Battery pack frame, battery pack and method of assembling the same, vehicle

Abstract

The application provides a battery pack frame, a battery pack and an assembling method thereof, and a vehicle. The battery pack frame comprises a frame assembly and a crossbeam assembly arranged on the frame assembly. The frame assembly comprises a first frame, a second frame, a third frame and a fourth frame which are sequentially connected in a head-to-tail mode to form a containing cavity. The second frame is provided with a first set of adapter blocks, and the fourth frame is provided with a second set of adapter blocks opposite to the first set of adapter blocks. The crossbeam assembly comprises a first crossbeam and a second crossbeam arranged in the containing cavity. One end of each of the first crossbeam and the second crossbeam is connected to the second frame through the first set of adapter blocks, and is connected to two surfaces of a corresponding adapter block in the first set of adapter blocks which are distributed in different directions. The other end of each of the first crossbeam and the second crossbeam is connected to the fourth frame through the second set of adapter blocks, and is connected to two surfaces of a corresponding adapter block in the second set of adapter blocks which are distributed in different directions.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and in particular to a battery pack frame, a battery pack and its assembly method, and a vehicle. Background Technology

[0002] In related technologies, to solve the problems of battery expansion and assembly, end plates are set in the battery pack and crossbeams are set in the lower casing. The battery pack is fixed by connecting the end plates and crossbeams. The bottom surface of the end plates is connected to the crossbeams by connecting bolts, presenting an L-shaped connection structure. However, this connection structure has poor stability when subjected to the pressure of cell expansion. In addition, the connecting bolts are Z-oriented, and slippage is likely to occur between the end plates and crossbeams when the cells expand. This means that the connecting bolts, which are more suitable for bearing axial forces, are subjected to shear forces when in contact with the end plates, further resulting in poor restriction of cell expansion. Summary of the Invention

[0003] In view of this, the purpose of this application is to provide a battery pack frame, a battery pack and its assembly method, and a vehicle.

[0004] In view of the aforementioned purpose, in a first aspect, this application provides a battery pack frame, including: a frame assembly and a beam assembly disposed on the frame assembly;

[0005] The frame assembly includes: a first frame, a second frame, a third frame, and a fourth frame connected end to end to form an accommodating cavity; wherein, the second frame is provided with a first set of transition blocks, and the fourth frame is provided with a second set of transition blocks opposite to the first set of transition blocks;

[0006] The beam assembly includes: a first beam and a second beam disposed within the accommodating cavity.

[0007] One end of each of the first and second crossbeams is connected to the second frame via the first set of adapter blocks, and each is connected to two surfaces of the corresponding adapter block in the first set of adapter blocks that are distributed in different directions.

[0008] The other ends of the first and second crossbeams are both connected to the fourth frame via the second set of adapter blocks, and are both connected to two surfaces of the corresponding adapter blocks in the second set of adapter blocks that are distributed in different directions.

[0009] In one possible implementation, the battery pack frame further includes: a first top rod and a second top rod;

[0010] The first top rod connects the first frame and the first crossbeam; the second top rod connects the third frame and the second crossbeam.

[0011] In one possible implementation, the battery pack frame further includes: a base plate connected to the frame assembly;

[0012] The first crossbeam has a first groove on the side away from the base plate; the second crossbeam has a second groove on the side away from the base plate.

[0013] The first push rod is provided with a first ramp at one end near the first crossbeam, and the first ramp cooperates with the first groove to connect the first push rod and the first crossbeam;

[0014] The second push rod has a second ramp at one end near the second crossbeam, and the second ramp cooperates with the second groove to connect the second push rod and the second crossbeam.

[0015] In one possible implementation, the first frame has a first connecting hole on the side near the first top rod; the third frame has a second connecting hole on the side near the second top rod.

[0016] The first top rod has a first protrusion at one end near the first frame, and the first protrusion cooperates with the first connecting hole to connect the first top rod and the first frame;

[0017] The second top rod has a second protrusion at one end near the third frame, and the second protrusion cooperates with the second connecting hole to connect the second top rod and the third frame.

[0018] In one possible implementation, the first set of transition blocks includes: a first transition block and a second transition block disposed on the second border; the second set of transition blocks includes: a third transition block and a fourth transition block disposed on the fourth border; wherein the first transition block corresponds to the third transition block, and the second transition block corresponds to the fourth transition block;

[0019] The first crossbeam includes two first notches respectively disposed at both ends;

[0020] The second crossbeam includes two second notches respectively disposed at both ends;

[0021] One of the first notches of the first crossbeam is connected to the second side frame via the first adapter block, and the other of the first notches of the first crossbeam is connected to the fourth side frame via a third adapter block;

[0022] One of the second notches of the second crossbeam is connected to the second side frame via the second adapter block, and the other of the second notches of the second crossbeam is connected to the fourth side frame via a fourth adapter block.

[0023] In one possible implementation, the transition block in the first set of transition blocks and the second set of transition blocks includes: a body and a protrusion connecting the body;

[0024] The two ends of the first crossbeam are respectively connected to the main body of the first transition block and the main body of the third transition block by bolts arranged along the first direction;

[0025] The two first notches of the first crossbeam are respectively connected to the protrusions of the first adapter block and the third adapter block by bolts arranged along the second direction;

[0026] The two ends of the second crossbeam are respectively connected to the main body of the second transition block and the main body of the fourth transition block by bolts arranged along the first direction;

[0027] The two second notches of the second crossbeam are respectively connected to the protrusions of the second adapter block and the fourth adapter block by bolts arranged along the second direction;

[0028] Wherein, the first direction is parallel to the extension direction of the second border, and the second direction is perpendicular to the first direction.

[0029] In one possible implementation, the bump is connected to the lower surface of the beam assembly.

[0030] In one possible implementation, the first crossbeam is provided with a first connector, the second crossbeam is provided with a second connector, the first crossbeam is connected to the base plate through the first connector, and the second crossbeam is connected to the base plate through the second connector.

[0031] In a second aspect, this application provides a battery pack, comprising:

[0032] Battery pack, top cover, and battery pack frame as described in the first aspect;

[0033] The battery pack is housed in a cavity formed by the frame assembly, the beam assembly, and the base plate;

[0034] The top cover is connected to the frame assembly and the beam assembly.

[0035] In one possible implementation, the battery pack includes: a plurality of battery cells placed between the first crossbeam and the second crossbeam; wherein each battery cell includes: a casing surrounding the periphery of the battery cell, the casing including large surfaces disposed opposite to each other;

[0036] The battery pack also includes: a liquid cooling system;

[0037] The liquid cooling system includes: a liquid cooling plate and liquid cooling pipes; wherein the liquid cooling plate is in contact with the large surface of each of the battery cells;

[0038] Water nozzles are provided at both ends of the liquid cooling plate that extend beyond the battery cell, and the liquid cooling pipe is connected to the liquid cooling plate through the water nozzles.

[0039] In a third aspect, this application provides a battery pack assembly method, comprising:

[0040] Battery packs are provided;

[0041] The system provides a base plate, a frame assembly, a crossbeam assembly, and a top cover. The frame assembly includes a first frame, a second frame, a third frame, and a fourth frame connected end to end in sequence. The second frame is provided with a first set of transition blocks, and the fourth frame is provided with a second set of transition blocks opposite to the first set of transition blocks. The crossbeam assembly includes a first crossbeam and a second crossbeam disposed between the second frame and the fourth frame.

[0042] The first set of adapter blocks is connected to the second frame, the second set of adapter blocks is connected to the fourth frame, and one end of both the first beam and the second beam is connected to the second frame through the first set of adapter blocks, and both are connected to two surfaces of the corresponding adapter blocks in the first set of adapter blocks that are distributed in different directions; and the other end of both the first beam and the second beam is connected to the fourth frame through the second set of adapter blocks, and both are connected to two surfaces of the corresponding adapter blocks in the second set of adapter blocks that are distributed in different directions.

[0043] The battery pack is placed in the accommodating cavity formed by the first crossbeam, the second frame, the second crossbeam, the fourth frame, and the bottom plate;

[0044] The top cover is connected to the first frame, the second frame, the third frame, the fourth frame, the first crossbeam, and the second crossbeam, respectively.

[0045] In one possible implementation, before placing the battery pack in the receiving cavity formed by the first crossbeam, the second frame, the second crossbeam, the fourth frame, and the base plate, the following steps are also included:

[0046] A first connector and a second connector are provided, wherein the first crossbeam is connected to the base plate via the first connector, and the second crossbeam is connected to the base plate via the second connector.

[0047] In a fourth aspect, this application provides a vehicle including a battery pack frame as described in the first aspect or a battery pack as described in the second aspect.

[0048] As can be seen from the above description, this application provides a battery pack frame, a battery pack and its assembly method, and a vehicle, including a base plate, a frame assembly connected to the base plate assembly, and a crossbeam assembly disposed on the frame assembly. The frame assembly further includes a first frame, a second frame, a third frame, and a fourth frame connected end-to-end to form a receiving cavity; wherein the second frame is provided with a first set of adapter blocks, and the fourth frame is provided with a second set of adapter blocks opposite to the first set of adapter blocks. The crossbeam assembly further includes a first crossbeam and a second crossbeam disposed within the receiving cavity. The first crossbeam and the second crossbeam are connected between the second frame and the fourth frame via adapter blocks. The first crossbeam is connected to the second frame and the fourth frame via adapter blocks, and the second crossbeam is connected to the second frame and the fourth frame via another set of adapter blocks. One end of both the first and second crossbeams is connected to the second frame via the first set of adapter blocks, and both are connected to two surfaces distributed in different directions of corresponding adapter blocks in the first set of adapter blocks. The other ends of both the first and second crossbeams are connected via the second set of adapter blocks. The fourth frame, and each of the two surfaces of the corresponding adapter blocks in the second set of adapter blocks, are connected in different directions. This not only restricts the position of the battery pack installed in the battery pack frame through the first and second crossbeams, avoiding the problem of uneven force caused by connecting bolts, but also connects the two ends of the first and second crossbeams to the two surfaces of the two sets of adapter blocks respectively. This allows them to connect to the frame assembly through the adapter blocks, ensuring that the crossbeam assembly and the frame assembly can simultaneously decompose the pressure of cell expansion in two directions. This effectively restricts the expansion of the cells in the battery pack and improves the effect of restricting cell expansion. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in this application or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0050] Figure 1 An exemplary structural diagram of a battery pack frame provided in an embodiment of this application is shown.

[0051] Figure 2 An exemplary structural diagram of a border component provided in an embodiment of this application is shown.

[0052] Figure 3 An exemplary structural schematic diagram of the first crossbeam provided in an embodiment of this application is shown.

[0053] Figure 4An exemplary structural diagram of the first push rod provided in an embodiment of this application is shown from a first perspective.

[0054] Figure 5 An exemplary structural diagram of the first push rod provided in an embodiment of this application is shown from a second perspective.

[0055] Figure 6 A partial assembly drawing of the first crossbeam 131 and the first transition block 1221 provided in the embodiments of this application is shown.

[0056] Figure 7 An exemplary structural diagram of a battery pack provided in an embodiment of this application is shown.

[0057] Figure 8 An exemplary structural diagram of the top cover provided in an embodiment of this application is shown.

[0058] Figure 9 An exemplary structural diagram of the battery pack provided in an embodiment of this application is shown.

[0059] Figure 10 An exemplary structural diagram of the water cooling system provided in an embodiment of this application is shown.

[0060] Figure 11 An exemplary flowchart of a battery pack assembly method provided in an embodiment of this application is shown.

[0061] Explanation of reference numerals in the attached figures:

[0062] 1-Battery pack frame, 11-Base plate, 12-Frame assembly, 121-First frame, 1211-First connecting hole, 122-Second frame, 1221-First adapter block, 12211-Body of the first adapter block, 12212-Protrusion of the first adapter block, 1222-Second adapter block, 12221-Body of the second adapter block, 12222-Protrusion of the second adapter block, 123-Third frame, 1231-Second connecting hole, 124-Fourth frame, 1241-Third adapter block, 12411-Body of the third adapter block, 12412-Protrusion of the third adapter block, 1242-Fourth adapter block, 12421-Body of the fourth adapter block, 12422-Second connecting hole 13-Crossbeam assembly, 131-First crossbeam, 1311-First connector, 1312-First groove, 1313-First notch, 132-Second crossbeam, 1321-Second connector, 1322-Second groove, 1323-Second notch, 14-First top rod, 141-First ramp, 142-First protrusion, 15-Second top rod, 151-Second ramp, 152-Second protrusion, 2-Battery pack, 21-Cell pack, 211-Cell, 2111-Electrode, 2112-Shell, 21121-Large surface, 22-Liquid cooling system, 221-Liquid cooling plate, 2211-Water nozzle, 222-Liquid cooling pipe, 23-Buffer pad, 3-Top cover. Detailed Implementation

[0063] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0064] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this application should have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," and similar terms used in the embodiments of this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0065] As described in the background section, in order to solve the problems of battery expansion and assembly, an end plate is set in the battery pack and a crossbeam is set in the lower housing. The short plate and the crossbeam are connected to fix the battery pack. The connecting bolts of the end plate and the crossbeam are in the Z direction. However, there are problems such as many parts, heavy weight, large space occupation, and the connecting bolts being easily damaged by shear force.

[0066] In one related technology, when obtaining the battery pack, the battery assembly is formed first, and then the lower casing is assembled. End plates are installed on the battery assembly, and crossbeams are installed on the lower casing. The end plates and crossbeams are connected and fixed. Furthermore, the bolts connecting the end plates and crossbeams are Z-oriented, thus solving the problems of cell expansion and assembly. Further, to strengthen the restriction of expansion above the cells, straps are also installed above the battery assembly.

[0067] However, the applicant's research revealed that in the aforementioned technologies, the bottom surface of the end plate is connected to the crossbeam via connecting bolts, forming an L-shaped connection structure. This connection structure exhibits poor stability when subjected to the pressure of cell expansion. The inclusion of end plates, crossbeams, and straps results in numerous parts, increased weight, and a large space requirement. Furthermore, the need for a gap between the end plate and the crossbeam further increases the overall space requirements. Since the connecting bolts between the end plate and the crossbeam are Z-oriented, slippage between the end plate and the crossbeam is likely during cell expansion, causing the connecting bolts to contact the end plate hole walls and subjecting them to shear forces. The applicant's research found that connecting bolts are better suited to withstand axial forces. Therefore, the overall structure in these technologies is prone to damage due to uneven stress on the connecting bolts.

[0068] Therefore, this application provides a battery pack frame, a battery pack and its assembly method, and a vehicle, including a base plate, a frame assembly connected to the base plate assembly, and a crossbeam assembly disposed on the frame assembly. The frame assembly further includes a first frame, a second frame, a third frame, and a fourth frame connected end-to-end to form a receiving cavity; wherein the second frame is provided with a first set of adapter blocks, and the fourth frame is provided with a second set of adapter blocks opposite to the first set of adapter blocks. The crossbeam assembly further includes a first crossbeam and a second crossbeam disposed within the receiving cavity. The first crossbeam and the second crossbeam are connected between the second frame and the fourth frame via adapter blocks. The first crossbeam is connected to the second frame and the fourth frame via adapter blocks, and the second crossbeam is connected to the second frame and the fourth frame via another set of adapter blocks. One end of both the first and second crossbeams is connected to the second frame via the first set of adapter blocks, and both are connected to two surfaces distributed in different directions of corresponding adapter blocks in the first set of adapter blocks. The other ends of both the first and second crossbeams are connected via the second set of adapter blocks. Connected to the fourth frame and to the two surfaces of the corresponding adapter blocks in the second set of adapter blocks distributed in different directions, the first and second crossbeams not only restrict the position of the battery pack installed in the battery pack frame by means of the first and second crossbeams, avoiding the problem of uneven force caused by connecting bolts, but also the first and second crossbeams are connected to the two surfaces of the adapter blocks respectively, and then connected to the frame assembly through the adapter blocks. This ensures that the crossbeam assembly and the frame assembly can simultaneously decompose the pressure of cell expansion in two directions, thereby limiting the expansion of the cells in the battery pack and improving the effect of limiting cell expansion.

[0069] In addition, the battery pack frame also enhances the rigidity of the battery pack. Furthermore, the components are tightly connected, resulting in even stress distribution. The connectors occupy little space, and the adapter block, crossbeam assembly, first connector, and second connector are lightweight, structurally stable, and not easily damaged.

[0070] The battery pack frame provided in this application will be specifically described below through specific embodiments.

[0071] Figure 1 An exemplary structural diagram of a battery pack frame provided in an embodiment of this application is shown.

[0072] refer to Figure 1The battery pack frame 1 includes: a base plate 11, a frame assembly 12 connected to the base plate 11, and a crossbeam assembly 13 disposed on the frame assembly 12. The frame assembly 12 further includes: a first frame 121, a second frame 122, a third frame 123, and a fourth frame 124. The second frame 122 has two adapter blocks, namely a first adapter block 1221 and a second adapter block 1222. Correspondingly, the fourth frame 124 has a third adapter block 1241 opposite to the first adapter block 1221 and a fourth adapter block 1242 opposite to the second adapter block 1222. The battery pack frame 1 also includes a first crossbeam 131 and a second crossbeam 132, wherein the first crossbeam 131 is connected to the second frame 122 and the fourth frame 124 respectively through a first adapter block 1221 and a third adapter block 1241, and the second crossbeam 132 is connected to the second frame 122 and the fourth frame 124 respectively through a second adapter block 1222 and a fourth adapter block 1242. The first crossbeam 131 is also provided with a first connector 1311, and the second crossbeam 132 is also provided with a second connector 1321. The first crossbeam 131 is connected and fixed to the base plate 11 via the first connector 1311, and the second crossbeam 132 is connected and fixed to the base plate 11 via the second connector 1321. The first connector 1311 and the second connector 1321 respectively increase the contact area between the first crossbeam 131 and the second crossbeam 132 and the base plate 11, thereby better fixing the first crossbeam 131 and the second crossbeam 132, and limiting the expansion of the battery cells 211 located inside the battery pack frame 1. It should be noted that the first crossbeam 131 and the second crossbeam 132 can be parallel to each other. It should also be noted that, in order to minimize the overall space occupied by the structure, the first connector 1311 and the second connector 1321 can be flanges.

[0073] Figure 2 This illustration shows an exemplary structural diagram of a border component 12 provided in an embodiment of this application.

[0074] refer to Figure 2 The first frame 121, the second frame 122, the third frame 123 and the fourth frame 124 are connected end to end to form the outer shell 2112 of the battery pack frame 1. The frame assembly 12 is connected to the base plate 11 to obtain the lower box of the battery pack frame 1.

[0075] Figure 3 An exemplary structural schematic diagram of the first crossbeam 131 provided in an embodiment of this application is shown.

[0076] refer to Figure 3Taking the first crossbeam 131 as an example, in some optional embodiments, when the battery cell 211 inside the battery pack frame 1 expands, the upper rigidity of the battery pack frame 1 may be poor, and it is easily affected by the expansion of the battery cell 211, resulting in compression deformation. Therefore, the battery pack frame 1 may also include a first top rod 14 and a second top rod 15, wherein the first top rod 14 connects the first side frame 121 and the first crossbeam 131 respectively, and the second top rod 15 connects the third side frame 123 and the second crossbeam 132 respectively. Specifically, the side of the first crossbeam 131 away from the bottom plate 11 is provided with a first groove 1312, and the end of the first top rod 14 near the first crossbeam 131 is provided with a first ramp 141. The first ramp 141 cooperates with the first groove 1312 to connect the first top rod 14 and the first crossbeam 131. Furthermore, a first connecting hole 1211 is provided on the side of the first frame 121 near the first top rod 14, and a first protrusion 142 is provided on the end of the first top rod 14 near the first frame 121. The first protrusion 142 cooperates with the first connecting hole 1211 to connect the first top rod 14 and the first frame 121. The cross-section of the first protrusion 142 can be semi-circular. The cooperation between the first crossbeam 131 and the first top rod 14 increases the lateral stability of the overall structure. Moreover, the cooperation between the first ramp 141 and the first groove 1312 on the first top rod 14 helps to reduce the thickness at the connection of the first crossbeam 131 and reduce the weight of the overall structure.

[0077] Figure 4 An exemplary structural schematic diagram of the first push rod 14 provided in the embodiments of this application is shown from a first perspective.

[0078] Figure 5 An exemplary structural schematic diagram of the first push rod 14 provided in the embodiments of this application is shown from a second perspective.

[0079] Furthermore, taking the first push rod 14 as an example, refer to... Figure 3 , Figure 4 and Figure 5The second crossbeam 132 has a second groove 1322 on the side away from the base plate 11, and the second top rod 15 has a second ramp 151 at the end near the second crossbeam 132. The second ramp 151 cooperates with the second groove 1322 to connect the second top rod 15 and the second crossbeam 132. Further, the third frame 123 has a second connecting hole 1231 on the side near the second top rod 15, and the second top rod 15 has a second protrusion 152 at the end near the third frame 123. The second protrusion 152 cooperates with the second connecting hole 1231 to connect the second top rod 15 and the third frame 123. The cross-section of the second protrusion 152 can be semi-circular. When the cell 211 expands, it compresses the first crossbeam 131 and the second crossbeam 132. The first frame 121 supports the first crossbeam 131 through the first push rod 14, and the third frame 123 supports the second crossbeam 132 through the second push rod 15. As a result, the first crossbeam 131 and the second crossbeam 132 have stronger rigidity in all directions, which can limit the expansion of the cell 211.

[0080] It should be noted that, in order to enhance the rigidity of the first crossbeam 131 and the second crossbeam 132, multiple first top rods 14 and multiple second top rods 15 can be provided. Furthermore, flanges can be provided at the connections between the first top rod 14 and the first frame 121 and the first crossbeam 131, and flanges can also be provided at the connections between the second top rod 15 and the third frame 123 and the second crossbeam 132. When the internal battery cell 211 expands, the flanges fit snugly against the surfaces of the first frame 121, the first crossbeam 131, the third frame 123, and the second crossbeam 132, thereby limiting the expansion of the battery cell 211, protecting the overall structure of the battery pack frame 1, and enhancing structural stability.

[0081] In some alternative embodiments, the first top rod 14 and the first crossbeam 131 can be connected by bolts, and the second top rod 15 and the second crossbeam 132 can also be connected by bolts. The first top rod 14 and the first crossbeam 131 are both provided with semi-circular notches, and the bolts each press half of the two semi-circular notches. The second top rod 15 and the second crossbeam 132 are both provided with semi-circular notches, and the bolts each press half of the two semi-circular notches, thereby reducing the thickness of the first crossbeam 131 and the second crossbeam 132 at the positions corresponding to the first top rod 14 and the second top rod 15, and further reducing the weight of the overall structure.

[0082] In some optional embodiments, the first adapter block 1221 disposed on the second frame 122 may correspond to the third adapter block 1241 disposed on the fourth frame 124, and the second adapter block 1222 may correspond to the fourth adapter block 1242. The first crossbeam 131 may include two first notches 1313 disposed at both ends, one of which is connected to the second frame 122 via the first adapter block 1221, and the other is connected to the fourth frame 124 via the third adapter block 1241. The second crossbeam 132 may include two second notches 1323 disposed at both ends, one of which is connected to the second frame 122 via the second adapter block 1222, and the other is connected to the fourth frame 124 via the fourth adapter block 1242.

[0083] Figure 6 A partial assembly drawing of the first crossbeam 131 and the first transition block 1221 provided in the embodiments of this application is shown.

[0084] It should be noted that, to ensure greater stability in the connection between the crossbeam assembly and the frame assembly, and to better distribute the pressure from different directions on the battery pack frame during cell expansion, one end of each of the first crossbeam 131 and the second crossbeam 132 is connected to the second frame 122 via a first set of adapter blocks, and each is connected to two surfaces of the corresponding adapter blocks in the first set that are distributed in different directions. The other ends of each of the first crossbeam 131 and the second crossbeam 132 are connected to the fourth frame 124 via a second set of adapter blocks, and each is connected to two surfaces of the corresponding adapter blocks in the second set that are distributed in different directions. Specifically, taking the connection method of the first crossbeam 131 as an example, refer to... Figure 6The first and second sets of adapter blocks each include a body and a protrusion. A first notch 1313 of the first crossbeam 131 is connected to the body 12211 of the first adapter block via a bolt arranged in a first direction, and to the protrusion 12212 of the first adapter block via a bolt arranged in a second direction. Another first notch 1313 is connected to the body 12411 of the third adapter block via a bolt arranged in a first direction, and to the protrusion 12412 of the third adapter block via a bolt arranged in a second direction. A second notch 1323 of the second crossbeam 132 is connected to the body 12221 of the second adapter block via a bolt arranged in a first direction, and to the protrusion 12222 of the second adapter block via a bolt arranged in a second direction. Another second notch 1323 is connected to the body 12421 of the fourth adapter block via a bolt arranged in a first direction, and to the protrusion 1242 of the fourth adapter block via a bolt arranged in a second direction. It should be noted that the first direction is parallel to the extension direction of the second frame 122, and the second direction is perpendicular to the first direction and perpendicular to the base plate 11. Since the expansion force of the battery cell 211 is applied along the first direction, the first crossbeam 131 and the second crossbeam 132 are connected to the adapter blocks located on the second frame 122 and the fourth frame 124 respectively by bolts along the first direction. In order to enhance the structural stability at the crossbeams, the first crossbeam 131 and the second crossbeam 132 are then connected to the adapter blocks located on the second frame 122 and the fourth frame 124 respectively by bolts along the second direction, thereby ensuring the strength of the connection.

[0085] It should be noted that for each connecting block, when connected to the crossbeam assembly, the protrusion can be located below the crossbeam assembly, that is, the lower surface of the connection between the protrusion and the crossbeam assembly is connected. This allows the protrusion to not only limit the expansion of the battery cell, but also enhance the stability of the connection, provide support for the crossbeam assembly, further enhance the rigidity of the connection, and further improve the overall structure's ability to withstand the pressure of battery cell expansion.

[0086] In some alternative embodiments, the base plate 11 and the first crossbeam 131 can be glued together, and the base plate 11 and the second crossbeam 132 can also be glued together. The bonding strength can be used to limit the expansion of the internal battery cell 211.

[0087] The battery pack provided in this application will be specifically described below through specific embodiments.

[0088] Figure 7 An exemplary structural diagram of a battery pack provided in an embodiment of this application is shown.

[0089] refer to Figure 7The battery pack may include a battery pack 2, a top cover 3, and a battery pack frame 1 as described in any of the above embodiments. The battery pack 2 may be housed within a cavity formed by a frame assembly 12, a beam assembly 13, and a base plate 11. The top cover 3 may be connected to the frame assembly 12 and the beam assembly 13 to form a closed structure for the battery pack.

[0090] Figure 8 An exemplary structural schematic diagram of the top cover 3 provided in an embodiment of this application is shown.

[0091] refer to Figure 8 The top cover 3 is connected and sealed to the frame assembly 12. The top cover 3 is connected to the first crossbeam 131 and the second crossbeam 132 by multiple connection points. It can be connected by bolts or adhesive. After the top cover 3 connects the first crossbeam 131 and the second crossbeam 132, it can further limit the expansion of the battery pack 2 when the battery cell 211 in the battery pack expands.

[0092] Figure 9 An exemplary structural diagram of the battery pack 2 provided in an embodiment of this application is shown.

[0093] refer to Figure 9 The battery pack 2 may further include a group 211 of battery cells 211 disposed between the first crossbeam 131 and the second crossbeam 132, the group 211 of battery cells 211 comprising cells along a first direction and a third direction (see reference). Figure 1 Multiple battery cells 211 are arranged in a third-direction array, wherein the third-direction is a direction perpendicular to the second frame 122 and different from the first and second directions. Each battery cell 211 includes electrodes 2111 distributed at both ends of the battery cell 211 and a shell 2112 surrounding the battery cell 211. The shell 2112 may include a set of large surfaces 21121 and a set of small surfaces arranged opposite each other, and the first large surface, the first small surface, the second large surface, and the second small surface are connected sequentially to form the shell 2112.

[0094] It should be noted that the large surfaces 21121 of the cells 211 arranged along the first direction are bonded to each other, and the electrodes 2111 of the cells 211 arranged along the third direction are bonded to each other.

[0095] Figure 10 An exemplary structural diagram of the water cooling system provided in an embodiment of this application is shown.

[0096] refer to Figure 10The battery pack 2 may also include a liquid cooling system 22, which includes liquid cooling plates 221 and liquid cooling pipes 222. Since the large surface 21121 of the battery cell 211 expands when the cell 211 expands, multiple liquid cooling plates 221 can be provided, each contacting the large surface 21121 of each cell 211. The liquid cooling plates 221 can be arranged along a third direction. Each liquid cooling plate 221 has a water nozzle 2211 extending beyond both ends of the cell 211 group 21. The liquid cooling pipes 222 can pass through the water nozzles 2211 of each liquid cooling plate 221 to connect to each liquid cooling plate 221. The liquid cooling pipes 222 can be arranged along a first direction.

[0097] In some alternative embodiments, due to tolerances in the size of the battery pack 2 and its position relative to the adapter block, the spacing between the crossbeam assembly 13 and the battery pack 2 becomes uncontrollable. Therefore, a buffer pad 23 is provided between the liquid cooling plate 221 near the first crossbeam 131 and the first crossbeam 131, and between the liquid cooling plate 221 near the second crossbeam 132 and the second crossbeam 132. This is to limit the position of the battery pack 2 and restrict the expansion of the cell 211, and also to enhance the rigidity of the battery pack. Furthermore, when the crossbeam assembly 13 is reassembled, it can be pressed against the battery pack 2, compressing the buffer pad 23 and further pressing the cell 211, which can better limit the position of the battery pack 2.

[0098] Figure 11 An exemplary flowchart of a battery pack assembly method provided in an embodiment of this application is shown.

[0099] refer to Figure 11 The battery pack assembly method provided in this application specifically includes the following steps:

[0100] S1102: Provides battery pack.

[0101] S1104: Provides a base plate, a frame assembly, a crossbeam assembly, and a top cover. The frame assembly includes: a first frame, a second frame, a third frame, and a fourth frame connected end to end in sequence; wherein the second frame is provided with a first set of transition blocks, and the fourth frame is provided with a second set of transition blocks opposite to the first set of transition blocks; the crossbeam assembly includes: a first crossbeam and a second crossbeam disposed between the second frame and the fourth frame.

[0102] S1106: Connect the first set of adapter blocks to the second frame, connect the second set of adapter blocks to the fourth frame, and connect one end of the first beam and the second beam to the second frame through the first set of adapter blocks, and connect them to two surfaces of the corresponding adapter blocks in the first set of adapter blocks that are distributed in different directions; and connect the other end of the first beam and the second beam to the fourth frame through the second set of adapter blocks, and connect them to two surfaces of the corresponding adapter blocks in the second set of adapter blocks that are distributed in different directions.

[0103] S1108: The battery pack is placed in the accommodating cavity formed by the first crossbeam, the second side frame, the second crossbeam, the fourth side frame, and the bottom plate.

[0104] S1110: Connect the top cover to the first frame, the second frame, the third frame, the fourth frame, the first crossbeam, and the second crossbeam respectively.

[0105] In some alternative implementations, before step S1108, a first connector and a second connector may be provided to connect the first crossbeam to the base plate via the first connector and the second crossbeam to the base plate via the second connector.

[0106] In some alternative implementations, the battery pack can be assembled first, with the battery cells and liquid cooling system integrated into one unit, and then assembled into the battery pack frame. In this configuration, the larger surface of the battery cell contacts the liquid cooling plate, and the portion of the liquid cooling plate extending beyond the battery cell is equipped with a water nozzle. Liquid cooling pipes connect to adjacent water nozzles, thereby connecting all the liquid cooling plates.

[0107] Further, the first, second, third, and fourth frame components are connected end-to-end in sequence, and then the connected frame components are connected to the base plate. A first and second adapter block are installed on the second frame, and a third and fourth adapter block are installed on the fourth frame. The two first notches of the first crossbeam are then connected to the main bodies of the first and third adapter blocks respectively using bolts along a first direction. The two first notches of the first crossbeam are then connected to the protrusions of the first and third adapter blocks respectively using bolts along a second direction. Similarly, the two second notches of the second crossbeam are connected to the main bodies of the second and fourth adapter blocks respectively using bolts along a first direction. The two second notches of the second crossbeam are then connected to the protrusions of the second and fourth adapter blocks respectively using bolts along a second direction. The two first and two second notches allow for clearance of the liquid cooling pipes, and the lower parts of all notches are completely open.

[0108] Furthermore, the lower parts of the first and second crossbeams are connected to the base plate via first and second connectors, respectively, and are bonded to the base plate with adhesive. The first push rod is first inserted into the first frame and then pressed onto the first crossbeam; the second push rod is first inserted into the third frame and then pressed onto the second crossbeam. A buffer pad can also be placed between the first crossbeam and the liquid cooling plate, and another buffer pad can be placed between the second crossbeam and the liquid cooling plate.

[0109] Furthermore, the top cover can be sealed to the frame assembly and the crossbeam assembly respectively to obtain the battery pack.

[0110] As can be seen from the above description, this application provides a battery pack frame, a battery pack and its assembly method, and a vehicle, including a base plate, a frame assembly connected to the base plate assembly, and a crossbeam assembly disposed on the frame assembly. The frame assembly further includes a first frame, a second frame, a third frame, and a fourth frame connected end-to-end to form a receiving cavity; wherein the second frame is provided with a first set of adapter blocks, and the fourth frame is provided with a second set of adapter blocks opposite to the first set of adapter blocks. The crossbeam assembly further includes a first crossbeam and a second crossbeam disposed within the receiving cavity. The first crossbeam and the second crossbeam are connected between the second frame and the fourth frame via adapter blocks. The first crossbeam is connected to the second frame and the fourth frame via adapter blocks, and the second crossbeam is connected to the second frame and the fourth frame via another set of adapter blocks. One end of both the first and second crossbeams is connected to the second frame via the first set of adapter blocks, and both are connected to two surfaces distributed in different directions of corresponding adapter blocks in the first set of adapter blocks. The other ends of both the first and second crossbeams are connected via the second set of adapter blocks. The fourth frame, and all its components connected to the two surfaces of the corresponding adapter blocks in the second set of adapter blocks distributed in different directions, not only restrict the position of the battery pack installed within the battery pack frame through the first and second crossbeams, avoiding uneven stress caused by connecting bolts, but also connect the two ends of the first and second crossbeams to the two surfaces of the two sets of adapter blocks respectively. This allows the frame to connect to the frame assembly via the adapter blocks, ensuring that the crossbeam assembly and the frame assembly can simultaneously distribute the pressure of cell expansion from two directions, thus limiting the expansion of the cells within the battery pack and improving the effectiveness of limiting cell expansion. Furthermore, this battery pack frame also enhances the rigidity of the battery pack. Moreover, the components are tightly connected, resulting in uniform stress distribution. The connectors occupy little space, and the adapter blocks, crossbeam assembly, first connector, and second connector are lightweight, structurally stable, and not easily damaged.

[0111] It should be noted that the method in this embodiment can be executed by a single device, such as a computer or server. The method can also be applied in a distributed scenario, where multiple devices cooperate to complete the task. In such a distributed scenario, one of these devices may execute only one or more steps of the method in this embodiment, and the multiple devices will interact with each other to complete the method described.

[0112] It should be noted that some embodiments of this application have been described. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps recorded in the claims can be performed in a different order than that shown in the embodiments and still achieve the desired result. Furthermore, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0113] Based on the same inventive concept, corresponding to any of the above embodiments, this application also provides a vehicle, including a battery pack frame or battery pack corresponding to any of the embodiments.

[0114] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of this application (including the claims) is limited to these examples; within the framework of this application, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of the embodiments of this application as described above, which are not provided in the details for the sake of brevity.

[0115] Additionally, to simplify the description and discussion, and to avoid obscuring the embodiments of this application, the well-known power / ground connections to integrated circuit (IC) chips and other components may or may not be shown in the provided drawings. Furthermore, the apparatus may be shown in block diagram form to avoid obscuring the embodiments of this application, and this also takes into account the fact that the details of the implementation of these block diagram apparatuses are highly dependent on the platform on which the embodiments of this application will be implemented (i.e., these details should be fully understood by those skilled in the art). While specific details (e.g., circuits) have been set forth to describe exemplary embodiments of this application, it will be apparent to those skilled in the art that the embodiments of this application can be implemented without these specific details or with variations thereof. Therefore, these descriptions should be considered illustrative rather than restrictive.

[0116] Although this application has been described in conjunction with specific embodiments thereof, many substitutions, modifications, and variations of these embodiments will be apparent to those skilled in the art from the foregoing description. For example, other memory architectures (e.g., dynamic RAM (DRAM)) may be used with the embodiments discussed.

[0117] The embodiments of this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the embodiments of this application should be included within the protection scope of this application.

Claims

1. A battery pack frame, characterized in that, include: A border assembly and a beam assembly disposed on the border assembly; The frame assembly includes: a first frame, a second frame, a third frame, and a fourth frame connected end to end to form an accommodating cavity; wherein, the second frame is provided with a first set of transition blocks, and the fourth frame is provided with a second set of transition blocks opposite to the first set of transition blocks; The beam assembly includes: a first beam and a second beam disposed within the accommodating cavity, one end of each of the first beam and the second beam being connected to the second frame via the first set of adapter blocks, and each being connected to two surfaces of the corresponding adapter blocks in the first set of adapter blocks distributed in different directions. The other ends of the first and second crossbeams are both connected to the fourth frame via the second set of transition blocks, and are both connected to two surfaces of the corresponding transition blocks in the second set of transition blocks that are distributed in different directions. The first set of adapter blocks and the second set of adapter blocks each include: a main body and a protrusion connecting the main body; both ends of the first crossbeam and the second crossbeam are respectively fixedly connected to the main body surface and the protrusion surface of the corresponding adapter block in the first set of adapter blocks and the second set of adapter blocks, and the two connecting surfaces of the main body surface and the protrusion surface are spatially distributed in different directions, so that when the cell expansion force is applied to the crossbeam assembly, the cell expansion force is decomposed by the two connecting surfaces distributed in different directions.

2. The battery pack frame as described in claim 1, characterized in that, The battery pack frame further includes: a first push rod and a second push rod; The first top rod connects the first frame and the first crossbeam; the second top rod connects the third frame and the second crossbeam.

3. The battery pack frame as described in claim 2, characterized in that, The battery pack frame further includes: a base plate connected to the frame assembly; The first crossbeam has a first groove on the side away from the base plate; the second crossbeam has a second groove on the side away from the base plate. The first push rod is provided with a first ramp at one end near the first crossbeam, and the first ramp cooperates with the first groove to connect the first push rod and the first crossbeam; The second push rod has a second ramp at one end near the second crossbeam, and the second ramp cooperates with the second groove to connect the second push rod and the second crossbeam.

4. The battery pack frame as described in claim 2, characterized in that, The first frame has a first connecting hole on the side near the first top rod; the third frame has a second connecting hole on the side near the second top rod. The first top rod has a first protrusion at one end near the first frame, and the first protrusion cooperates with the first connecting hole to connect the first top rod and the first frame; The second top rod has a second protrusion at one end near the third frame, and the second protrusion cooperates with the second connecting hole to connect the second top rod and the third frame.

5. The battery pack frame as described in claim 1, characterized in that, The first set of transition blocks includes: a first transition block and a second transition block disposed on the second frame; the second set of transition blocks includes: a third transition block and a fourth transition block disposed on the fourth frame; wherein, the first transition block corresponds to the third transition block, and the second transition block corresponds to the fourth transition block; The first crossbeam includes two first notches respectively disposed at both ends; The second crossbeam includes two second notches respectively disposed at both ends; One of the first notches of the first crossbeam is connected to the second side frame via the first adapter block, and the other of the first notches of the first crossbeam is connected to the fourth side frame via the third adapter block; One of the second notches of the second crossbeam is connected to the second frame via the second adapter block, and the other of the second notches of the second crossbeam is connected to the fourth frame via the fourth adapter block.

6. The battery pack frame as described in claim 5, characterized in that, The two ends of the first crossbeam are respectively connected to the main body of the first transition block and the main body of the third transition block by bolts arranged along the first direction; The two first notches of the first crossbeam are respectively connected to the protrusions of the first adapter block and the third adapter block by bolts arranged along the second direction; The two ends of the second crossbeam are respectively connected to the main body of the second transition block and the main body of the fourth transition block by bolts arranged along the first direction; The two second notches of the second crossbeam are respectively connected to the protrusions of the second adapter block and the fourth adapter block by bolts arranged along the second direction; Wherein, the first direction is parallel to the extension direction of the second border, and the second direction is perpendicular to the first direction.

7. The battery pack frame as described in claim 6, characterized in that, The protrusion is connected to the lower surface of the beam assembly.

8. The battery pack frame as described in claim 3, characterized in that, The first crossbeam is provided with a first connecting member, and the second crossbeam is provided with a second connecting member. The first crossbeam is connected to the base plate through the first connecting member, and the second crossbeam is connected to the base plate through the second connecting member.

9. A battery pack, characterized in that, include: The battery pack, the top cover, and the battery pack frame as described in any one of claims 3-8; The battery pack frame further includes: a base plate connected to the frame assembly; The battery pack is housed in a cavity formed by the frame assembly, the beam assembly, and the base plate; The top cover is connected to the frame assembly and the beam assembly.

10. The battery pack as claimed in claim 9, characterized in that, The battery pack includes: a plurality of battery cells placed between the first crossbeam and the second crossbeam; wherein each battery cell includes: a shell surrounding the periphery of the battery cell, the shell including large surfaces disposed opposite to each other; The battery pack also includes: a liquid cooling system; The liquid cooling system includes: a liquid cooling plate and liquid cooling pipes; wherein the liquid cooling plate is in contact with the large surface of each of the battery cells; Water nozzles are provided at both ends of the liquid cooling plate that extend beyond the battery cell, and the liquid cooling pipe is connected to the liquid cooling plate through the water nozzles.

11. A battery pack assembly method based on the battery pack as described in any one of claims 9-10, characterized in that, include: Battery packs are provided; The system provides a base plate, a frame assembly, a crossbeam assembly, and a top cover. The frame assembly includes a first frame, a second frame, a third frame, and a fourth frame connected end to end in sequence. The second frame is provided with a first set of transition blocks, and the fourth frame is provided with a second set of transition blocks opposite to the first set of transition blocks. The crossbeam assembly includes a first crossbeam and a second crossbeam disposed between the second frame and the fourth frame. The first set of adapter blocks is connected to the second frame, the second set of adapter blocks is connected to the fourth frame, and one end of both the first beam and the second beam is connected to the second frame through the first set of adapter blocks, and both are connected to two surfaces of the corresponding adapter blocks in the first set of adapter blocks that are distributed in different directions; and the other end of both the first beam and the second beam is connected to the fourth frame through the second set of adapter blocks, and both are connected to two surfaces of the corresponding adapter blocks in the second set of adapter blocks that are distributed in different directions. The battery pack is placed in the accommodating cavity formed by the first crossbeam, the second frame, the second crossbeam, the fourth frame, and the bottom plate; The top cover is connected to the first frame, the second frame, the third frame, the fourth frame, the first crossbeam, and the second crossbeam, respectively.

12. The battery pack assembly method according to claim 11, further comprising the following steps before placing the battery pack in the receiving cavity formed by the first crossbeam, the second frame, the second crossbeam, the fourth frame, and the bottom plate: A first connector and a second connector are provided, wherein the first crossbeam is connected to the base plate via the first connector, and the second crossbeam is connected to the base plate via the second connector.

13. A vehicle, characterized in that, Includes the battery pack frame as described in any one of claims 1-8 or the battery pack as described in any one of claims 9-10.

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