the pressure relief channel.

8. The battery system according to claim 7, wherein: The end plate of the battery bracket is provided with a notch to connect the explosion-proof valve of the battery with the pressure relief channel.

9. The battery system according to claim 7, wherein: A pressure relief valve is installed on the side plate of the pressure relief channel, and the pressure relief valve is communicated with the pressure relief channel; The side plate includes a first side plate and a second side plate that are oppositely arranged, and a first pressure relief valve is provided on the first side plate of the box assembly close to the first end of the battery; And / or, a second pressure relief valve is provided on the second side plate of the box assembly close to the second end of the battery.

10. The battery system according to claim 7, wherein: Both ends of the battery are provided with explosion-proof valves, and the pressure relief channel includes a first pressure relief channel and a second pressure relief channel respectively located on both sides of the battery bracket. The first pressure relief channel is directly connected to the explosion-proof valve at the first end of the battery, and the second pressure relief channel is directly connected to the explosion-proof valve at the second end of the battery.

11. The battery system according to claim 7, wherein: The battery system further includes a BMS assembly connected to the battery, and the pressure relief channel and the BMS assembly are arranged on different sides of the battery bracket.

12. The battery system according to claim 11, wherein: The battery holder includes a base plate located at the bottom of the first battery slot, the BMS assembly is installed on the side of the base plate away from the battery, and the end of the base plate abuts against the side plate of the box assembly to form the pressure relief channel on the side of the base plate close to the battery.

13. The battery system according to claim 12, wherein: The battery holder also includes a third side plate connected to the side of the bottom plate close to the battery, the end of the third side plate abuts against the side plate of the box assembly to form the pressure relief channel on the side of the bottom plate close to the battery, and the side of the third side plate facing away from the pressure relief channel is provided with a connecting portion configured to fix the battery holder to the box assembly.

14. The battery system according to claim 13, wherein: A reinforcing rib is provided on the side of the third side plate facing away from the battery, and the connecting portion is provided on the end of the third side plate away from the bottom plate, the reinforcing rib is respectively connected to the third side plate and the connecting portion, the connecting portion and the pressure relief channel are respectively located on different sides of the battery holder, and the connecting portion is configured to fix the battery holder to the box assembly.

15. The battery system according to any one of claims 1 to 14, wherein: The battery system further includes a tab, which is disposed on the battery bracket and connected to the battery.

16. The battery system according to any one of claims 1 to 14, wherein: The battery system further includes a cover assembly, which is disposed on the box assembly and configured to cover the box assembly.

17. The battery system according to any one of claims 1 to 12, wherein: The battery bracket is connected to the box assembly.

18. A method for assembling a battery system, the method comprising: A battery bracket is provided, wherein each first battery slot in the battery bracket is pre-set with a first arc-shaped rib and structural adhesive; Install the battery in the first battery slot and connect the pre-installed BMS assembly and the battery to the battery; Providing a box assembly, wherein each second battery slot in the box assembly is pre-set with a second arc-shaped rib and structural adhesive; Assembling the battery holder equipped with the battery with the box assembly; A cover assembly is provided, and the cover assembly is covered with the assembled box assembly.

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