Upper Box of Power Battery Pack for Pure Electric Commercial Vehicle

Abstract

The present invention discloses an upper box body of a power battery box for a pure electric commercial vehicle, comprising: the edges of the top surface of the upper box body formed by multiple corner profiles, and the edges of the bottom surface of the upper box body formed by multiple rabbet profiles; the bottom surface and the top surface have the same shape, and the side length of the bottom surface is greater than that of the top surface; each corner of the top surface and each corner of the bottom surface are connected by a corner profile; the corner profile includes a straight plate edge connected at the end; three corner profiles at each vertex of the top surface of the upper box body are riveted through an internal connecting angle plate; a flat plate is adhesively sealed with the straight plate edge to form an upper box body with an open bottom. The present invention innovates in the structure and process of the integral battery box upper box body, and can adopt small-sized extrusion profiles, flat plates, and connecting angle plates to realize a sealed structure with a large-sized square shape through a bonding and riveting process, and provide support strength and sealing rabbets. As a lightweight and extensible solution, it saves the investment in large-scale equipment and molds, and has flexible size expandability.

Description

Technical Field

[0001] The present invention relates to a power battery box, specifically an upper box body of a power battery box for a pure electric commercial vehicle. Background Art

[0002] The power battery box body of a new energy passenger vehicle is divided into an upper box body and a lower box body. The upper box body, that is, the upper cover, bears relatively little load. Mainly consider the strength and protection performance of the box cover to bear its own weight, and ensure that the protection requirements and mechanical safety performance are met.

[0003] At present, the relatively mature upper cover materials mainly include sheet metal upper covers, aluminum plate upper covers, and composite material upper covers. There are two forming processes for sheet metal and aluminum plate upper covers: bending + welding and integral stamping forming. Composite materials generally use integral forming (molding or SMC).

[0004] For the sake of weight reduction, the upper cover is generally made relatively thin. However, for the batteries of general pure electric vehicles, the upper cover is relatively large in size, and local convex hulls or reinforcing ribs need to be added; in terms of processing technology, integral forming needs to consider the draft angle and fillet radius, and the stretching depth is limited by materials and processes; while the bending + welding process is limited by the bending size, welding position, and the feasibility of anti-corrosion paint.

[0005] Since pure electric commercial vehicles require a large amount of power battery power, at present, the vast majority of them adopt the method of assembling multiple standard packages together. For the standard packages side-hung outside the vehicle frame, protective covers are often installed. For the standard packages behind the cab, protective plates are often assembled outside the installation skeleton of the standard packages. The protective covers and protective plates do not have the function of box body sealing and can only play a certain role in shielding and protection.

[0006] Since pure electric commercial vehicles require a large amount of power, the existing battery box body structure that assembles multiple standard packages plus protective covers, due to its own structural characteristics, sufficient installation and wiring gaps need to be left between each standard package. The volume and weight energy density of the standard package itself are limited, and it has been difficult to meet the requirements of pure electric trucks for the battery system to increase power, reduce weight, reduce volume, increase energy density, and reduce costs; with the progress of battery technology itself and the development of the automotive industry, the CTC or MTB technology of directly assembling batteries or modules has become possible.

[0007] With the development of battery CTC / MTB technology, the trend of the power battery system of pure electric commercial vehicles is towards integration and centralization, and a large-sized sealed box body needs to be configured. Due to the large external dimensions in length, width, and height, it is very difficult to use traditional stamping forming or non-metallic molding, which requires large-scale equipment and mold investment, and different box body sizes require different molds.

[0008] However, if the structure of the upper and lower boxes of a passenger car is adopted for the battery box of a commercial vehicle, due to its very large size, two of the length, width and height dimensions of the battery box will be close to or exceed 2 meters. If the upper box is formed by an integrated molding process, it will require extremely large molds and integrated molding equipment, and the draft angle and fillet and other structures will result in reduced space utilization; while for large-size thin plate materials, if the bending + welding process is adopted, it is difficult to ensure their own strength, anti-corrosion and sealing performance at the welding joints. Summary of the Invention

[0009] Aiming at the problems existing in the background technology, the purpose of the present invention is to provide an upper box of a pure electric commercial vehicle power battery box with large capacity, high space utilization rate, reliable connection and sealing.

[0010] To achieve the above object, the upper box of the pure electric commercial vehicle power battery box designed by the present invention includes:

[0011] The edges of the top surface of the upper box formed by multiple corner profiles, and the edges of the bottom surface of the upper box formed by multiple rabbet profiles; the bottom surface and the top surface have the same shape, and the side length of the bottom surface is greater than that of the top surface;

[0012] Each corner of the top surface is connected to each corner of the bottom surface through a corner profile.

[0013] The corner profile includes a straight plate edge connected at the end; three corner profiles at each vertex of the top surface of the upper box are riveted through an internal connection angle plate.

[0014] A flat plate is bonded and sealed with the straight plate edge to form an upper box with an open bottom.

[0015] Preferably, the outer wall of the straight plate edge is bonded to the inner wall of the flat plate.

[0016] More preferably, at least one groove is provided along the length direction of the outer wall of the straight plate edge. In this way, the bonding effect between the straight plate edge and the flat plate is increased.

[0017] More preferably, a boss is provided at the connection of the ends of the straight plate edge. In this way, it is convenient to position and install the flat plate.

[0018] Even more preferably, the height of the boss is equal to the thickness of the flat plate.

[0019] Preferably, the folding angle profile is integrally extruded.

[0020] Preferably, the internal connection angle plate is an open member formed by three equal-thickness quadrilateral plate members sharing a common vertex and adjacent quadrilateral plate members sharing a common side.

[0021] More preferably, the straight plate edge is riveted to the quadrilateral plate member; the riveting holes are located on the diagonal line of the quadrilateral plate member.

[0022] More preferably, the diagonal line where the riveting holes are located on the same quadrilateral plate does not pass through the common vertex of the three quadrilateral plates.

[0023] Preferably, the inner connecting angle plate is integrally formed by stamping.

[0024] Preferably, the straight plate edge is provided with a chamfer, and the intersection line of the chamfers is adapted to the common side and vertex of the quadrilateral plate, so that the inner wall of the straight plate edge fits against the outer wall of the quadrilateral plate.

[0025] Preferably, the rabbet profile includes a horizontal plate and vertical plates located on both sides of the horizontal plate and perpendicularly connected to the two ends of the horizontal plate respectively; the flat plate is bonded to one of the vertical plates, and the flat plate and the horizontal plate are respectively located on both sides of the bonded vertical plate.

[0026] More preferably, the joints of the rabbet profiles surrounding the upper box body are riveted through outer connecting angle plates.

[0027] As a preferred solution, the outer connecting angle plate is an open member formed by three quadrilateral plates of equal thickness surrounding a common vertex and adjacent quadrilateral plates sharing a common side.

[0028] Preferably, the end of the vertical plate not bonded to the flat plate is inserted into the outer connecting angle plate and riveted through rivets, and the connecting line of the rivet hole centers on the same quadrilateral plate passes through the common vertex of the three quadrilateral plates.

[0029] Preferably, a rabbet is provided on the quadrilateral plate of the outer connecting angle plate without a riveting hole, and the vertical plate bonded with the flat plate abuts against the rabbet.

[0030] Preferably, the end of the rabbet profile plate is provided with a chamfer, and the intersection line of the chamfers is adapted to the common side and vertex of the quadrilateral plate, so that the outer wall of the vertical plate not bonded to the flat plate fits against the inner wall of the quadrilateral plate.

[0031] Preferably, the rabbet profile is integrally extruded.

[0032] The beneficial effects of the present invention are: it is composed of a flat plate, a folding angle profile, a rabbet profile, a connecting angle plate, etc. connected by rivets and adhesives; the folding angle profile forms the ridge line of the upper box body, the flat plate forms each surface of the upper box body, and the rabbet profile forms a circumferential strengthening and sealing surface at the opening boundary of the bottom of the upper box body.

[0033] Due to the characteristics of the extruded profiles, such as consistent cross-section and no process limitation on the single-piece length, using extruded profiles to form the edges and rabbets of the upper box can achieve a box size of 2 to 3 meters on one side, overcome the problem of difficult forming of large-size upper boxes, and eliminate the need for large-scale (molding / stamping) equipment; the upper box formed by combining profiles and panels does not require a draft angle, can achieve a square shape and internal volume, which is more conducive to the layout of internal components such as battery modules / cells, and has a higher space utilization rate compared to the integrally formed upper box with a draft angle.

[0034] By adopting the technical solution of the present invention, innovation is carried out in the structure and process of the upper box of the integral battery box. A sealed structure with a large-size square shape can be achieved by using small-sized extruded profiles, flat plates, and connecting angle plates through adhesive riveting technology, and provide support strength and sealing rabbets. As a lightweight and extensible solution, it saves the investment in large-scale equipment and molds and has flexible size scalability. Brief Description of the Drawings

[0035] Figure 1 is a three-dimensional schematic diagram of the present invention, in which the flat plate is not shown;

[0036] Figure 2 is Figure 1 an enlarged schematic diagram of part A in

[0037] Figure 3 is Figure 1 an enlarged schematic diagram of part B in

[0038] Figure 4 is a structural schematic diagram of the corner profile of the present invention;

[0039] Figure 5 is a bonding schematic diagram of the corner profile and the flat plate of the present invention;

[0040] Figure 6 is a bonding schematic diagram of the rabbet profile and the flat plate of the present invention;

[0041] Figure 7 is an exploded schematic diagram at the vertex of the top surface of the upper box of the present invention;

[0042] Figure 8 is an exploded schematic diagram at the vertex of the bottom surface of the upper box of the present invention. Detailed Embodiments

[0043] The technical solutions (including the preferred technical solutions) of the present invention will be further described in detail below by way of the drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope of protection of the present invention.

[0044] As Figures 1 to 8 shown, the upper box body of the power battery box of the pure electric commercial vehicle designed by the present invention includes: the edges of the top surface of the upper box body formed by multiple corner profiles 1, and the edges of the bottom surface of the upper box body formed by multiple rabbet profiles 2; the bottom surface and the top surface have the same shape, and the side length of the bottom surface is greater than that of the top surface; each corner of the top surface and each corner of the bottom surface are connected by a corner profile 1; the corner profile includes a straight plate edge 1.1 connected at the end; three corner profiles 1 at each vertex of the top surface of the upper box body are riveted by an internal connecting angle plate 3; a flat plate 5 is adhesively sealed with the straight plate edge 1.1 to form an upper box body with an open bottom.

[0045] The flat plate 5 is connected with the corner profile 1, the rabbet profile 2, the connecting angle plates 3, 4, etc. through rivets and adhesives; the corner profile 1 forms the ridge line of the upper box body, the flat plate 5 forms each surface of the upper box body, and the rabbet profile 2 forms a circumferential strengthening and sealing surface at the opening boundary of the bottom of the upper box body.

[0046] In some optional embodiments of the present invention, the outer wall of the straight plate edge 1.1 is adhesively bonded to the inner wall of the flat plate 5.

[0047] In some optional embodiments of the present invention, at least one groove 1.2 is provided along the length direction of the outer wall of the straight plate edge 1.1. In this way, the adhesive effect between the straight plate edge 1.1 and the flat plate 5 is increased.

[0048] In some optional embodiments of the present invention, a boss 1.2 is provided at the connection of the ends of the straight plate edge 1.1. In this way, it is convenient to position and install the flat plate 5.

[0049] In some optional embodiments of the present invention, the height of the boss 1.2 is equal to the thickness of the flat plate 5.

[0050] In some optional embodiments of the present invention, the corner profile 1 is integrally extruded.

[0051] In some optional embodiments of the present invention, the internal connecting angle plate 3 is an open member formed by three quadrilateral plate members of equal thickness surrounding a common vertex and adjacent quadrilateral plate members sharing a common side.

[0052] In some optional embodiments of the present invention, the straight plate edge 1.1 is riveted to the quadrilateral plate member; the riveting holes are located on the diagonal of the quadrilateral plate member.

[0053] In some optional embodiments of the present invention, the diagonal line where the riveting holes are located on the same quadrilateral plate member does not pass through the common vertex of the three quadrilateral plate members.

[0054] In some optional embodiments of the present invention, the internal connecting angle plate 3 is integrally stamped.

[0055] In some optional embodiments of the present invention, the straight plate edge 1.1 is provided with a chamfer, and the intersection of the chamfers matches the common edges and vertices of the quadrilateral plate, so that the inner wall of the straight plate edge 1.1 fits the outer wall of the quadrilateral plate.

[0056] In this embodiment, the angled profile 1 is an extruded long strip profile with a uniform cross-section, and the overall cross-section is an equilateral right angle of 90°, providing two inner and outer horizontal mounting surfaces and two inner and outer vertical mounting surfaces. A boss 1.2 is provided at the intersection of the outer mounting surface, and the thickness of the boss 1.2 is consistent with that of the flat plate material 5; parallel grooves are provided on the outer mounting surface to enhance the bonding effect.

[0057] At the four corners of the top surface of the upper box body, three angled profiles 1 are perpendicular to each other, and the butt ends are cut at 45° angles on both surfaces, and the pointed ends are butted at one point, which is one of the top corner vertices of the upper box body. The three angled profiles 1 are provided with connecting through holes with sinks on the mounting surface behind the butt points. The sinks are located on the outer mounting surface and are connected and fixed to the inner connecting angle plate by countersunk rivets to form the contour edges of the upper box body.

[0058] The inner connecting angle plate 3 is in the shape of three square plates of equal thickness connected in pairs, which are formed by stamping and cutting. Each square surface has a through hole corresponding to the connecting through hole of the connecting profile, and the holes are located on both sides of the diagonal. The inner connecting angle plate is lined on the inner surface of the joint of the angle profile, and the countersunk rivet extends from the outer mounting surface of the angle profile. The inner connecting angle plate 3 and the angle profile 1 are connected by riveting to provide connection strength. Before riveting, glue is applied on the joint surface of the inner connecting angle plate 3, and the glue ensures the sealing of the seams of the three angle profiles 1.

[0059] After the angled profiles 1 at the corners of the top surface of the upper box body are butt-jointed, their outer mounting surfaces provide a bonding basis for the flat plate material 5, and the flat plate material 5 is bonded to form the outer surface of the upper box body, including the top surface and the peripheral surface.

[0060] In some optional embodiments of the present invention, the stop profile 2 includes a horizontal plate 2.1, and vertical plates located on both sides of the horizontal plate and whose ends are respectively vertically connected to both ends of the horizontal plate 2.1; the flat plate 5 is bonded to one of the vertical plates, which is the first vertical plate 2.2 in this embodiment, and the flat plate 5 and the horizontal plate 2.1 are respectively located on both sides of the above-mentioned bonded vertical plate, that is, the first vertical plate 2.2 in this embodiment.

[0061] In some optional embodiments of the present invention, the intersections of the stop profiles 2 forming the upper box body are riveted together by external connecting angle plates 4 .

[0062] In some optional embodiments of the present invention, the external connecting angle plate 4 is an opening piece surrounded by three quadrilateral plates of equal thickness, which shares a common vertex and adjacent quadrilateral plates share a common side.

[0063] In some alternative embodiments of the present invention, the end of the vertical plate that is not bonded to the flat plate member 5, i.e., the end of the second vertical plate 2.3, is inserted into the outer connecting angle plate 4 and riveted by rivets, and the connecting line of the rivet hole centers on the same quadrilateral plate member passes through the common vertex of the three quadrilateral plate members.

[0064] In some alternative embodiments of the present invention, a rabbet 4.1 is provided on the quadrilateral plate member of the outer connecting angle plate 4 where no rivet hole is provided, and the vertical plate bonded with the flat plate member, i.e., the first vertical plate 2.2, abuts against the rabbet 4.1.

[0065] In some alternative embodiments of the present invention, the end of the rabbet profile 2 is provided with a chamfer, and the intersection line of the chamfers is adapted to the common side and vertex of the quadrilateral plate member, so that the outer wall of the vertical plate that is not bonded to the flat plate member, i.e., the second vertical plate 2.3, fits against the inner wall of the quadrilateral plate member.

[0066] In some alternative embodiments of the present invention, the rabbet profile 2 is integrally extruded.

[0067] The rabbet profile 2 is an extruded profile with a constant cross-section, and the cross-section is Z-shaped. The upper vertical surface on the inner side is adhesively bonded to the bottom of the outer surface of the upper box body along the circumference. The lower horizontal surface is a sealing surface, and the lower vertical surface on the outer side is adhesively riveted and fixed to the outer connecting angle plate at the corner docking.

[0068] The outer connecting angle plate 4 has an outer shape of an equal-thickness plate member formed by combining three mutually perpendicular squares. It is formed by stamping and then cutting. Through holes corresponding to the connecting through holes of the connecting profile are provided on the two square surfaces connected to the outer vertical surface of the rabbet profile 2, and the hole positions are on the diagonal line. The plane connected to the upper surface of the rabbet profile has a square notch to avoid the docking space of the upper vertical surface of the rabbet profile.

[0069] The bonding combination of the angled profile and the flat plate, and the rabbet structure of the profile is adhesively bonded to the butting joint of the flat plate. The rabbet is beneficial for the positioning and adhesive filling of the plate, ensuring reliable sealed connection.

[0070] The angled profile and the connecting angle plate are connected by countersunk head rivets, which can realize the combined process of the profile edge skeleton, directly build the bonding foundation of the flat plate, and at the same time provide the necessary strength and stiffness for the upper box body.

[0071] After the rabbet profile is adhesively bonded to the opening of the lower box body along the circumference, the local structure of the box body opening is strengthened, and a flat sealing reference surface is provided.

[0072] In this embodiment, it is a large-sized upper box body of a power battery box, with a single side length of more than 1 meter, which is difficult to process using conventional one-piece molding technology; the top surface and the vertical surfaces along the circumference are composed of 5 flat plate materials, 8 corner profiles and 4 internal connecting angle plates constitute the edges of the box body, and 4 stop profiles and 4 external connecting angle plates constitute the circumferential structure of the bottom opening of the upper box body, forming an overall large-sized upper box body structure with a square appearance.

[0073] The corner profile is a long strip profile with equal cross-section extrusion. The overall cross-section is a 90° equilateral right angle, providing two inner and outer horizontal mounting surfaces and two inner and outer vertical mounting surfaces. A boss is set at the intersection of the outer mounting surface, and the thickness of the boss is consistent with that of the flat plate. Two parallel grooves are set on the outer mounting surface to enhance the bonding effect.

[0074] At the four corners of the top surface of the upper box, three angle profiles are perpendicular to each other, and the butt ends are cut at a 45° angle on both surfaces. The arrows butt at one point, which is one of the top corner vertices of the upper box. The three angle profiles are provided with connecting through holes with sinks on the mounting surface behind the butt points. The sinks are located on the outer mounting surface. The inner connecting angle plate is lined in the angle profile. The three perpendicular surfaces are fitted with the inner surface of the angle profile. The inner connecting angle plate is connected and fixed to the angle profile by countersunk rivets. The countersunk side of the rivets is located on the outside. Glue is applied on the butt surface of the connecting angle plate before riveting. The glue ensures the sealing of the seams of the three angle profiles to form the contour edges of the upper box.

[0075] The inner connecting angle plate is in the shape of three equal-thickness plates connected in pairs and perpendicular to each other, which are formed by stamping and then cutting. Each square surface has a through hole corresponding to the connecting through hole of the connecting profile, and the holes are located on both sides of the diagonal.

[0076] The appearance of the external connecting angle plate is three equal-thickness plates connected in pairs of perpendicular squares. It is formed by stamping and then cutting. The two square surfaces connected to the outer vertical surface of the stop profile have through holes corresponding to the connecting through holes of the connecting profile. The holes are located on the diagonal line. The plane connected to the upper surface of the stop profile has a square notch to avoid the docking space of the vertical surface of the stop profile.

[0077] The stop profile is an extruded profile with a uniform cross-section and a Z-shaped cross-section. The inner upper vertical surface is bonded to the outer surface bottom of the upper box along the circumferential opening, the lower horizontal surface is a sealing surface, and the outer lower vertical surface is riveted to the external connecting angle plate at the corner joint. Countersunk rivets are used for connection, and the countersunk side is on the inner side of the stop profile.

[0078] The panels and profile joints at the opening corners at the bottom of the upper box body are provided with supporting surfaces to ensure reliable gluing.

[0079] It is easily understandable to those skilled in the art that the above are only the preferred embodiments of the present invention and do not limit the present invention. Any modifications, combinations, substitutions, improvements, etc. made under the spirit and principle of the present invention are all included in the protection scope of the present invention.

Claims

1. An upper box body of a power battery box for a pure electric commercial vehicle, characterized in that, Comprising: Edges on the top surface of the upper box body composed of multiple corner profiles, and edges on the bottom surface of the upper box body composed of multiple rabbet profiles; the bottom surface and the top surface have the same shape, and the side length of the bottom surface is greater than that of the top surface; Each corner of the top surface and each corner of the bottom surface are connected by a corner profile; The corner profile includes two straight plate edges connected at the ends, providing two horizontal mounting surfaces on the inner and outer sides and two vertical mounting surfaces on the inner and outer sides, and a boss is provided at the intersection of the outer mounting surfaces; Three corner profiles at each vertex of the top surface of the upper box body are riveted through an inner connecting angle plate; the inner connecting angle plate is an open piece formed by three quadrilateral plate pieces of equal thickness enclosing a common vertex and adjacent quadrilateral plate pieces sharing a common side; The rabbet profile includes a horizontal plate, and vertical plates located on both sides of the horizontal plate and perpendicularly connected to the two ends of the horizontal plate at the ends; The flat plate is adhesively sealed with the straight plate edge to form an upper box body with an open bottom; the flat plate is adhesively bonded to one of the vertical plates, and the flat plate and the horizontal plate are respectively located on both sides of the adhesively bonded vertical plate; The intersections of the rabbet profiles enclosing the upper box body are riveted through an outer connecting angle plate; the outer connecting angle plate is an open piece formed by three quadrilateral plate pieces of equal thickness enclosing a common vertex and adjacent quadrilateral plate pieces sharing a common side.

2. The upper box body of the power battery box of the pure electric commercial vehicle according to claim 1, wherein: The outer wall of the straight plate edge is adhesively bonded to the inner wall of the flat plate; at least one groove is provided along the length direction of the outer wall of the straight plate edge.

3. The upper box body of the power battery box of the pure electric commercial vehicle according to claim 1 or 2, characterized in that: The height of the boss is equal to the thickness of the flat plate.

4. The upper box body of the power battery box of the pure electric commercial vehicle according to claim 1, characterized in that: The straight plate edge is riveted to the quadrilateral plate piece; the riveting holes are located on the diagonal of the quadrilateral plate piece; the diagonal where the riveting holes are located on the same quadrilateral plate piece does not pass through the common vertex of the three quadrilateral plate pieces; the straight plate edge is provided with a chamfer, and the intersection line of the chamfer is adapted to the common side and vertex of the quadrilateral plate piece, so that the inner wall of the straight plate edge fits with the outer wall of the quadrilateral plate piece.

5. The upper box body of the power battery box of the pure electric commercial vehicle according to claim 1, wherein: The end of the vertical plate not adhesively bonded to the flat plate is inserted into the outer connecting angle plate and riveted through a rivet, and the connecting line of the riveting hole centers on the same quadrilateral plate piece passes through the common vertex of the three quadrilateral plate pieces; the end of the rabbet profile plate is provided with a chamfer, and the intersection line of the chamfer is adapted to the common side and vertex of the quadrilateral plate piece, so that the outer wall of the vertical plate not adhesively bonded to the flat plate fits with the inner wall of the quadrilateral plate piece.

6. The upper box body of the power battery box of the pure electric commercial vehicle according to claim 5, characterized in that: A rabbet is provided on the quadrilateral plate piece of the outer connecting angle plate without a riveting hole, and the vertical plate adhesively bonded with the flat plate abuts against the rabbet.

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