A battery pack case for a commercial vehicle or energy storage tank

Abstract

The application belongs to the technical field of battery packs, and specifically relates to a battery pack box for a commercial vehicle or an energy storage box, which comprises, from top to bottom, an upper cover, a steel fence and an aluminum bottom support, the material of the upper cover is a non-metal fire-retardant material, the upper cover is in a rectangular shape and covers the top surface of the steel fence, and the bottom surface of the steel fence is fixed with the aluminum bottom support; the steel fence comprises a door-shaped frame and a front panel, the aluminum bottom support comprises a base and front and rear beams symmetrically arranged on the front and rear sides of the base, and the base is welded and fixed with the front and rear beams respectively. By adopting the upper cover made of the non-metal fire-retardant material, the door-shaped frame and the front panel made of steel, and the front and rear beams and the base made of aluminum, the amount of aluminum material of the battery pack can be reduced, the weight of the battery pack box for the commercial vehicle or the energy storage box itself can be reduced, the production cost and the transportation cost of the battery pack can be reduced, and the problem of thermal runaway of the current sheet metal box body is solved by adopting the non-metal fire-retardant material for the box cover.

Description

Technical Field

[0001] This invention belongs to the field of battery pack technology, specifically a battery pack housing for commercial vehicles or energy storage boxes. Background Technology

[0002] Currently, battery packs account for a large proportion of the overall vehicle cost. To achieve vehicle weight reduction, lightweight design of the battery pack is necessary. However, the current mainstream battery housing is mainly a sheet metal housing, with an overall structure consisting of a sheet metal top cover and an aluminum profile welded lower housing. This results in an overall heavy weight, which cannot meet the requirements for vehicle weight reduction. Furthermore, aluminum alloy battery housings are expensive, leading to high costs. Additionally, the surface of the sheet metal top cover requires electrophoresis, and the electrophoretic paint can ignite when heated to 380-400℃, potentially causing the battery pack to burn and posing a significant safety hazard.

[0003] In addition, considering the safe operating environment of the battery, the battery pack is designed with a water cooling system to cool at high temperatures. This design can greatly increase the battery's lifespan and the system's safety. However, in the existing technology, many water pipe connectors are designed inside the battery pack, and the pipeline layout is relatively complex. Once the connectors become loose or damaged, it will undoubtedly cause great damage to the battery and affect the lifespan of the battery pack.

[0004] Therefore, reducing battery pack costs and increasing battery pack lifespan are of great significance for commercial vehicles or energy storage boxes. Summary of the Invention

[0005] The purpose of this invention is to provide a battery pack housing for commercial vehicles or energy storage boxes. By using a non-metallic flame-retardant material for the top cover, a steel gantry frame and front panel, and aluminum front and rear beams and base, the amount of aluminum material used in the battery pack can be reduced, thus reducing the weight of the battery pack housing itself. This achieves the goal of reducing battery pack production and transportation costs. Furthermore, the use of non-metallic flame-retardant materials for the cover solves the problem of thermal runaway in current sheet metal housings.

[0006] To solve the above technical problems, the present invention provides a battery pack housing for commercial vehicles or energy storage boxes, comprising a top cover, a steel fence and an aluminum base arranged sequentially from top to bottom. The top cover is made of PCM or SMC, the top cover is rectangular and covers the top surface of the steel fence, and the bottom surface of the steel fence is fixed to the aluminum base.

[0007] The steel fence includes a fixedly connected gantry frame and a front panel. The aluminum base includes a base and front beams and rear beams symmetrically arranged on the front and rear sides of the base. The base is welded and fixed to the front beams and the rear beams respectively.

[0008] Furthermore, the base includes two welded and fixed bases, each of which includes a support plate and a side beam. Both support plates are double-layered hollow structures with interconnected water-cooling channels inside. The front beam and the rear beam are symmetrically arranged between the two side beams and welded and fixed to the support plates.

[0009] Furthermore, the front beam includes a first mounting part and a first connecting part. The two ends of the first mounting part are respectively welded and fixed to the two side beams, and the first connecting part is embedded in the support plate and fixed by welding.

[0010] The first mounting section has a cavity, and sealing plates are provided at both ends of the cavity. The cavity is divided into an inlet section, a partition section, and an outlet section by two pre-embedded rivet plugs.

[0011] The water inlet section is provided with a water inlet pipe and several first water passage holes communicating with it, and the water outlet section is provided with a water outlet pipe and several second water passage holes communicating with it. The first connecting part is provided with connecting holes communicating with the first water passage holes and the second water passage holes respectively, and the connecting holes are connected to the water cooling channel.

[0012] Furthermore, the pallet is provided with a module mounting plate, and the rear beam includes a second connecting part and a second mounting part. The second connecting part is embedded in the pallet and fixed by welding. The second mounting part and the module mounting plate constitute a battery module mounting part.

[0013] Furthermore, the bottom surface of the portal frame is fixed to the top surface of the rear beam and the side beam by adhesive and bolts, the bottom surface of the front panel is fixed to the top surface of the front beam by adhesive and bolts, and pressure strips are provided on the bottom inner surface and top surface of the portal frame and the front panel.

[0014] Furthermore, the pallet and the side beam are integrally formed by an extrusion process.

[0015] Furthermore, the first mounting part and the first connecting part are integrally formed.

[0016] Furthermore, the inner cavity of the side beam is configured as a mounting hole for disassembly components, and a slide rail is provided at the bottom of the side beam.

[0017] Furthermore, the side beams and the outer walls of the portal frame are provided with lifting lugs.

[0018] Furthermore, the gantry frame is formed by bending, and the gantry frame and the front panel are fixed by laser welding; the front panel has a maintenance port and a connector port, and the maintenance port is equipped with a protective cover.

[0019] The beneficial effects of this invention are:

[0020] 1. The battery pack housing of the present invention for commercial vehicles or energy storage boxes adopts a non-metallic flame-retardant material for the top cover, a steel gantry frame and front panel, and aluminum front and rear beams and base. This can reduce the amount of aluminum material used in the battery pack and reduce the weight of the battery pack housing itself, thereby achieving the purpose of reducing the production and transportation costs of the battery pack. Specifically, PCM or SMC materials can be selected for the housing cover, solving the problem of thermal runaway of current sheet metal housings.

[0021] 2. The steel fence of the present invention is rectangular in shape and has good stability. It is formed into a portal frame by bending process. The front panel is punched by a stamping machine and then welded to the portal frame. The steel fence produced by this process has good sealing effect, small welding deformation, and can be transported separately. Due to its steel material, compared with the current transportation of aluminum profile welded box bodies, the weight and transportation cost of the steel fence can be greatly reduced.

[0022] 3. The bottom surface of the steel fence of the present invention is fixed to the aluminum base by bonding and bolting. Compared with the current production of aluminum profile welded box body, it can reduce welds, reduce thermal deformation, and reduce process cost.

[0023] 4. The present invention, through the design of several connecting holes, a first water passage hole, and a second water passage hole, not only ensures the inflow and outflow of water, but also allows the wall thickness between each small hole to act as the FSW support when welding the first connecting part to the support plate, eliminating the need for additional support blocks as FSW support, thus improving welding efficiency. It also avoids the problem that when a single water passage hole passes through the FSW weld bead, an additional support block needs to be added below the water channel to support it, otherwise stir welding defects will occur at thin-walled areas.

[0024] 5. The present invention, through the structure of the water cooling channel, can achieve cooling of the battery module above the tray. The water pipe is arranged externally, making the connection between the water pipe and the present invention more convenient. It can solve the problem of water leakage caused by the loosening or damage of the water pipe connector when it is designed inside the battery pack, and improve the safety of the battery pack box used in commercial vehicles or energy storage boxes.

[0025] 6. The cavity of the present invention is provided with sealing plates at both ends. The sealing method of side sealing avoids CNC machining of both the sealing plates and the housing outline, and the side sealing welding qualification rate is high. In addition, the use of rivet plugs to isolate the inlet and outlet water passages prevents water from crossing and improves the stability of the water cooling system during use. Attached Figure Description

[0026] To more clearly illustrate the technical solution of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a structural schematic diagram of the battery pack housing for commercial vehicles or energy storage boxes according to the present invention;

[0028] Figure 2 yes Figure 1 A sectional view;

[0029] Figure 3 This is a partial structural schematic diagram of the battery pack housing for commercial vehicles or energy storage boxes according to the present invention;

[0030] Figure 4 This is a structural schematic diagram of the steel fence of the present invention;

[0031] Figure 5 This is a schematic diagram of the aluminum base of the present invention;

[0032] Figure 6 This is a schematic diagram of the water inlet and outlet of the water cooling channel of the present invention;

[0033] Figure 7-8 This is a schematic diagram of the base of the present invention;

[0034] Figure 9 This is a schematic diagram of the base structure of the present invention;

[0035] Figure 10 This is a schematic diagram of the front beam structure of the present invention;

[0036] Figure 11 and Figure 12 yes Figure 10 A sectional view;

[0037] Figure 13 This is a schematic diagram of the rear beam structure of the present invention;

[0038] In the diagram: 1-Top cover, 2-Steel fence, 3-Aluminum base, 4-Lifting lug, 21-Gantry frame, 22-Front panel, 31-Front beam, 32-Rear beam, 33-Base, 100-Pressure strip, 311-First mounting part, 312-First connecting part, 3111-Cavity, 3112-Sealing piece, 3113-Embedded rivet plug, 3121-Connecting hole, 321-Second connecting part, 322-Second mounting part, 3221-Step surface, 331-Pattern, 332-Side beam, 333-Water inlet pipe, 334-First water passage hole, 335-Water outlet pipe, 336-Second water passage hole, 337-Module mounting plate, 3311-Water cooling channel, 3321-Disassembly part mounting hole, 3322-Slide rail. Detailed Implementation

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

[0040] In one specific embodiment of the present invention, such as Figure 1-13 As shown, a battery pack enclosure for commercial vehicles or energy storage boxes includes, from top to bottom, a top cover 1, a steel fence 2, and an aluminum base 3. The top cover 1 is rectangular and covers the top surface of the steel fence 2, while the bottom surface of the steel fence 2 is fixed to the aluminum base 3. The top cover 1 is made of a non-metallic flame-retardant material, such as PCM or SMC. This invention uses a non-metallic flame-retardant material for the enclosure cover, solving the problem of thermal runaway in current enclosures.

[0041] like Figure 4 The steel fence 2 includes a fixedly connected portal frame 21 and a front panel 22. The portal frame 21 and the front panel 22 are fixed by laser welding. The portal frame 21 is formed by bending. The front panel 22 has a maintenance port and a connector port. The maintenance port is equipped with a protective cover. The bottom surface of the portal frame 21 is fixed to the top surface of the rear beam 32 and the side beam 332 by adhesive and bolts. The bottom surface of the front panel 22 is fixed to the top surface of the front beam 31 by adhesive and bolts. The bottom inner surface and the top surface of the portal frame 21 and the front panel 22 are both provided with pressure strips 100. The design of the pressure strips can improve the connection firmness and the flatness of the profile.

[0042] like Figure 5 The aluminum base 3 includes a base and a front beam 31 and a rear beam 32 symmetrically arranged on the front and rear sides of the base. The base is welded and fixed to the front beam 31 and the rear beam 32 respectively.

[0043] Specifically, such as Figure 7-8 The base includes two welded and fixed bases 33. Each base 33 includes a support plate 331 and a side beam 332. The support plate 331 and the side beam 332 are integrally formed by extrusion. The front beam 31 and the rear beam 32 are symmetrically arranged between the two side beams 332 and welded and fixed to the support plate 331. The inner cavity of the side beam 332 is configured as a disassembly component mounting hole 3321. The bottom of the side beam 332 is provided with a slide rail 3322, which allows the disassembly component to be inserted into the disassembly component mounting hole 3321 when disassembling the invention. Then, by pulling the disassembly component, the invention can be slid out through the slide rail, improving the speed of disassembly. The disassembly component can be, for example, a bolt, that is, the disassembly component mounting hole 3321 is designed to be threadedly connected to it.

[0044] Specifically, such as Figure 6Both trays 331 have a double-layer hollow structure and are equipped with interconnected water cooling channels 3311 inside. Through the structure of the water cooling channels 3311, the present invention can achieve cooling of the battery module above the tray.

[0045] like Figure 10-12 The front beam 31 includes a first mounting part 311 and a first connecting part 312. The first mounting part 311 and the first connecting part 312 are integrally formed. The two ends of the first mounting part 311 are welded and fixed to the two side beams 332 respectively. The first connecting part 312 is embedded in the support plate 331 and fixed by welding.

[0046] The first mounting part 311 has a cavity 3111 inside. The cavity 3111 has sealing pieces 3112 at both ends. The cavity 3111 is divided into a water inlet section, a partition section and a water outlet section by two pre-embedded rivet plugs 3113. The water inlet section has a water inlet pipe 333 and several first water passage holes 334 communicating with it. The water outlet section has a water outlet pipe 335 and several second water passage holes 336 communicating with it. The first connecting part 312 has a connecting hole 3121 that communicates with the first water passage holes 334 and the second water passage holes 336 respectively. The connecting hole 3121 communicates with the water cooling channel 3311.

[0047] The present invention, through the design of several connecting holes 3121, a first water passage hole 334 and a second water passage hole 336, can ensure the water flow rate, and when welding the first connecting part and the support plate, the wall thickness between each small hole can act as the FSW support, without the need to add an additional support block as the FSW support, thus improving the welding efficiency.

[0048] like Figure 6 Cold water enters the water inlet section inside the cavity through the water inlet pipe 333, then enters the water cooling channel 3311 through the first water passage 334, and finally enters the water outlet section through the second water passage 336, and then flows out from the water outlet pipe 335. The support plate 331 is provided with a module mounting plate 337. Through the above structural design, the water pipe is arranged externally, making it easier to connect the water pipe to the present invention. This solves the problem of water leakage caused by the previous design of the water pipe connector inside the battery pack, which was loose or damaged, and improves the overall safety of use.

[0049] like Figure 13 The rear beam 32 includes a second connecting part 321 and a second mounting part 322. The second connecting part 321 is embedded in the support plate 331 and fixed by welding. The second mounting part 322 and the module mounting plate 337 constitute the battery module mounting part.

[0050] In this embodiment, the side beam 332 and the outer wall of the portal frame 21 are provided with lifting lugs 4. The present invention can achieve overall transfer by using a crane to lift the lifting lugs.

[0051] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A battery pack housing for commercial vehicles or energy storage boxes, characterized in that, The structure includes a top cover (1), a steel fence (2), and an aluminum base (3) arranged sequentially from top to bottom. The top cover (1) is made of non-metallic flame-retardant material. The top cover (1) is rectangular and covers the top surface of the steel fence (2). The bottom surface of the steel fence (2) is fixed to the aluminum base (3). The steel fence (2) includes a fixedly connected portal frame (21) and a front panel (22). The aluminum base (3) includes a base and a front beam (31) and a rear beam (32) symmetrically arranged on the front and rear sides of the base. The base is welded and fixed to the front beam (31) and the rear beam (32) respectively. The base includes two welded and fixed bases (33), each base (33) includes a support plate (331) and a side beam (332). Both support plates (331) are double-layer hollow structures and have interconnected water cooling channels (3311) inside. The front beam (31) and the rear beam (32) are symmetrically arranged between the two side beams (332) and welded and fixed to the support plate (331). The front beam (31) includes a first mounting part (311) and a first connecting part (312). The two ends of the first mounting part (311) are respectively welded and fixed to the two side beams (332). The first connecting part (312) is embedded in the support plate (331) and fixed by welding. The first mounting part (311) is provided with a cavity (3111), and the two ends of the cavity (3111) are provided with sealing pieces (3112). The cavity (3111) is divided into a water inlet section, a partition section and a water outlet section by two pre-embedded rivet plugs (3113). The water inlet section is provided with a water inlet pipe (333) communicating with it and a number of first water passage holes (334). The water outlet section is provided with a water outlet pipe (335) communicating with it and a number of second water passage holes (336). The first connecting part (312) is provided with a connecting hole (3121) communicating with the first water passage hole (334) and the second water passage hole (336) respectively. The connecting hole (3121) is connected to the water cooling channel (3311).

2. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The pallet (331) is provided with a module mounting plate (337), and the rear beam (32) includes a second connecting part (321) and a second mounting part (322). The second connecting part (321) is embedded in the pallet (331) and fixed by welding. The second mounting part (322) and the module mounting plate (337) constitute a battery module mounting part.

3. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The bottom surface of the portal frame (21) is fixed to the top surface of the rear beam (32) and the side beam (332) by adhesive bonding and bolts. The bottom surface of the front panel (22) is fixed to the top surface of the front beam (31) by adhesive bonding and bolts. The bottom inner surface and the top surface of the portal frame (21) and the front panel (22) are both provided with pressure strips (100).

4. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The pallet (331) and the side beam (332) are integrally formed by extrusion process.

5. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The first mounting part (311) and the first connecting part (312) are integrally formed.

6. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The inner cavity of the side beam (332) is configured as a disassembly mounting hole (3321), and the bottom of the side beam (332) is provided with a slide (3322).

7. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The side beam (332) and the outer wall of the portal frame (21) are provided with lifting lugs (4).

8. A battery pack housing for commercial vehicles or energy storage boxes according to claim 1, characterized in that, The gantry frame (21) and the front panel (22) are fixed by laser welding, and the gantry frame (21) is formed by bending process.

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