A battery box integrated with a liquid cooling system, a power battery system and an electric vehicle

Abstract

This invention discloses a battery box housing, a power battery system, and an electric vehicle with an integrated liquid cooling system, relating to the field of new energy electric vehicle technology. The system includes a liquid cooling plate, one end of which is connected to the front beam and the other end to the rear beam. The liquid cooling plate is divided into an inlet water area and a return water area, which form a liquid cooling circuit through liquid cooling manifolds within the front and rear beams. Side beams are installed on both sides of the liquid cooling plate, and a base plate is fixed to the bottom of the liquid cooling plate. This invention forms a liquid cooling circuit with the front and rear beams through the liquid cooling plate, eliminating the need for pipes and joints and reducing the risk of leakage. Furthermore, the liquid cooling plate has a continuous cooling liquid flow channel, eliminating the need for re-molding for different batteries and making it suitable for electric vehicles of different capacities.

Description

Technical Field

[0001] This invention relates to the field of new energy electric vehicle technology, and in particular to a battery box with an integrated liquid cooling system, a power battery system, and an electric vehicle. Background Technology

[0002] With the increasing popularity of electric vehicles, the requirements for all aspects of electric vehicles are also becoming more stringent, especially in terms of cost reduction and improved safety performance. As a crucial component of electric vehicles, the power battery system has become a key factor in controlling costs and other related aspects. The cost and weight of the power battery liquid cooling system account for a significant portion of the overall power battery system. Traditional power battery liquid cooling systems are relatively heavy, which significantly impacts the energy density of the power battery; the numerous pipe interfaces in the power battery liquid cooling system increase the risk of water leakage; and the large space occupied by the power battery liquid cooling system reduces the space available for cell placement, indirectly reducing the overall vehicle range. Therefore, it is necessary to optimize the power battery liquid cooling system.

[0003] For example, CN113594600A discloses a lightweight liquid-cooled battery housing, including a base plate, front and rear frames, and left and right side frames. The front and rear frames are integrally formed with the base plate, and the left and right side frames are connected to the base plate by welding or fasteners. A liquid cooling system is integrated at the bottom by welding, and an insulation layer is added to provide temperature uniformity within the battery pack. This solution reduces the number of parts and the amount of welding by integrally forming the front and rear frames with the base plate; however, integrating the liquid cooling system at the bottom of the base plate reduces battery life. Although this solution reduces the weight of the battery housing, the liquid cooling system is an additional structure at the bottom of the base plate and is not integrated with the main body of the battery housing, resulting in a relatively limited function. Furthermore, the liquid cooling plate uses a serpentine arrangement of pipes, which require connection via pipe fittings and other components, making leakage a potential problem.

[0004] CN106935756B discloses an integrated cooling and heating enclosure structure. The main body of the enclosure includes a bottom plate and side plates, which together form a cavity for accommodating batteries. A liquid cooling system and a heating system are alternately arranged inside the bottom plate. The liquid cooling system consists of serpentine coolant channels distributed within the bottom plate. The heating system includes a first cavity between adjacent coolant channels and a heating device filled within the first cavity. In this design, the side plates have fluid inlets and outlets connected to the liquid cooling system. One fluid inlet corresponds to multiple channels larger than the inlet size, which can easily lead to uneven flow and affect the cooling effect. Similarly, in the above design, the coolant channels are arranged in a serpentine pattern, with adjacent coolant channels connected by channel bridges to allow the coolant to change direction. Due to the complex distribution of the coolant channels and the presence of reversing sections at both ends, different molds are required to manufacture bottom plates that meet the corresponding requirements for batteries of different sizes, increasing processing difficulty and cost. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a battery box, power battery system, and electric vehicle with an integrated liquid cooling system. By forming a liquid cooling circuit with the front and rear beams through the liquid cooling plate, pipes and joints are eliminated, reducing the risk of water leakage. Moreover, the liquid cooling plate is equipped with a through-flow cooling liquid channel, so there is no need to re-mold for different batteries, making it suitable for electric vehicles of different capacities.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] In a first aspect, embodiments of the present invention provide a battery box housing with an integrated liquid cooling system, including a liquid cooling plate. One end of the liquid cooling plate is connected to a front beam, and the other end is connected to a rear beam. The liquid cooling plate is divided into an inlet water area and an outlet water area. The inlet water area and the outlet water area form a liquid cooling circuit through liquid cooling manifolds in the front beam and the rear beam. Side beams are installed on both sides of the liquid cooling plate, and a base plate is fixed at the bottom of the liquid cooling plate.

[0008] As a further implementation, the water inlet area and the water return area are each provided with multiple coolant channels, and the coolant channels extend from one end of the liquid cooling plate to the other end.

[0009] As a further implementation, the water inlet area is connected to the water inlet, and the water return area is connected to the water outlet.

[0010] As a further implementation, both the front beam and the rear beam are provided with multiple cavities from top to bottom, wherein the bottom cavity serves as a liquid cooling manifold that is connected to the coolant flow channel.

[0011] As a further implementation, the liquid-cooled manifold of the front beam is divided into: a first part connected to one end of the coolant flow channel in the inlet area and a second part connected to one end of the coolant flow channel in the return area.

[0012] The coolant flow channels in the inlet and outlet water areas are connected at the other end through the liquid-cooled manifold of the rear beam.

[0013] As a further implementation, the liquid-cooled manifolds of the front and rear beams are sealed on both sides by side sealing plates, and the liquid-cooled manifold of the front beam is divided into a first part and a second part by a middle sealing plate.

[0014] As a further implementation, the liquid-cooled manifold has a liquid-cooled plate interface on the side facing the liquid-cooled plate.

[0015] As a further implementation, the longitudinal section of the liquid-cooled manifold forms an expansion structure from the side closest to the liquid-cooled plate to the other side.

[0016] As a further implementation, the bottom of the front beam and the rear beam have a first mounting portion that mates with the base plate.

[0017] As a further implementation, the first mounting part is a stepped structure.

[0018] As a further implementation, one side of the side beam is provided with a first rib fixed to the liquid cooling plate, and the other side is provided with a second rib for cooperating with the vehicle body.

[0019] As a further implementation, the bottom of the side beam is provided with a second mounting part that matches the base plate.

[0020] As a further implementation, the second mounting part is a stepped structure.

[0021] As a further implementation, an insulation layer is filled between the base plate and the liquid cooling plate.

[0022] As a further implementation, the bottom plate is provided with concave ribs at both ends, and multiple transverse ribs and multiple longitudinal ribs perpendicular to the transverse ribs are provided at intervals on the surface of the bottom plate.

[0023] As a further implementation, the upper side of the liquid cooling plate is provided with at least two inner beams parallel to the side beams.

[0024] Secondly, embodiments of the present invention also provide a power battery system, including the aforementioned battery housing, wherein a power battery is disposed within the battery housing.

[0025] Thirdly, embodiments of the present invention also provide an electric vehicle equipped with the aforementioned power battery system.

[0026] The beneficial effects of this invention are as follows:

[0027] (1) The liquid cooling plate of the present invention is divided into an inlet water area and a return water area. The inlet water area and the return water area form a liquid cooling circuit through the liquid cooling collection chambers in the front beam and the rear beam, forming a beam-plate combined structure. The beam replaces the pipeline, reducing the risk of leakage and cost.

[0028] (2) The present invention forms an inlet and return water area by means of a coolant flow channel that runs through the liquid cooling plate. The coolant flow channel is arranged in a regular manner and is easy to process. Moreover, the inlet and return water areas cover a large area, which can achieve sufficient cooling of the power battery. For power batteries of different sizes, it is only necessary to cut them to a longer or shorter length according to the requirements of the power battery. There is no need to re-open the mold, which can be adapted to electric vehicles of different capacities.

[0029] (3) The bottom cavity of the front beam and the rear beam of the present invention serves as a liquid cooling collection chamber. In addition to being part of the main body of the box, it can also realize the function of collecting coolant. The liquid cooling collection chamber has an expansion structure, which increases the coolant stroke at the water inlet and water outlet to ensure that the flow rate of each coolant channel entering from the cavity is consistent. At the same time, the expansion structure facilitates the connection of the water inlet and water outlet. Attached Figure Description

[0030] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0031] Figure 1 This is a structural schematic diagram of the present invention according to one or more embodiments;

[0032] Figure 2 This is an exploded view of the present invention according to one or more embodiments;

[0033] Figure 3 This is a schematic diagram of the front beam structure according to one or more embodiments of the present invention;

[0034] Figure 4 This is a schematic diagram of the base plate structure according to one or more embodiments of the present invention;

[0035] Figure 5 This is a schematic diagram of the liquid cooling plate structure according to one or more embodiments of the present invention;

[0036] Figure 6 This is a schematic diagram of the side beam structure according to one or more embodiments of the present invention.

[0037] Among them, 1. front beam; 2. rear beam; 3. bottom plate; 4. liquid cooling plate; 5. side beam; 6. insulation layer; 7. inner beam; 8. water inlet; 9. side sealing plate; 10. intermediate sealing plate; 11. liquid cooling plate butt joint; 12. liquid cooling manifold; 13. first mounting part; 14. concave rib; 15. longitudinal rib; 16. transverse rib; 17. coolant flow channel; 18. first convex rib; 19. chamfer to avoid weld; 20. second mounting part; 21. second convex rib; 22. water outlet. Detailed Implementation

[0038] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] Furthermore, the terms “first”, “second”, etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0040] Example 1:

[0041] This embodiment provides a battery housing with an integrated liquid cooling system, such as Figure 1 As shown, with the actual installation direction of the power battery as a reference, one end of the battery box is the front and the other end is the rear; the front-to-back direction is set as longitudinal and the left-to-right direction is set as transverse.

[0042] like Figure 1 and Figure 2 As shown, the battery housing in this embodiment includes a liquid cooling plate 4, a bottom plate 3, a front beam 1, a rear beam 2, two side beams 5, and multiple inner beams 7. One end of the liquid cooling plate 4 is connected to the front beam 1, and the other end is connected to the rear beam 2. The bottom plate 3 is disposed below the liquid cooling plate 4, and an insulation layer 6 is filled between the two. The two sides of the bottom plate 3 are connected to the front beam 1 and the rear beam 2 respectively through the side beams 5. The inner beams 7 are spaced apart on the upper side of the liquid cooling plate 4, with one end of the inner beam 7 connected to the front beam 1 and the other end connected to the rear beam 2.

[0043] In this embodiment, the external frame is formed by the front beam 1, the rear beam 2, and two side beams 5. The bottom is composed of a liquid cooling plate 4, an insulation layer 6, and a bottom plate 3 arranged sequentially from top to bottom. This combination can protect the liquid cooling plate 4 while providing cooling, preventing the lower surface of the liquid cooling plate 4, which contains the coolant channels 17, from being directly exposed to the outside. The bottom plate 3 serves both as support and protection. Moreover, the power battery is in direct contact with the upper surface of the liquid cooling plate 4, resulting in good cooling performance.

[0044] Preferably, the battery box liquid cooling plate 4 and each beam are made of aluminum profile extrusion molding; the insulation layer 6 is made of insulation foam, which is foamed and then die-cut to the design size.

[0045] In this embodiment, the liquid cooling plate 4 is integrated with the front beam 1 and the rear beam 2 to form a liquid cooling circuit. The beam replaces the pipeline, eliminating the need for liquid cooling plate pipelines and connectors, reducing the risk of water leakage and lowering costs.

[0046] Specifically, the liquid cooling plate 4 is welded to the front beam 1 and the rear beam 2 to form a liquid cooling circuit, and then welded to the side beam 5 and the inner beam 7 of the box body. Finally, the water inlet 8 and the water outlet 22 are welded, and the bottom plate 3 and the thermal insulation foam are installed.

[0047] Since the liquid cooling circuit requires both inlet and outlet water, two liquid cooling plates 4 are provided in this embodiment, such as... Figure 5 As shown, each liquid cooling plate 4 has multiple coolant channels 17 distributed inside. The multiple coolant channels 17 are arranged in the same direction and form a through structure; that is, the coolant channels 17 extend from one end of the liquid cooling plate 4 to the other end.

[0048] Adjacent coolant channels 17 may be in close contact with each other or have a certain distance between them, depending on the cooling requirements of different power batteries. One coolant channel 17 in the liquid cooling plate 4 serves as the water inlet area, and the coolant channel 17 in the other liquid cooling plate 4 serves as the water return area.

[0049] Preferably, the coolant flow channels 17 in the inlet and outlet water areas have the same area to ensure uniform cooling. The coolant flow channels 17 are channels through which coolant flows, and their cross-sectional shape can be set according to actual cooling requirements, such as circular, square, polygonal, or other shapes.

[0050] The liquid cooling plate 4 in this embodiment has a simple structure with regularly arranged coolant channels 17 inside, which is easy to process. The required length of the coolant channels 17 is also different for power batteries of different sizes. Therefore, the requirements of different power batteries can be met by controlling the length of the liquid cooling plate 4, so that it can be used for electric vehicles of different capacities without the need to re-make molds, further reducing costs.

[0051] Understandably, in other embodiments, the number of liquid cooling plates 4 can also be set to other numbers, such as three, with the middle liquid cooling plate being twice the width of the two side liquid cooling plates. The middle liquid cooling plate serves as the water inlet area, and the two side liquid cooling plates serve as the water return area. In this case, the bottom chambers in the front beam 1 and the rear beam 2 also need to be adapted, that is, the front beam 1 needs to be divided into three parts, and the rear beam 2 needs to be divided into two parts. Then the corresponding water outlets 22 also become two, corresponding to the water return area.

[0052] One end of the water inlet area is connected to the water inlet 8 via the front beam 1, and one end of the water return area is connected to the water outlet 22 via the front beam 1. The other ends of the water inlet area and the water return area are connected via the rear beam 2, thus forming a liquid cooling circuit.

[0053] like Figure 2 As shown, the inlet 8 and outlet 22 are located on the outside of the front beam 1, and the positions of the inlet 8 and outlet 22 can be interchanged; the inlet 8 and outlet 22 are machined.

[0054] like Figure 3 As shown, the front beam 1 has a certain height and can limit the power battery; the front beam 1 has a rectangular structure and multiple cavities are provided in the vertical direction inside the front beam 1, and each cavity is separated by a partition; the number of cavities can be set according to actual requirements, as long as the strength requirements are met.

[0055] In this embodiment, the front beam 1 has three cavities, with the bottom cavity serving as the liquid cooling manifold 12. The two sides of the bottom cavity are sealed by side sealing plates 9 to prevent coolant from flowing out of the front beam 1; the bottom cavity is divided into two parts by a middle sealing plate 10, namely the first part connected to the coolant flow channel 17 of the water inlet area and the second part connected to the coolant flow channel 17 of the water return area.

[0056] The shapes of the side sealing plate 9 and the middle sealing plate 10 are adapted to the cross-section of the bottom cavity. The front beam 1 is provided with a liquid cooling plate interface 11 on the inner side of the bottom cavity. The front beam 1 and the liquid cooling plate 4 are connected through the liquid cooling plate interface 11 to realize the connection between the liquid cooling manifold 12 and the coolant flow channel 17.

[0057] In this embodiment, the liquid cooling plate interface 11 is a rectangular opening. The length of the rectangular opening is adapted to the sum of the widths of the two liquid cooling plates 4, and the width of the rectangular opening is adapted to the thickness of the liquid cooling plate 4.

[0058] In this embodiment, the longitudinal section of the liquid-cooled manifold 12 forms a trapezoidal expansion structure from the side closer to the liquid-cooled plate 4 (inner side) to the side farther away from the liquid-cooled plate 4 (outer side). That is, the cross-sectional dimension of the side of the liquid-cooled manifold 12 that is connected to the coolant flow channel 17 is smaller than the cross-sectional dimension of the other side. Through the above-mentioned cavity enlargement structure, the coolant stroke is increased, the unevenness of the flow distribution of each liquid-cooled plate flow channel 17 is reduced, and the flow is balanced.

[0059] Furthermore, the aforementioned structural arrangement of the liquid-cooled manifold 12 facilitates the connection between the inlet 8 and the outlet 22.

[0060] In this embodiment, the main structure of the rear beam 2 is the same as that of the front beam 1, that is, multiple cavities are arranged vertically inside the rear beam 2, and the bottom cavity serves as a liquid-cooled manifold 12. The two ends of the liquid-cooled manifold 12 are sealed by side sealing plates 9. The inner side of the rear beam 2 has a liquid-cooled plate mating interface 11 adapted to the liquid-cooled plate 4; the bottom of the rear beam 2 is provided with a first mounting part 13 that mates with the base plate 3.

[0061] The difference between the rear beam 2 and the front beam 1 is that the rear beam 2 does not have an intermediate sealing plate 10 inside; that is, the rear beam 2 contains a single liquid-cooled manifold 12, through which the water inlet area and the water return area of ​​the liquid-cooled plate 4 are connected. Furthermore, the outer side of the rear beam 2 is not connected to the water inlet 8 and the water outlet 22.

[0062] In this embodiment, the liquid-cooled manifold 12 of the front beam 1 and the rear beam 2 are matched with the coolant flow channel 17 in the corresponding area to replace the existing structure of laying pipes inside the liquid-cooled plate. Only one inlet 8 and one outlet 22 are retained, reducing pipe joints and reducing costs while ensuring cooling effect.

[0063] Both the front beam 1 and the rear beam 2 have a first mounting part 13 on the side of the bottom surface facing the liquid cooling plate 4. The first mounting part 13 has a stepped structure and is used to cooperate with the base plate 3 to achieve a tight connection with the base plate 3.

[0064] like Figure 4 As shown, the base plate 3 is a rectangular plate, which serves as the main support. Horizontal ribs 16 and longitudinal ribs 15 are distributed on its surface. Multiple horizontal ribs 16 are spaced apart along the length of the base plate 3 and are parallel to each other. Longitudinal ribs 15 are spaced apart along the width and are parallel to each other.

[0065] To match the dimensions of the base plate 3, the number of longitudinal reinforcement bars 15 is less than the number of transverse reinforcement bars 16; the support strength of the base plate 3 is increased by using transverse reinforcement bars 16 and longitudinal reinforcement bars 15.

[0066] The bottom plate 3 is provided with concave ribs 14 at both ends. The concave ribs 14 are lower than the surface of the bottom plate 3 and are arranged along the width direction of the bottom plate 3. The concave ribs 14 make the bottom plate 3 form a stepped surface at both ends. The concave ribs 14 cooperate with the first mounting part 13 of the front beam 1 and the rear beam 2 to realize the connection between the bottom plate 3 and the front beam 1 and the rear beam 2.

[0067] like Figure 6 As shown, the side beam 5 has multiple cavities inside, such as four or other numbers; the side beam 5, front beam 1, and rear beam 2 achieve weight reduction through the cavity structure. The inner side of the side beam 5 is provided with a first rib 18 protruding from the surface. The first rib 18 is arranged in the horizontal direction and is welded and fixed to the liquid cooling plate 4 through the first rib 18.

[0068] The first raised rib 18 has chamfers 19 at both ends to avoid weld seams, so that the first raised rib 18 can avoid weld seams when welding with the liquid cooling plate 4.

[0069] A second rib 21 is provided on the outer side of the side beam 5. The second rib 21 is also horizontally arranged and is fixed to the vehicle body. In this embodiment, both the first rib 18 and the second rib 21 are hollow structures to achieve the purpose of weight reduction. The cross-section of the first rib 18 and the second rib 21 is rectangular to accommodate the corresponding connection objects.

[0070] The bottom of the side beam 5 is provided with a second mounting part 20, which forms a stepped structure. The side beam 5 and the base plate 3 are connected through the cooperation of the second mounting part 20 and the base plate 3.

[0071] The manufacturing process of this embodiment is as follows:

[0072] After the front beam 1, rear beam 2, and liquid cooling plate 4 are butted together, they are fully welded by MIG to form a sub-assembly. The side beam 5 and inner beam 7 are butted together with the above sub-assembly around the perimeter and then fully welded. The inner beam 7 and liquid cooling plate 4 are welded in sections. The butt joints between the liquid cooling plate 4 and the front beam 1, rear beam 2, and side beam 5 are welded by friction stir welding.

[0073] After connecting the inlet 8 and outlet 22 to the two mounting holes on the outside of the integrated front beam 1, weld them fully. Finally, flip the above welded assembly over and install the insulation foam. Apply glue to the first mounting part 13 and the second mounting part 20 to bond the base plate 3 to the bottom of the insulation foam. After drying, use the FDS process (hot melt self-tapping screw) to fix it at the mounting surface of the base plate.

[0074] This embodiment significantly reduces the cost and weight of the power battery system by integrating the liquid cooling system with the housing; it also improves the vehicle's power economy and increases the energy density of the power battery. Furthermore, the combination of the liquid cooling plate and the beam eliminates the need for traditional liquid cooling pipes, reducing the risk of water leakage and improving safety. By eliminating connectors and pipe joints, the space for power battery cell placement is increased, leading to greater capacity and improved vehicle range.

[0075] Example 2:

[0076] This embodiment provides a power battery system, including a battery housing with an integrated liquid cooling system, a power battery assembly disposed inside the battery housing, an upper housing on the upper side of the power battery assembly, and the upper housing and the aforementioned battery housing being detachably connected.

[0077] Among them, several battery cells or battery packs are connected in series to form a battery unit, and multiple battery units are connected in series to form a power battery assembly; the battery units are located between the side beams and main beams of the battery box and between adjacent main beams.

[0078] Specifically, the battery box is a rectangular frame structure formed by the front beam 1, the first side beam, the rear beam 2, and the second side beam. The bottom of the rectangular frame is provided with a liquid cooling plate 4, an insulation layer 6, and a bottom plate 3 from top to bottom. One end of the liquid cooling plate 4 is connected to the front beam 1, and the other end is connected to the rear beam 2.

[0079] The coolant flow channel 17 inside the liquid-cooled plate 4 forms a liquid-cooled circuit with the liquid-cooled manifold 12 in the front beam 1 and the rear beam 2. The bottom surface of the battery cell is in direct contact with the upper surface of the liquid-cooled plate 4, so that the coolant in the liquid-cooled manifold 12 absorbs the heat generated by the battery cell, thereby achieving the purpose of cooling.

[0080] Multiple inner beams 7 are spaced apart on the upper side of the liquid cooling plate 4. The spacing between the inner beams 7 and the side beams 5, as well as the spacing between adjacent side beams 5, is adapted to the battery cells. The inner beams 7 are used to avoid the influence of heat from adjacent battery cells. The height of the battery cells is higher than the rectangular frame to fit the upper housing.

[0081] In this embodiment, the coolant flow channel 17 is oriented in the same direction as the length of the battery cell to achieve effective cooling of the battery cell; each battery cell has multiple coolant flow channels 17 at its bottom to cover the bottom surface of the battery cell as much as possible.

[0082] In this embodiment, two liquid cooling plates 4 are provided. One liquid cooling plate 4 is connected to the water inlet 8 through the front beam 1, and the other liquid cooling plate 4 is connected to the water outlet 22 through the front beam 1. The other ends of the two liquid cooling plates 4 are connected through the rear beam 2. The flow direction of the coolant in the coolant flow channel 17 in the two liquid cooling plates 4 is opposite, thereby forming a liquid cooling circuit.

[0083] Since one inlet 8 and one outlet 22 correspond to multiple coolant flow channels 17, liquid-cooled manifolds 12 are respectively provided in the front beam 1 and the rear beam 2 to ensure balanced flow. Preferably, the longitudinal cross-section of the liquid-cooled manifold 12 is similar to a trapezoidal structure, and the dimension of the side connecting the inlet and outlet is larger than that of the other side, thereby increasing the stroke.

[0084] In this embodiment, the specially shaped liquid-cooled manifolds 12 in the front beam 1 and rear beam 2, combined with the flow direction of the coolant channels 17, namely, a portion of the coolant in the coolant channels 17 flows in the inlet direction and another portion of the coolant in the coolant channels 17 moves in the return direction, the two work together to achieve cooling of the entire power battery assembly.

[0085] Moreover, the length of the liquid cooling plate 4 is adapted to the length of the battery cell. For different models of battery cells, only liquid cooling plates 4 of the corresponding length need to be matched, and the processing technology is simple.

[0086] This embodiment reduces the weight of the power battery system by about 5% and lowers its cost by about 3% by integrating a liquid cooling system into the battery box of the power battery assembly; it also increases the usable internal space of the power battery system by 9%; and eliminates the need for pipe joints inside the power battery, thereby improving system safety.

[0087] Example 3:

[0088] This embodiment provides an electric vehicle equipped with the power battery system described in Embodiment 2. The power battery system is fixed to the vehicle body via the outer side ribs of the side beam of the battery box.

[0089] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A battery housing with an integrated liquid cooling system, characterized in that, It includes a liquid-cooled plate, one end of which is connected to the front beam and the other end to the rear beam. The liquid-cooled plate is divided into an inlet water area and a return water area. The inlet water area and the return water area form a liquid-cooled circuit through the liquid-cooled manifolds in the front beam and the rear beam. Side beams are installed on both sides of the liquid-cooled plate, and a base plate is fixed at the bottom of the liquid-cooled plate. An insulation layer is filled between the base plate and the liquid-cooled plate. The base plate serves as both support and protection. The front beam's liquid-cooled manifold is divided into: a first part connected to one end of the coolant flow channel in the water inlet area, and a second part connected to one end of the coolant flow channel in the water return area; the other ends of the coolant flow channels in the water inlet area and the water return area are connected through the rear beam's liquid-cooled manifold. The liquid-cooled manifolds of the front beam and the rear beam are sealed on both sides by side sealing plates, and the liquid-cooled manifold of the front beam is divided into a first part and a second part by a middle sealing plate. The longitudinal section of the liquid-cooled manifold forms an expansion structure from the side closest to the liquid-cooling plate to the other side. The cross-sectional dimension of the side of the liquid-cooled manifold that is connected to the cooling liquid flow channel is smaller than the cross-sectional dimension of the other side. Multiple cavities are set in the rear beam along the vertical direction. The bottom cavity serves as the liquid-cooled manifold. Both ends of the liquid-cooled manifold are sealed by side sealing plates. One side of the side beam is provided with a first rib that is fixed to the liquid cooling plate, and the other side is provided with a second rib that is used to cooperate with the vehicle body.

2. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, The water inlet area and the water return area are each provided with multiple coolant channels, and the coolant channels extend from one end of the liquid cooling plate to the other end.

3. The battery housing of an integrated liquid cooling system according to claim 1 or 2, characterized in that, The water inlet area is connected to the water inlet, and the water return area is connected to the water outlet.

4. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, Both the front beam and the rear beam have multiple cavities from top to bottom, with the bottom cavity serving as a liquid cooling manifold connected to the coolant flow channel.

5. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, The liquid-cooled manifold has a liquid-cooled plate interface on the side facing the liquid-cooled plate.

6. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, The front beam and the rear beam have a first mounting part at the bottom that mates with the base plate.

7. The battery housing of an integrated liquid cooling system according to claim 6, characterized in that, The first mounting part has a stepped structure.

8. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, The bottom of the side beam is provided with a second mounting part that matches the base plate.

9. The battery housing of an integrated liquid cooling system according to claim 8, characterized in that, The second mounting part has a stepped structure.

10. The battery housing of an integrated liquid cooling system according to claim 1, characterized in that, The bottom plate has concave ribs at both ends, and multiple transverse ribs and multiple longitudinal ribs perpendicular to the transverse ribs are spaced apart on the surface of the bottom plate.

11. The battery housing of an integrated liquid cooling system according to claim 10, characterized in that, The upper side of the liquid cooling plate is provided with at least two inner beams parallel to the side beams.

12. A power battery system, characterized in that, It includes the battery housing as described in claim 1, wherein a power battery is disposed within the battery housing.

13. An electric vehicle, characterized in that, It is equipped with the power battery system as described in claim 12.

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