A battery box can be quickly disassembled

Abstract

The application provides a battery box for battery replacement, which can be quickly disassembled, and comprises a box upper cover, a lower box, a module support plate and a box connecting plate. The box upper cover is used for covering the lower box. The lower box comprises a lower box bottom plate and a side beam arranged around the side of the lower box bottom plate to form a cavity in the lower box. A cross beam is arranged in the cavity to separate a battery module installation area for installing the battery module in the cavity. The module support plate is detachably arranged in the module installation area. The battery module is installed on the upper surface of the module support plate and detachably connected with the lower box. When two or more battery replacement battery boxes are used in cooperation, the two or more battery replacement battery boxes are detachably connected through the box connecting plate. In the application, the battery module can be disassembled without damaging the battery cell and other parts. When the battery module is repaired, the original structure can be guaranteed to be intact, and the battery module can be quickly disassembled.

Description

Technical Field

[0001] This invention relates to the field of battery swapping enclosure technology for new energy vehicle power batteries, and in particular to a battery swapping enclosure with quickly detachable modules. Background Technology

[0002] Currently, the power battery pack in new energy vehicles is typically an integral part of the vehicle assembly. For most cars, the manufacturing cost of the power battery pack accounts for 30%-60% of the total vehicle cost. During daily commutes, approximately 60% of the battery's capacity remains idle, only being used on long journeys. This not only fails to fully utilize the large capacity of the power battery but also adds several hundred kilograms to the vehicle's weight.

[0003] The traditional charging method for new energy vehicles is the charging station system. With this system, users often have to wait 1-2 hours for charging stations during long journeys due to insufficient availability, which limits the use and promotion of electric vehicles. Battery swapping, on the other hand, is a new energy vehicle charging method that involves replacing the battery at a swapping station to quickly recharge the car. With battery swapping, users can fully charge their vehicles in just a few minutes, significantly reducing time costs compared to the charging station system.

[0004] In existing technologies, battery casings are typically welded together, with the lower casing being a single unit. When the battery module is installed into the casing, structural adhesive is applied to its bottom to connect it to the base plate on the casing. With this connection method, if a single or a few cells malfunction and require repair, the entire battery module needs to be disassembled. However, due to the presence of structural adhesive, the usual disassembly method involves inserting a pry bar into the gap between the side wall of the battery casing and the side wall of the battery module, and forcefully prying upwards to separate the casing from the module. Then, a lifting device is used to remove the battery module. This disassembly method is difficult to perform and prone to damage to the cells, battery module, or even the battery casing due to excessive force or improper prying direction, leading to increased repair costs. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings and defects of existing technologies by providing a battery swapping housing that allows for quick disassembly of modules.

[0006] To achieve the objectives of this invention, the present invention provides a battery swapping housing with a quickly detachable module, comprising an upper cover, a lower housing, a module support plate, and a housing connecting plate.

[0007] The top cover of the box is used to close and fit onto the lower box.

[0008] The lower housing includes a lower housing bottom plate and side beams that surround and are arranged on the sides of the lower housing bottom plate to form a cavity inside the lower housing;

[0009] A crossbeam is provided inside the cavity to separate a battery module installation area for installing the battery module.

[0010] The module support plate is detachably installed in the module placement area;

[0011] The battery module is mounted on the upper surface of the module support plate and is detachably connected to the lower housing;

[0012] When two or more battery swapping boxes are used together, the two or more battery swapping boxes can be detachably connected through the box connecting plate.

[0013] Preferably, the box connecting plate is threaded onto two or more battery swapping boxes.

[0014] Preferably, a second rivet nut is provided on the top of the side beam, and bolt holes are provided on the box connecting plate. The box connecting plate connects two or more battery swapping boxes through the provided second bolts, bolt holes, and second rivet nuts.

[0015] Preferably, the number of second rivet nuts provided on a single lower housing is between 2 and 10 to meet the connection strength requirements between battery housings. More preferably, the structural strength and manufacturability are optimal when the number of second rivet nuts is between 4 and 6.

[0016] Preferably, the size of the box connecting plate and the number of bolt holes are determined according to the number of battery swapping boxes to be connected.

[0017] Preferably, the battery module and the module support plate are connected by structural adhesive.

[0018] Preferably, the distance d from the top of the reinforcing rib in the module support plate to the adhesive surface is 4-6 mm.

[0019] Preferably, it also includes a sealing element disposed between the upper cover and the lower cover of the housing.

[0020] Preferably, the upper cover and lower box body are connected by a combination of rivet nuts and bolts.

[0021] Preferably, the connecting plate of the box body is a plain aluminum profile, a thin steel stamping plate, or a die-cast aluminum structure. More preferably, the thickness of the plain aluminum profile is between 3-5 mm; the thickness of the thin steel stamping plate is between 1-2 mm; and the thickness of the die-cast aluminum structure is between 2.5-5 mm.

[0022] Preferably, the bottom inner side of the module support plate is provided with reinforcing ribs.

[0023] Preferably, a first rivet nut is provided at the bottom of the crossbeam and at the bottom of the side beam opposite to the crossbeam in the battery module installation area. Bolt holes are provided on both sides of the module support plate. The first bolts on both sides of the module support plate are respectively engaged with the corresponding bolt holes and the first rivet nut in sequence to realize the detachable setting of the module support plate.

[0024] Preferably, each side beam is fixed to the base plate, and each crossbeam is fixed to the side beam by welding. The welding methods can include TIG welding, MIG welding, friction stir welding, and laser welding. More preferably, laser welding produces a more aesthetically pleasing weld with minimal welding deformation and residual stress.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1) This invention provides a battery swapping housing with a quickly detachable module. By adding a module support plate, damage to the battery cells and other parts can be avoided during the disassembly process of the battery module; when the battery cells are being repaired, the battery module can be quickly disassembled while ensuring the integrity of the original structure.

[0027] 2) This invention provides a battery swapping housing with quickly detachable modules. The battery housing can be used individually or in flexible combinations of two or four units. Users can rent different combinations of battery housings according to their actual needs during daily travel, thereby reducing usage costs. Attached Figure Description

[0028] Figure 1 This is an exploded perspective view of a battery swapping housing structure with a quickly detachable module, provided by the present invention.

[0029] Figure 2 This is a three-dimensional structural diagram of a battery swapping box structure that allows for quick disassembly of modules, provided by the present invention.

[0030] Figure 3 This invention provides a three-dimensional structural diagram of a module support plate in a battery swapping housing structure that allows for quick disassembly of modules.

[0031] Figure 4 This is a partial cross-sectional view of a module support plate and structural adhesive in a battery swapping box structure that allows for quick disassembly of modules, provided by the present invention.

[0032] Figure 5 This invention provides a battery swapping housing structure that allows for quick disassembly of modules, and a schematic diagram of the structure after the battery modules are installed.

[0033] Figure 6This is a partial cross-sectional view of a battery swapping housing structure with a quickly detachable module, provided by the present invention, showing the battery module mounted on the lower housing.

[0034] Figure 7 This is a partial cross-sectional view of a battery swapping housing structure with a quickly detachable module provided by the present invention, showing the housing connecting plate mounted on the lower housing.

[0035] Figure 8 This invention provides a battery swapping housing structure with a quick-disassembly module, and includes a schematic diagram of the planar structure of three types of housing connection plates.

[0036] Figure 9 This invention provides a battery swapping housing structure that allows for quick disassembly of modules, and a schematic diagram of the planar structure after two battery housings are horizontally connected.

[0037] Figure 10 The present invention provides a battery swapping housing structure for quick-disassembly of modules, and a schematic diagram of the planar structure after two battery housings are longitudinally connected. Figure 2 .

[0038] Figure 11 This invention provides a battery swapping housing structure that allows for quick disassembly of modules, and a schematic diagram of the planar structure after the four battery housings are connected. Detailed Implementation

[0039] The technical solutions of the present invention will now be clearly and completely described with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0040] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are only for the convenience of describing the 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, and therefore should not be construed as limiting the invention. 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 indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0041] 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 a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] refer to Figures 1 to 11 The present invention provides a battery swapping box structure that allows for quick disassembly of modules, including a box top cover 1, a lower box 2, and a box connecting plate 3.

[0043] The bottom of the upper cover 1 of the box is connected to the top of the lower box 2.

[0044] The lower housing 2 includes a rectangular lower housing base plate 22.

[0045] The top of the lower box base plate 22 is surrounded by four side beams 20 to form a cavity on the inside.

[0046] A crossbeam 21 is installed inside the cavity of the four side beams 20 to separate a battery module installation area 23 for installing the battery module.

[0047] A module support plate 4 is detachably installed in the module placement area 23.

[0048] The module support plate 4 has four bolt holes 40 at each end, and a reinforcing rib 41 is formed at the bottom of the module support plate 4. The function of the reinforcing rib 41 is to distinguish between the glued surface and the non-glued surface, and its height is consistent with the glue thickness in the design.

[0049] The module support plate 4 is located between the battery module 6 and the side beam 20 or the cross beam 21.

[0050] The battery module is mounted on the upper surface of the module support plate 4 and is detachably connected to the lower housing 2.

[0051] When two or more battery swapping boxes are used together, the two or more battery swapping boxes can be detachably connected through the box connecting plate 3.

[0052] In some embodiments of the present invention, the lower housing base plate 22, the side beam 20 and the crossbeam 21 enclose two areas, the larger area being the module placement area 23, and the smaller area generally being used to place electronic control components such as BMS and BDU.

[0053] In some embodiments of the present invention, a first rivet nut 8 is provided on the crossbeam 21 and the parallel and distant side beam 20, at a position corresponding to each bolt hole 40 of the module support plate 4. The battery module 6, the module support plate 4, and the crossbeam 21 or the side beam 20 are connected together by a first bolt 7 (such as an M6 long bolt) and a first rivet nut 8 (such as an M6 rivet nut), thereby enabling the battery module 6 to be installed in the lower housing 2.

[0054] In some embodiments of the present invention, a second rivet nut 10 is provided on the top of the side beam 20, and a screw hole 33 is provided on the box connecting plate 3. The box connecting plate 3 connects two or more battery swapping boxes through the provided first bolt 7, the bolt hole 33, and the second rivet nut 10. Thus, multiple lower boxes 2 can be connected together by the cooperation of the second bolt 9 (which can be a short M5 bolt) and the second rivet nut 10 (which can be an M5 rivet nut) with the box connecting plate 3. It should be noted that the structural strength and manufacturability are optimal when the number of second rivet nuts is 4-6.

[0055] The dimensions of the housing connecting plate 3 and the number of bolt holes 33 are determined according to the number of battery swapping housings to be connected. In some embodiments of the present invention, specifically, for the housing connecting plate 3, such as... Figure 8 As shown, there are three different structural forms, defined as a first box connecting plate 30, a second box connecting plate 31, and a third box connecting plate 32. The first box connecting plate 30 is rectangular with bolt holes on both sides and in the middle. The second box connecting plate 31 is square with three rows of screw holes. When two battery swapping boxes are used together, they can be connected using either the first box connecting plate 30 or the second box connecting plate 31. Figure 9 and Figure 10 The third box connecting plate 32 is rectangular, with a relatively wide length and width, making it suitable for connecting multiple battery swapping boxes, such as... Figure 11 Of course, the above are just specific embodiments, and the size of the box connecting plate 3 and the location and number of bolt holes thereon are not limited to the examples mentioned above.

[0056] In some embodiments of the present invention, the structure of the box connecting plate 4 can be either a regular aluminum profile flat plate or a steel stamping sheet and an aluminum die-cast structure.

[0057] More preferably, when using ordinary aluminum profile flat plates, the thickness is between 3-5mm; when using steel stamping thin plates, the thickness is between 1-2mm; and when using aluminum die-casting structures, the thickness is between 2.5-5mm.

[0058] In this invention, reference Figure 4, Figure 5 As shown, the top of the module support plate 4 is connected to the bottom of the battery module 6 (specifically, they are connected by structural adhesive 5).

[0059] In some embodiments of the present invention, the top of the module support plate 4 is bonded to the bottom of a battery module 6 by a horizontally distributed, elongated structural adhesive. The total application area of ​​the elongated structural adhesive at the bottom is approximately 0.8 times the adhesive application area of ​​the module support plate 4.

[0060] In some embodiments of the present invention, the distance d from the top of the reinforcing rib 41 in the module support plate to the adhesive surface 410 is 4-6 mm. Preferably, when applying the structural adhesive 5, the thickness of the adhesive should not exceed the distance d from the top of the reinforcing rib to the adhesive surface 410.

[0061] In some embodiments of the present invention, the crossbeam 21 and the side beam 20, as well as the crossbeam 21 and the lower box base plate 22, are fixed by welding.

[0062] In some embodiments of the present invention, the side beams 20, crossbeams 21, and lower box base plate 22 are all made of 6061 or 6063 aluminum alloy. Preferably, the welding type can be TIG welding, MIG welding, friction stir welding, and laser welding.

[0063] It should be noted that laser welding produces more aesthetically pleasing welds with minimal welding deformation and residual stress; TIG welding is the most economical and suitable for manual welding in the production of battery box prototypes.

[0064] In some embodiments of the present invention, reference is made to Figure 1 As shown, the bottom of the upper cover 1 and the top of the lower cover 2 can be connected by a combination of rivet nuts (specifically M5 rivet nuts) and bolts (M5 bolts). In other embodiments, the bottom of the upper cover 1 and the top of the lower cover 2 can also be connected by a combination of rivet studs and nuts.

[0065] In some embodiments of the present invention, to prevent outside air from entering the interior of the lower housing 2 through the installation gap between the upper housing cover 1 and the lower housing 2, a seal should be installed between the upper housing cover 1 and the lower housing 2. Preferably, the seal can be an annular gasket or sealant.

[0066] In some embodiments of the present invention, reference is made to Figure 5 , Figure 6 As shown, for a single lower housing 2, the number of the second rivet nuts 10 is between 2 and 10, which can meet the connection strength between the battery housings.

[0067] It should be noted that the installation process for battery module 6 is as follows: First, apply a horizontal strip of structural adhesive to the module support plate 4, with the adhesive strips spaced approximately 15-20mm apart. Next, place the module support plate 4 on the lower housing 2, ensuring that the axis of the bolt holes 40 on the module support plate 4 is aligned with the axis of the first rivet nut 8. Then, place the battery module 6 into the lower housing 2, so that the bottom of the battery module 6 is bonded to the module support plate 4. Finally, use the first bolt 7 to pass through the front and rear end plates of the battery module 6 and the module support plate 4, connecting it to the first rivet nut 8 installed on the crossbeam 21 or side beam 20.

[0068] For the present invention, when the battery cell needs to be repaired, the disassembly process of the battery module 6 has three steps: First, remove the first bolt 7 used to connect the battery module 6, the module support plate 4 and the lower housing 2.

[0069] Second, use hoisting equipment (such as a gantry crane) to hoist the battery module 6 and module support plate 4 out simultaneously.

[0070] Third, the battery module 6 and the module support plate 4 are separated using tools.

[0071] It should be noted that in the third step of the disassembly process of battery module 6, workers can use tools such as handheld square blocks to insert into the bonding position between battery module 6 and module support plate 4, moving from the outside of each cell towards the center. This breaks the long strip of structural adhesive that bonds the cells in battery module 6 to module support plate 4, allowing the two to separate.

[0072] Compared with existing battery box removal methods, the battery module disassembly method mentioned in this invention has the following two advantages:

[0073] (1) After removing the first bolt 7, the battery module 6 and module support plate 4 can be directly removed using the hoisting equipment. Disassembly is convenient and will not damage the battery box, cells, or other parts.

[0074] (2) The staff has a large working space and simple operation. They can use less force to break the structural adhesive connecting the battery module 6 and the module support plate 4, thereby improving maintenance efficiency.

[0075] In this invention, for specific implementation, refer to Figures 7-11 The box body connecting plate 3 and multiple lower box bodies 2 are connected together by the second bolt 9 and the second rivet nut 10.

[0076] It should be noted that the assembly process for multiple battery boxes 2 is as follows: First, place two or four battery boxes 2 on the mounting platform. Then, place the box connecting plate 3 on the flange surface of the second rivet nut 10 installed on the top of the side beam 20. Finally, connect the box connecting plate 3 and the second rivet nut 10 installed on the side beam 20 with the second bolt 9.

[0077] In practice, when placing the box connecting plate 3 on the flange surface of the second rivet nut 10 installed on the top of the side beam 20, it should be ensured that the axis of the bolt hole 33 and the axis of the second rivet nut 10 are aligned.

[0078] Based on the above technical solutions, it can be seen that the present invention not only provides a design scheme for a battery swapping box, but also improves the efficiency of removing the battery module from the battery box when repairing the battery cell.

[0079] In summary, the battery swapping housing with quick-disassembly modules designed in this invention has the following advantages: During the disassembly of the battery modules, damage to the cells and other components can be avoided; when the battery modules are returned for repair, their original structure can be preserved, enabling quick disassembly; in terms of battery housing options, the housing can be used individually or flexibly combined in pairs or groups of four; and users can rent different combinations of battery housings according to their actual needs during daily travel, thereby reducing usage costs.

[0080] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several improvements based on the present invention. These improvements should also be considered within the scope of protection of the present invention without departing from its principles.

Claims

1. A battery swapping housing with a quickly detachable module, characterized in that, It includes the top cover (1), the lower box (2), the module support plate (4), and the box connecting plate (3). The top cover (1) of the box is used to cover the bottom box (2); The lower box (2) includes a lower box bottom plate (22) and side beams (20) surrounding the lower box bottom plate (22) to form a cavity inside the lower box (2); A crossbeam (21) is provided in the cavity to separate a battery module installation area (23) for installing the battery module. The module support plate (4) is detachably installed in the module placement area (23); The battery module is mounted on the upper surface of the module support plate (4) and is detachably connected to the lower housing (2); The bottom inner side of the module support plate (4) is provided with reinforcing ribs (41). The distance d from the top of the reinforcing ribs (41) to the adhesive surface (410) is 4-6mm. The battery module (6) and the module support plate (4) are connected by structural adhesive (5). The structural adhesive (5) is a horizontally distributed strip and the coating area is 0.8 times the coating area of ​​the module support plate (4). The bottom of the crossbeam (21) and the bottom of the side beam (20) opposite to the crossbeam (21) in the battery module installation area (23) are provided with first rivet nuts (8). The two sides of the module support plate (4) are provided with first bolt holes (40). The two sides of the module support plate (4) are respectively connected to the corresponding first bolt holes (40) and first rivet nuts (8) by the provided first bolts (7) in sequence, so as to realize the detachable setting of the module support plate (4). When two or more battery swapping boxes are used together, the two or more battery swapping boxes are detachably connected by a box connecting plate (3). The top of the side beam (20) is provided with a second rivet nut (10). The box connecting plate (3) is provided with a second bolt hole (33). The box connecting plate (3) connects the two battery swapping boxes through the provided second bolt (9), the second bolt hole (33), and the second rivet nut (10). The size of the box connecting plate (3) and the number of the second bolt holes (33) are determined according to the number of battery swapping boxes to be connected. The side beam (20) is fixed to the bottom plate (22) of the lower box and the crossbeam (21) is fixed to the side beam (20) by laser welding.

2. The battery swapping housing according to claim 1, characterized in that, It also includes a sealing element disposed between the upper cover (1) and the lower cover (2) of the housing.

3. The battery swapping housing according to claim 1, characterized in that, The upper cover (1) and the lower box (2) are connected by a combination of rivet nuts and bolts.

4. The battery swapping housing according to claim 1, characterized in that, The box connecting plate (3) is made of ordinary aluminum profile flat plate, steel stamping thin plate or aluminum die casting structure.

5. The battery swapping housing according to claim 1, characterized in that, The reinforcing ribs (41) on the bottom inner side of the module support plate (4) are a grid structure with intersecting lines.

6. The battery swapping housing according to claim 1, characterized in that, The thickness of the adhesive layer of the structural adhesive (5) does not exceed the distance d from the top of the reinforcing rib (41) to the adhesive surface (410).

7. The battery swapping housing according to claim 1, characterized in that, The side beams (20), cross beams (21) and the bottom plate of the lower box body (22) are made of 6061 or 6063 aluminum alloy.

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