Integrated battery assembly, new energy vehicle and design method

Abstract

The application discloses an integrated battery assembly, a new energy vehicle and a design method, and relates to the technical field of battery assemblies, and aims to improve the integration degree, reduce the weight of the vehicle and the battery, and improve the economy and power of the vehicle. The battery assembly is modularly designed, the number of internal parts of the battery is effectively reduced, the quick plug connector module can make the battery more convenient to install and maintain while being integrated with the vehicle, the thermal runaway protection structure inside the battery can effectively ensure the safety of the battery, and the design method can effectively ensure that the battery can bear the weight of the trunk cargo and ensure the safe use of the battery in various driving conditions of the vehicle.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle battery technology, and in particular to integrated battery assemblies, new energy vehicles, and design methods. Background Technology

[0002] In recent years, the new energy industry has flourished, and the sales of new energy vehicles have repeatedly reached new highs. my country is also transforming and upgrading its automotive industry through new energy electrification, and new energy electric vehicles are gradually developing towards intelligent, highly integrated, and lightweight trends.

[0003] As a crucial core component of new energy vehicles, the power battery contains dozens or even hundreds of parts. These parts are numerous and varied, and the battery weight often reaches tens or even hundreds of kilograms. Furthermore, as a critical safety component, the battery requires meticulous protection after installation, including insulation and impact resistance. This results in low integration between the battery and the vehicle, a large number of parts, a heavy overall vehicle weight, and excessive energy consumption during operation, impacting driving range and performance. To address these issues, research focuses on battery-vehicle integration design and modular development of battery assemblies. These methods can improve battery integration, reduce weight and the number of parts, and increase driving range. Current industry research primarily focuses on placing the battery under the vehicle's floor, with most proposed solutions integrating the battery with the floor. However, the battery can also be placed in the trunk. Integration design with the spare tire tray is less studied. Furthermore, the battery integrated into the spare tire tray needs to bear the weight of cargo in the trunk, requiring load-bearing design while ensuring battery safety. This design approach remains a technical challenge. Summary of the Invention

[0004] To address the aforementioned issues, this invention proposes an integrated battery assembly, a new energy vehicle, and a design method. The battery assembly is integrated with the vehicle's spare tire tray, effectively improving integration, reducing the weight of the vehicle and battery, and enhancing the vehicle's economy and power. The modular design of the battery assembly effectively reduces the number of internal battery components, and the quick-connect module facilitates installation and maintenance while integrating the battery with the vehicle. The internal thermal runaway protection structure effectively ensures battery safety. Furthermore, the proposed design method, due to the integration of the battery with the vehicle's spare tire tray, ensures that the battery can effectively support the weight of cargo in the trunk and guarantees safe battery use under various driving conditions.

[0005] The present invention provides an integrated battery assembly, including a spare tire tray assembly, a battery module housing, a high-voltage system, a low-voltage system, a liquid cooling system, a battery module, a quick-connect module, a fireproof plate assembly, and a cover. The modular design of the battery assembly can effectively reduce the number of internal battery components, and the quick-connect module can make the battery assembly easier to install and maintain while integrating the battery with the vehicle.

[0006] The spare tire tray assembly is part of the vehicle chassis. It has a frame structure. The battery module housing is matched and housed in the frame structure of the spare tire tray assembly and is limited, sealed and fixed to the upper end of the frame structure of the spare tire tray assembly.

[0007] The high-voltage system, low-voltage system, and liquid cooling system are each housed within the battery module housing.

[0008] The battery module is housed in a battery module housing and mounted on a liquid cooling system. The high-voltage system and the low-voltage system are electrically connected to the battery module, respectively.

[0009] The bottom wall of the battery module housing has an opening, and the quick-connect module is embedded and sealed at the opening.

[0010] The high-voltage system, low-voltage system, and liquid cooling system are respectively connected to the corresponding high-voltage connector assembly, low-voltage connector assembly, and water pipe connector assembly on the quick-connect module within the battery module housing.

[0011] The fireproof plate assembly is housed in the battery module housing and is matched and seated on the upper surface of the battery module.

[0012] The cover is fitted onto the upper surface of the battery module housing and is sealed and fixed to the circumferential upper edge of the upper surface of the battery module housing.

[0013] The high-voltage system and low-voltage system are located on one side inside the battery module housing, and the battery module is located on the other side inside the battery module housing. The high-voltage system includes a high-voltage copper busbar, a high-voltage distribution box, and a high-voltage connector. The high-voltage copper busbar is electrically connected to both the battery module and the high-voltage distribution box, and the high-voltage distribution box is electrically connected to the high-voltage connector. The low-voltage system includes a BMS (Battery Management System). The SYSTEM (Battery Management System) acts as the link between the battery and the user, primarily aiming to improve battery utilization and prevent overcharging and over-discharging. The BMS (Battery Management System) is electrically connected to the low-voltage harness and low-voltage connector, respectively. The low-voltage harness is electrically connected to the battery module. An opening is located on the bottom wall of the battery module housing, between the high-voltage and low-voltage systems. The high-voltage and low-voltage connectors are located above the opening of the battery module housing. The battery module housing is a cast aluminum housing. A liquid cooling system is integrated into the battery module housing below the battery module. This liquid cooling system cools and dissipates heat from the battery module. The water pipe connector of the liquid cooling system is located above the opening of the battery module housing.

[0014] The high-voltage connector, low-voltage connector, and water pipe connector are respectively connected to the high-voltage connector assembly, low-voltage connector assembly, and water pipe connector assembly above the quick-connect connector module, which are sealed to the opening of the battery module housing. They are quick-connect and easy to disassemble and maintain.

[0015] The quick-connect module includes a high-voltage connector assembly, a low-voltage connector assembly, a water pipe connector assembly, and a housing. The housing is made of steel, aluminum, or non-metallic materials and has a hollow basin-shaped structure. The upper end of the basin-shaped structure has an edge with a sealing strip to ensure a sealed connection between the housing and the battery module housing. The edge of the housing is screwed to the battery module housing.

[0016] The high-voltage connector assembly includes a high-voltage DC connector assembly, a high-voltage DC-DC connector assembly, and a high-voltage compressor connector assembly; the high-voltage DC connector assembly, the high-voltage DC-DC connector assembly, the high-voltage compressor connector assembly, the low-voltage connector assembly, and the water pipe connector assembly are respectively sealed and fixedly connected to the housing; one end of the high-voltage DC connector assembly, the high-voltage DC-DC connector assembly, and the high-voltage compressor connector assembly, which are located on the bottom wall of the quick-connect connector module's basin structure, is electrically connected to the high-voltage connector of the high-voltage system through a quick-connect structure.

[0017] The spare tire tray assembly is constructed by welding crossbeams and longitudinal beams. As part of the vehicle chassis, it eliminates the need for sheet metal flooring in existing trunks. A battery module housing with a tray structure is installed within the space enclosed by the crossbeams and longitudinal beams, making full use of the rear space of the vehicle. The assembly includes a left longitudinal beam, a right longitudinal beam, a front crossbeam, and a rear crossbeam. These beams are welded together to form a rectangular frame structure, with a cavity in the center. The upper surfaces of the left, right, front, and rear crossbeams are flush with each other on the same horizontal plane, forming a mounting surface. The battery module housing is housed within the cavity, and its upper end is matched and fixed to the mounting surface.

[0018] The battery module housing includes an open housing, a sealing strip, an opening, and an upper edge of the housing. An opening is provided on the bottom wall of the housing, and an upper edge is located at the open position at the top of the housing. The housing is housed within the housing cavity of the spare tire tray assembly. A sealing strip is circumferentially fixed to the lower surface of the upper edge of the housing. The lower surface of the upper edge of the housing and the sealing strip are in contact with the mounting surface and are fixedly connected by bolts or FDS (Flow Drill Screw) riveting process. The edge of the housing is screwed to the bottom wall of the housing at the outer edge of the opening. Based on these connections and fixations, the internal sealing of the battery assembly and the sealing of the entire vehicle are ensured.

[0019] The fireproof panel assembly is composed of a mica plate with an overall thickness of 2mm to 5mm. The specific length is designed according to the battery module structure. The inner surface of the mica plate is coated with a heat-absorbing coating with a thickness of 0.2mm to 1mm. The heat-absorbing coating is made of an insulating heat-absorbing material, which can absorb some of the heat during battery thermal runaway. The left and right ends of the mica plate have flanges facing the inner surface of the mica plate, designed to prevent flame leakage in the early stages of thermal runaway. At least two tubular flame-retardant material-filled cavities are horizontally opened between the front and rear ends of the mica plate. The tubular flame-retardant material filling cavity is located corresponding to the cell explosion-proof valve on the upper surface of the battery module. Each tubular flame-retardant material filling cavity is filled with flame-retardant material, which is flame-retardant gel. The tubular flame-retardant material filling cavity is designed above the cell explosion-proof valve. The cavity is filled with flame-retardant gel. When thermal runaway occurs, the cell valve burns the thin wall of the inner surface of the fireproof plate assembly below the corresponding tubular flame-retardant material filling cavity, causing the flame-retardant gel to leak downward and flow into the cell explosion-proof valve. The flame-retardant gel has heat absorption and flame-retardant properties, which can play a fire extinguishing role and prevent the spread of thermal runaway.

[0020] This invention also proposes a new energy vehicle containing an integrated battery assembly, including an integrated battery assembly, a vehicle chassis, and a vehicle trunk. The spare tire tray assembly is part of the vehicle chassis and is welded to the rear of the vehicle chassis. The integrated battery assembly forms the floor sheet metal of the vehicle trunk. The vehicle spare tire can be installed on the floor sheet metal, and together with the side wall sheet metal of the trunk, it forms the vehicle trunk. The integrated integration of the battery assembly and the vehicle spare tire tray can effectively improve the integration level, reduce the weight of the whole vehicle and the battery, and improve the economy and power of the whole vehicle.

[0021] This invention also proposes a design method for an integrated battery assembly, including static load design and dynamic load design, wherein the static load design steps are as follows:

[0022] S1. Determine the static load design target: the maximum stress σp of the battery box is less than the yield stress σs of the selected material, and the battery will not produce permanent deformation.

[0023] S2. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk.

[0024] S3. Conduct battery assembly design: This mainly includes the selection of battery box materials, including but not limited to steel, aluminum alloy, titanium alloy, etc., and structural design and feature design.

[0025] S4. Conduct CAE-aided design: including simulation analysis, morphology optimization, and topology optimization;

[0026] If the result is determined, and σp < σs, then the static load design requirements are met; if σp ≥ σs, then return to step S3 and start the battery assembly design again.

[0027] The dynamic load design steps are as follows:

[0028] S101. Determine the dynamic load design target: the battery assembly shall be free from structural damage such as cracks, fractures or sealing failures;

[0029] S102. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk.

[0030] S103. Determine the impact load xg. Under the maximum load of the vehicle and different working conditions, road spectrum data is collected at different locations of the battery pack to determine the maximum impact load xg.

[0031] S104. Conduct battery assembly design: This mainly includes the selection of battery box materials, including but not limited to steel, aluminum alloy, titanium alloy, etc., and structural design and feature design.

[0032] S105. Conduct CAE-aided design: Conduct CAE mechanical impact simulation analysis, load a half-sine shock wave onto the vehicle where the test battery assembly is located, with the direction ±Z, acceleration xg, pulse time 5ms~10ms, and the number of impacts 4~10 times in both positive and negative directions, and perform morphology optimization and topology optimization.

[0033] If the simulation results show no structural damage such as cracks, breaks, or sealing failures in the battery, then the dynamic load design requirements are met; otherwise, the process returns to step S104 to redesign the battery assembly.

[0034] The integrated battery pack needs to be designed according to the above methods to ensure that it meets both static load design and dynamic load design requirements. Since the battery is integrated with the vehicle's spare tire tray, the design method of the integrated battery pack can ensure that the battery can effectively bear the weight of the cargo in the trunk and ensure the safe use of the battery in all driving conditions of the vehicle.

[0035] Beneficial effects

[0036] The advantages of this invention compared to existing technologies are:

[0037] (1) The battery pack is integrated with the spare tire tray of the vehicle body, which can effectively improve the integration level, reduce the weight of the whole vehicle and the battery, and improve the economy and power of the whole vehicle.

[0038] (2) The modular design of the battery assembly can effectively reduce the number of internal components of the battery, and the quick-connect module can make the battery assembly easier to install and maintain while integrating the battery with the vehicle.

[0039] (3) The internal thermal runaway protection structure of the battery can effectively ensure the safety of the battery;

[0040] (4) A design method is proposed that, since the battery is integrated with the vehicle's spare tire tray, the design method can ensure that the battery can effectively bear the weight of the cargo in the trunk and ensure the safe use of the battery in all driving conditions of the vehicle. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall breakdown structure of the integrated battery of the present invention.

[0042] Figure 2 This is a schematic diagram of the quick-connect connector module structure of the present invention.

[0043] Figure 3 This is a schematic diagram of the spare tire tray assembly structure of the present invention.

[0044] Figure 4 This is an exploded structural diagram of the spare tire tray assembly, battery module housing, and quick-connect connector module of the present invention.

[0045] Figure 5 This is a schematic diagram of the fireproof board assembly structure of the present invention.

[0046] Figure 6 This is a static load design schematic diagram of the integrated battery assembly of the present invention.

[0047] Figure 7 This is a schematic diagram of the dynamic load design of the integrated battery assembly of the present invention.

[0048] In the picture:

[0049] 1. Spare tire tray assembly; 11. Left longitudinal beam; 12. Right longitudinal beam; 13. Front crossbeam; 14. Rear crossbeam; 15. Accommodating cavity; 16. Mounting surface;

[0050] 2. Battery module housing; 21. Opening; 22. Housing; 23. Sealing strip; 24. Upper edge of housing;

[0051] 3. High-voltage system;

[0052] 4. Low-voltage system;

[0053] 5. Liquid cooling system;

[0054] 6. Battery module;

[0055] 7. Quick-connect connector module; 71. High-voltage connector assembly; 711. High-voltage DC connector assembly; 712. High-voltage DC-DC connector assembly; 713. High-voltage compressor connector assembly; 72. Low-voltage connector assembly; 73. Water pipe connector assembly; 74. Housing; 741. Edge;

[0056] 8. Fireproof board assembly; 81. Mica board; 82. Heat-absorbing coating; 83. Flanged edge; 84. Tubular flame-retardant material filling cavity; 85. Flame-retardant material;

[0057] 9. Box lid. Detailed Implementation

[0058] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention. Furthermore, it should be noted that, for ease of description, only the parts related to the present invention are shown in the accompanying drawings, not all of them.

[0059] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions.

[0060] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0061] Example 1

[0062] See Figures 1-5 As shown, an integrated battery assembly includes a spare tire tray assembly 1, a battery module housing 2, a high-voltage system 3, a low-voltage system 4, a liquid cooling system 5, a battery module 6, a quick-connect connector module 7, a fireproof plate assembly 8, and a cover 9.

[0063] The spare tire tray assembly 1 is part of the vehicle chassis. It has a frame structure. The battery module housing 2 is matched and housed in the frame structure of the spare tire tray assembly 1 and is limited, sealed and fixed to the upper end of the frame structure of the spare tire tray assembly 1.

[0064] The high-voltage system 3, the low-voltage system 4, and the liquid cooling system 5 are respectively housed in the battery module housing 2;

[0065] The battery module 6 is housed in the battery module housing 2 and is fixed on the liquid cooling system 5. The high-voltage system 3 and the low-voltage system 4 are electrically connected to the battery module 6 respectively.

[0066] The bottom wall of the battery module housing 2 has an opening 21, and the quick-connect module 7 is embedded and sealed in the opening 21.

[0067] The high-voltage system 3, low-voltage system 4, and liquid cooling system 5 are connected to the corresponding high-voltage connector assembly 71, low-voltage connector assembly 72, and water pipe connector assembly 73 on the quick-connect module 7 within the battery module housing 2.

[0068] The fireproof plate assembly 8 is housed in the battery module housing 2 and is matched and seated on the upper surface of the battery module 6.

[0069] The cover 9 is fitted onto the upper surface of the battery module housing 2 and is sealed and fixed to the circumferential upper edge 24 of the upper surface of the battery module housing 2.

[0070] The high-voltage system 3 and low-voltage system 4 are located on one side inside the battery module housing 2, and the battery module 6 is located on the other side inside the battery module housing 2. The high-voltage system 3 includes a high-voltage copper busbar, a high-voltage distribution box, and a high-voltage connector. The high-voltage copper busbar is electrically connected to the battery module 6 and the high-voltage distribution box, and the high-voltage distribution box is electrically connected to the high-voltage connector. The low-voltage system 4 includes a BMS, a low-voltage wiring harness, and a low-voltage connector. The BMS is electrically connected to the low-voltage wiring harness and the low-voltage connector, and the low-voltage wiring harness is electrically connected to the battery module 6. An opening 21 is located on the bottom wall of the battery module housing 2 between the high-voltage system 3 and the low-voltage system 4. The high-voltage connector and the low-voltage connector are located above the opening 21 of the battery module housing 2. The battery module housing 2 is a cast aluminum housing. A liquid cooling system 5 is integrated on the battery module housing 2 below the battery module 6. The water pipe connector of the liquid cooling system 5 is located above the opening 21 of the battery module housing 2.

[0071] The high-voltage connector, low-voltage connector, and water pipe connector are respectively connected to the high-voltage connector assembly 71, low-voltage connector assembly 72, and water pipe connector assembly 73 above the quick-connect connector module 7, which are sealed and connected to the opening 21 of the battery module housing 2.

[0072] The quick-connect module 7 includes a high-voltage connector assembly 71, a low-voltage connector assembly 72, a water pipe connector assembly 73, and a housing 74. The housing 74 is made of non-metallic material and has a hollow basin-shaped structure. The upper end of the basin-shaped structure is provided with an edge 741, and a sealing strip is provided at the edge 741. The edge 741 of the housing 74 is screwed and fixed to the battery module housing 2.

[0073] The high-voltage connector assembly 71 includes a high-voltage DC connector assembly 711, a high-voltage DC-DC connector assembly 712, and a high-voltage compressor connector assembly 713. The high-voltage DC connector assembly 711, the high-voltage DC-DC connector assembly 712, the high-voltage compressor connector assembly 713, the low-voltage connector assembly 72, and the water pipe connector assembly 73 are respectively sealed and fixedly connected to the housing 74. One end of the high-voltage DC connector assembly 711, the high-voltage DC-DC connector assembly 712, and the high-voltage compressor connector assembly 713, which are located on the inner bottom wall of the quick-connect connector module 7, is electrically connected to the high-voltage connector of the high-voltage system 3 through a quick-connect structure.

[0074] The spare tire tray assembly 1 is constructed by welding crossbeams and longitudinal beams, including a left longitudinal beam 11, a right longitudinal beam 12, a front crossbeam 13, and a rear crossbeam 14. The left longitudinal beam 11, right longitudinal beam 12, front crossbeam 13, and rear crossbeam 14 are welded together to form a rectangular frame structure. The middle part of the rectangular frame structure forms an accommodating cavity 15. The upper surfaces of the left longitudinal beam 11, right longitudinal beam 12, front crossbeam 13, and rear crossbeam 14 that form the rectangular frame structure are flush with each other and are on the same horizontal plane, together forming a mounting surface 16. The battery module housing 2 is housed in the accommodating cavity 15, and the upper end of the battery module housing 2 is matched and limited and fixed on the mounting surface 16.

[0075] The battery module housing 2 includes an open housing 22, a sealing strip 23, an opening 21, and an upper edge 24. The opening 21 is provided on the bottom wall of the housing 22, and the upper edge 24 is provided at the open position at the top of the housing 22. The housing 22 is housed in the housing cavity 15 of the spare tire tray assembly 1. The sealing strip 23 is circumferentially fixed on the lower surface of the upper edge 24. The lower surface of the upper edge 24 and the sealing strip 23 are located on the mounting surface 16 and are fixedly connected by bolts. The edge 741 of the housing 74 is screwed and fixed to the bottom wall of the housing 22 at the outer edge of the opening 21.

[0076] The fireproof board assembly 8 is composed of a mica board 81 with a total thickness of 3.5 mm. The inner surface of the mica board 81 is coated with a heat-absorbing coating 82 with a thickness of 0.6 mm. The left and right end faces of the mica board 81 are respectively provided with flanges 83 facing the inner surface of the mica board 81. Two tubular flame-retardant material filling cavities 84 are horizontally opened between the front and rear end faces of the mica board 81. The position of each tubular flame-retardant material filling cavity 84 corresponds to the cell explosion-proof valve on the upper end face of the battery module 6. Each tubular flame-retardant material filling cavity 84 is filled with flame-retardant material 85, which is flame-retardant gel.

[0077] Example 2

[0078] The present invention also proposes a new energy vehicle containing an integrated battery assembly, including an integrated battery assembly, a vehicle chassis and a vehicle trunk, wherein the spare tire tray assembly 1 is part of the vehicle chassis and is welded to the rear of the vehicle chassis, and the integrated battery assembly constitutes the bottom sheet metal of the vehicle trunk.

[0079] Example 3

[0080] See Figures 6-7 As shown, this invention also proposes a design method for an integrated battery assembly, including static load design and dynamic load design, wherein the static load design steps are as follows:

[0081] S1. Determine the static load design target: the maximum stress σp of the battery box is less than the yield stress σs of the selected material, and the battery will not produce permanent deformation.

[0082] S2. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk.

[0083] S3. Conduct battery assembly design: This mainly includes the selection of battery box materials, including but not limited to steel, aluminum alloy, titanium alloy, etc., and structural design and feature design.

[0084] S4. Conduct CAE-aided design: including simulation analysis, morphology optimization, and topology optimization;

[0085] If the result is determined, and σp < σs, then the static load design requirements are met; if σp ≥ σs, then return to step S3 and start the battery assembly design again.

[0086] The dynamic load design steps are as follows:

[0087] S101. Determine the dynamic load design target: the battery assembly shall be free from structural damage such as cracks, fractures or sealing failures;

[0088] S102. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk.

[0089] S103. Determine the impact load xg. Under the maximum load of the vehicle and different working conditions, road spectrum data is collected at different locations of the battery pack to determine the maximum impact load xg.

[0090] S104. Conduct battery assembly design: This mainly includes the selection of battery box materials, including but not limited to steel, aluminum alloy, titanium alloy, etc., and structural design and feature design.

[0091] S105. Conduct CAE-aided design: Conduct CAE mechanical impact simulation analysis, load a half-sine shock wave onto the vehicle where the test battery assembly is located, with the direction ±Z, acceleration xg, pulse time 5ms~10ms, and the number of impacts 4~10 times in both positive and negative directions, and perform morphology optimization and topology optimization.

[0092] If the simulation results show no structural damage such as cracks, breaks, or sealing failures in the battery, then the dynamic load design requirements are met; otherwise, the process returns to step S104 to redesign the battery assembly.

[0093] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. An integrated battery assembly, characterized in that: The system includes a spare tire tray assembly (1), a battery module housing (2), a high-voltage system (3), a low-voltage system (4), a liquid cooling system (5), a battery module (6), a quick-connect module (7), a fireproof plate assembly (8), and a cover (9). The spare tire tray assembly (1) is part of the vehicle chassis and has a frame structure. The battery module housing (2) is matched and housed within the frame structure of the spare tire tray assembly (1) and is fixedly and sealed to the upper end of the frame structure of the spare tire tray assembly (1). The high-voltage system (3), the low-voltage system (4), and the liquid cooling system (5) are respectively housed within the battery module housing (2). The battery module (6) is housed within the battery module housing (2) and is fixedly mounted on the liquid cooling system (5). The high-voltage system (3) and the low-voltage system (4) are respectively housed within the battery module housing (2). The system (4) is electrically connected to the battery module (6); the bottom wall of the battery module housing (2) is provided with an opening (21), and the quick-connect module (7) is embedded and sealed at the opening (21); the high-voltage system (3), the low-voltage system (4), and the liquid cooling system (5) are connected to the corresponding high-voltage connector assembly (71), low-voltage connector assembly (72), and water pipe connector assembly (73) on the quick-connect module (7) in the battery module housing (2); the fireproof plate assembly (8) is housed in the battery module housing (2) and is matched and seated on the upper end face of the battery module (6); the cover (9) is matched and set on the upper end face of the battery module housing (2) and sealed and fixed with the circumferential upper edge (24) of the upper end face of the battery module housing (2).

2. The integrated battery assembly according to claim 1, characterized in that: The high-voltage system (3) and the low-voltage system (4) are located on one side inside the battery module housing (2), and the battery module (6) is located on the other side inside the battery module housing (2). The high-voltage system (3) includes a high-voltage copper busbar, a high-voltage distribution box, and a high-voltage connector. The high-voltage copper busbar is electrically connected to the battery module (6) and the high-voltage distribution box, respectively, and the high-voltage distribution box is electrically connected to the high-voltage connector. The low-voltage system (4) includes a BMS, a low-voltage wiring harness, and a low-voltage connector. The BMS is electrically connected to the low-voltage wiring harness and the low-voltage connector, respectively, and the low-voltage wiring harness is electrically connected to the battery module (6). The group (6) is electrically connected, and the opening (21) is located on the bottom wall of the battery module housing (2) between the high voltage system (3) and the low voltage system (4). The high voltage connector and the low voltage connector are located above the opening (21) of the battery module housing (2). The battery module housing (2) is a cast aluminum housing. The battery module housing (2) below the battery module (6) is integrated with a liquid cooling system (5). The water pipe connector of the liquid cooling system (5) is located above the opening (21) of the battery module housing (2).

3. The integrated battery assembly according to claim 2, characterized in that: The high-voltage connector, low-voltage connector and water pipe connector are respectively connected to the high-voltage connector assembly (71), low-voltage connector assembly (72) and water pipe connector assembly (73) above the quick-connect connector module (7) which are sealed to the opening (21) of the battery module housing (2).

4. The integrated battery assembly according to claim 1, characterized in that: The quick-connect module (7) includes a high-voltage connector assembly (71), a low-voltage connector assembly (72), a water pipe connector assembly (73), and a housing (74); the housing (74) is made of steel, aluminum, or non-metallic materials, and has a hollow basin-shaped structure. The upper end of the basin-shaped structure is provided with an edge (741), and a sealing strip is provided at the edge (741). The edge (741) of the housing (74) is screwed and fixed to the battery module housing (2).

5. An integrated battery assembly according to claim 4, characterized in that: The high-voltage connector assembly (71) includes a high-voltage DC connector assembly (711), a high-voltage DC-DC connector assembly (712), and a high-voltage compressor connector assembly (713); the high-voltage DC connector assembly (711), the high-voltage DC-DC connector assembly (712), the high-voltage compressor connector assembly (713), the low-voltage connector assembly (72), and the water pipe connector assembly (73) are respectively sealed and fixedly connected to the housing (74); one end of the high-voltage DC connector assembly (711), the high-voltage DC-DC connector assembly (712), and the high-voltage compressor connector assembly (713) located on the inner bottom wall of the quick-connect connector module (7) is electrically connected to the high-voltage connector of the high-voltage system (3) through the quick-connect structure.

6. An integrated battery assembly according to claim 5, characterized in that: The spare tire basin assembly (1) is constructed by welding crossbeams and longitudinal beams, including a left longitudinal beam (11), a right longitudinal beam (12), a front crossbeam (13), and a rear crossbeam (14). The left longitudinal beam (11), right longitudinal beam (12), front crossbeam (13), and rear crossbeam (14) are welded together to form a rectangular frame structure. The middle part of the rectangular frame structure forms an accommodating cavity (15). The upper surfaces of the left longitudinal beam (11), right longitudinal beam (12), front crossbeam (13), and rear crossbeam (14) that form the rectangular frame structure are flush with each other and are on the same horizontal plane, forming a mounting surface (16). The battery module housing (2) is housed in the accommodating cavity (15), and the upper end of the battery module housing (2) is matched and fixed on the mounting surface (16).

7. An integrated battery assembly according to claim 6, characterized in that: The battery module housing (2) includes an open housing (22), a sealing strip (23), an opening (21), and an upper edge (24) of the housing. The lower bottom wall of the housing (22) is provided with an opening (21), and the upper edge (24) of the housing is provided at the open position at the upper end of the housing (22). The housing (22) is housed in the housing cavity (15) of the spare tire basin assembly (1). The lower surface of the upper edge (24) of the housing is circumferentially fixed with a sealing strip (23). The lower surface of the upper edge (24) of the housing and the sealing strip (23) are in contact with the mounting surface (16) and are fixedly connected by bolts or FDS. The edge (741) of the housing (74) is screwed and fixed to the bottom wall of the housing (22) at the outer edge of the opening (21).

8. An integrated battery assembly according to claim 1, characterized in that: The fireproof board assembly (8) is composed of a mica board (81), the overall thickness of the mica board (81) is 2mm to 5mm, the inner surface of the mica board (81) is coated with a heat-absorbing coating (82), the thickness of the heat-absorbing coating (82) is 0.2mm to 1mm; the left and right end faces of the mica board (81) are respectively provided with flanges (83) facing the inner surface of the mica board (81), and at least two tubular flame-retardant material filling cavities (84) are horizontally opened between the front and rear end faces of the mica board (81). The position of each tubular flame-retardant material filling cavity (84) corresponds to the cell explosion-proof valve on the upper end face of the battery module (6), and each tubular flame-retardant material filling cavity (84) is filled with flame-retardant material (85), the flame-retardant material (85) is flame-retardant gel.

9. A new energy vehicle, characterized in that: The vehicle includes an integrated battery assembly as described in any one of claims 1-8, and also includes a vehicle chassis and a vehicle trunk. The spare tire tray assembly (1) is part of the vehicle chassis and is welded to the rear of the vehicle chassis. The integrated battery assembly constitutes the bottom sheet metal of the vehicle trunk.

10. A design method for an integrated battery assembly as described in any one of claims 1-8, characterized in that: This includes static load design and dynamic load design. The steps for static load design are as follows: S1. Determine the static load design target: the maximum stress σp of the battery box is less than the yield stress σs of the selected material, and the battery will not produce permanent deformation. S2. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk. S3. Conduct battery assembly design: Select battery box materials including steel, aluminum alloy, and titanium alloy, and carry out structural design and feature design; S4. Conduct CAE-aided design: including simulation analysis, morphology optimization, and topology optimization; If the result is determined, and σp < σs, then the static load design requirements are met; if σp ≥ σs, then return to step S3 and start the battery assembly design again. The dynamic load design steps are as follows: S101. Determine the dynamic load design target: the battery assembly shall be free from structural damage such as cracks, fractures or sealing failures; S102. Determine the load G, which includes the weight of the battery pack itself Gp and the maximum load Gs of the vehicle's trunk. S103. Determine the impact load xg. Under the maximum load of the vehicle and different working conditions, road spectrum data is collected at different locations of the battery pack to determine the maximum impact load xg. S104. Conduct battery assembly design: This mainly includes the selection of battery box materials, including but not limited to steel, aluminum alloy, titanium alloy, etc., and structural design and feature design. S105. Conduct CAE-aided design: Conduct CAE mechanical impact simulation analysis, load a half-sine shock wave onto the vehicle where the test battery assembly is located, with the direction ±Z, acceleration xg, pulse time 5ms~10ms, and the number of impacts 4~10 times in both positive and negative directions, and perform morphology optimization and topology optimization. If the simulation results show that the battery has no structural damage such as cracks, breaks, or sealing failures, then the dynamic load design requirements are met. If the design target requirements are not met, return to step S104 and start the battery assembly design again.

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