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KR-102961869-B1 - METHOD OF FABRICATING BATTERY PROTECTION UNIT OF SEPARATED ENERGY STORAGE SYSTEM

KR102961869B1KR 102961869 B1KR102961869 B1KR 102961869B1KR-102961869-B1

Abstract

The present invention discloses a method for manufacturing a BPU case for a separable ESS, comprising a step of preparing a fixed mold (110) (S110), a step of preparing a movable mold (120) (S120), a step of spraying a release agent (S130), a step of closing the mold (S140), an injection step (S150), a step of opening the mold (S160), a step of removing the BPU case (S170), a trimming step (S180), and a powder coating step (S190), thereby manufacturing a BPU case in which a bushing and bolt assembly tab, a gland assembly hole, an LED cover assembly hole, and an upper cover assembly boss are formed, and thereby providing a BPU case with improved airtightness reliability by a high-pressure die-casting method and improving productivity.

Inventors

  • 황삼경
  • 김달우

Assignees

  • (주)이원솔루텍

Dates

Publication Date
20260508
Application Date
20230417

Claims (5)

  1. A step of preparing a fixed mold for forming a BPU case having an internal space for housing a BMS; A step of preparing a movable mold for forming the above BPU case; A step of spraying a release agent onto the fixed mold and the movable mold; A step of closing the fixed mold and the movable mold; Step of injecting molten metal; A step of opening the fixed mold and the movable mold; Step of removing the cast-molded BPU case; The step of trimming the above BPU case; and Including the step of powder coating the above BPU case; A BPU case is manufactured in which a bushing and bolt assembly tap, a gland assembly hole, an LED cover assembly hole, and an upper cover assembly boss are formed. A rib hole is formed in the above fixed mold for forming a rib of the upper cover assembly boss portion, and No step is formed in the entrance of the tunnel slide for forming the above gland assembly hole, and A rib hole is formed in the above movable mold for forming the rib of the above bushing and bolt assembly tab, and The powder coating step comprises the steps of: degreasing the BPU case with a pretreatment solution in which clean water, an alkali, a zirconium-based phosphate, and a chromium-free coating pretreatment agent are mixed in a certain ratio; removing the pretreatment solution and preheating the BPU case to a certain temperature to dry it; masking the preheated BPU case and spraying it with a coating machine to apply paint; and curing the paint by hot air drying. Method for manufacturing a BPU case of a separated ESS.
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  5. In paragraph 1, The above molten metal is characterized as being aluminum, Method for manufacturing a BPU case of a separated ESS.

Description

Method of Fabricating a Battery Protection Unit of Separated Energy Storage System The present invention relates to a method for manufacturing a BPU case of a separable ESS that can improve productivity and provide a BPU case with improved airtightness reliability through a high-pressure die-casting method. Typically, a BPU case is a product used for batteries in a home energy storage system (ESS), and the battery consists of a battery module and a BPU. Conventional products have limited power capacity increase, and an inner case and an outer case are double-mounted for product protection on a BPU manufactured by a press method. In addition, conventional BPUs are integrated units that are difficult to transport and install due to their heavy loads, and there is a risk of safety accidents during transport, such as in mountainous areas where installation is difficult. In addition, due to the risks associated with lithium secondary batteries, protective devices such as cases are required. For example, when designing the initial product, the battery pack and BPU case were integrated into a single unit and manufactured using a press fitting method. However, as the total weight increases to increase the output capacity from 10 kWh to 15 kWh or more, it is difficult to work independently if the product is integrated, so there is a need to separate it so that it can be installed on-site. Accordingly, there is a need for a case-type BPU that allows the battery module and BPU to be simply assembled without being significantly affected by external environmental factors such as flooding, leakage, or direct sunlight during separate installation. Therefore, we propose a die-casting method that enables the production and mass production of a complex structure for assembling various components such as PCB boards, capacitors, and fuses, while serving as a case that reduces production costs by manufacturing the BPU, inner case, and outer case as a single unit and minimizes the impact of external environments such as contamination, corrosion, and shock. FIG. 1 illustrates a flowchart of a method for manufacturing a BPU case of a separable ESS according to an embodiment of the present invention. FIGS. 2 and FIGS. 3 illustrate the fixed mold and the movable mold of the manufacturing method of FIG. 1, respectively. Figures 4 and 5 illustrate a BPU case of a separated ESS manufactured by the manufacturing method of Figure 1. Figure 6 illustrates the product photos of Figure 5, respectively. Hereinafter, embodiments of the present invention having the aforementioned features will be described in more detail with reference to the attached drawings. The method for manufacturing a BPU case of a separable ESS according to an embodiment of the present invention comprises a fixed mold preparation step (S110), a movable mold preparation step (S120), a release agent spraying step (S130), a mold closing step (S140), an injection step (S150), a mold opening step (S160), a BPU case extraction step (S170), a trimming step (S180), and a powder coating step (S190), thereby manufacturing a BPU case in which a bushing and bolt assembly part tap, a gland assembly part hole, an LED cover assembly part hole, and an upper cover assembly part boss are formed, and thereby providing a BPU case with improved airtightness reliability through a high-pressure die casting method and improving productivity. Hereinafter, with reference to the drawings, the method for manufacturing the BPU case of the separated ESS with the above-described configuration is specifically described as follows. First, in the fixed mold preparation step (S110), a fixed mold (110) is prepared for die-casting a BPU (Battery Protection Unit) case in which an internal space for housing a BMS (Battery Management System) is formed. For reference, an Energy Storage System (ESS), particularly a home ESS, is composed of a battery, a Battery Management System (BMS), a Power Converter System (PCS), and a Power Management System (PMS). The BMS performs battery monitoring of voltage, state of charge (SOC), and state of health (SOH), cell balancing, and communication and diagnostic functions with the PMS. The BPU incorporates the BMS and can perform functions such as a circuit breaker for rack-level system protection, switching of charge and discharge modes, and signal transmission to the BMS through voltage and current performance monitoring. Next, in the movable mold preparation step (S120), a movable mold (120) for molding the BPU case is prepared. Next, in the release agent spraying step (S130), casting conditions are set, and a release agent is sprayed onto the fixed mold (110) and the movable mold (120) through an air spray robot. Next, in the mold closing step (S140), the fixed mold (110) and the movable mold (120) are closed. Next, in the injection step (S150), molten metal is injected through the runner gate and channel into the previously closed fixed mold (110) and movable mold (120).