Battery packs and vehicles

Abstract

This invention discloses a battery pack and a vehicle. The battery pack includes: a housing with a side access port; and an electronic control structure housed within the housing and positioned opposite the side access port. The electronic control structure includes a first battery drain unit (BDU) module, which comprises: a first electrical housing, a fuse, and a current sensor. The first electrical housing has a first opening facing the side access port. The fuse and current sensor are detachably mounted within the first electrical housing, with the current sensor connected in series with the fuse. The battery pack according to this invention facilitates high-voltage switching and safety protection functions. Since fuses and current sensors have a relatively high failure rate compared to other electrical components, their detachable configuration facilitates maintenance.

Description

Technical Field

[0001] This invention relates to the field of battery technology, and in particular to a battery pack and a vehicle. Background Technology

[0002] With the iterative updates in vehicle technology, the technology of battery-vehicle integration continues to develop. This means that the battery pack is directly integrated into the vehicle chassis, achieving a higher degree of integration. The battery pack includes a housing, a top cover, battery packs, and electrical connection components. The battery pack also includes a top cover, and a mounting cavity is defined between the housing and the top cover. The battery pack and electrical connection components are located within the mounting cavity, situated between the housing and the top cover. The top cover of the battery pack is located at the bottom of the vehicle body and serves as the chassis, bearing the weight of the entire battery pack.

[0003] In existing technical solutions, the design types for disassembly, assembly, and maintenance of the battery pack's electronic control structure are limited. To improve integration and rationalize the design, more types of electronic control structures need to be developed. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. Therefore, one object of the present invention is to provide a battery pack in which the electrical modules are arranged separately, thereby improving the convenience of inspection and maintenance.

[0005] The present invention also proposes a vehicle.

[0006] According to an embodiment of the present invention, a battery pack includes: a housing having a side access port; and an electronic control structure disposed within the housing and facing the side access port. The electronic control structure includes a first BDU module, which includes: a first electrical housing, a fuse, and a current sensor. The first electrical housing has a first opening facing the side access port, and the fuse and current sensor are detachably disposed within the first electrical housing. The current sensor is connected in series with the fuse.

[0007] According to embodiments of the present invention, the battery pack's electronic control structure is configured in such a way that the fuse and current sensor are accurately positioned, and this also contributes to a compact structure. The inclusion of the first BDU module facilitates the realization of high-voltage switching and safety protection functions. Since fuses and current sensors have a relatively high failure rate compared to other electrical components, their detachable design facilitates maintenance.

[0008] In some embodiments, the first electrical housing is provided with a first positioning cavity and a second positioning cavity that open toward the side access port, the fuse is located in the first positioning cavity, and the current sensor is located in the second positioning cavity;

[0009] A first positioning boss is formed on at least one side of the first positioning cavity within the first electrical housing, and the end of the fuse is detachably connected to the first positioning boss;

[0010] A second positioning boss is formed on at least one side of the second positioning cavity within the first electrical housing, and the end of the current sensor is detachably connected to the second positioning boss.

[0011] Specifically, both the first positioning boss and the second positioning boss have threaded holes on their surfaces facing the side inspection port. The fuse is bolted to the first positioning boss, and the current sensor is bolted to the second positioning boss.

[0012] Furthermore, the first positioning boss and the second positioning boss are staggered in height and are at different distances from the side inspection port.

[0013] Optionally, the first electrical housing is provided with at least one first positioning boss, the rear surface of the first positioning boss is provided with a second threaded hole, a first positioning cavity is defined between at least one first positioning boss, the fuse is located in the first positioning cavity, and the two ends of the fuse are connected to at least one first positioning boss by second bolts, each of the second bolts being threaded into the second threaded hole;

[0014] The first electrical housing is provided with at least one second positioning boss, the rear surface of the second positioning boss is provided with a third threaded hole, and a second positioning cavity is defined between at least one second positioning boss. The current sensor is located in the second positioning cavity, and the two ends of the current sensor are connected to at least one second positioning boss by a third bolt. Each third bolt is threaded into the third threaded hole.

[0015] Furthermore, at least one of the first positioning bosses is arranged in the left-right direction, at least one of the second positioning bosses is arranged in the left-right direction, at least one of the second positioning bosses has a different height from at least one of the first positioning bosses, and the rear surfaces of the first positioning bosses and the rear surfaces of the second positioning bosses are staggered in the front-back direction.

[0016] The projections of the second bolt and the third bolt on the rear side wall are both located within the side inspection port.

[0017] Advantageously, the first BDU module further includes: a first conductive sheet located within the first positioning cavity and on the front side of the fuse;

[0018] The second positioning boss is located directly above the first positioning boss, and the left-right dimension of the current sensor is smaller than the left-right dimension of the fuse.

[0019] A portion of the side edge of the first conductive sheet is bent and connected to a first positioning boss after extending laterally, so as to be electrically connected to the fuse;

[0020] The upper edge of a portion of the first conductive sheet extends upward and is bent to connect to another second positioning protrusion for electrical connection with the current sensor.

[0021] Specifically, the first electrical housing has a second opening at the top, and the first BDU module further includes a top cover and two second conductive plates. The two second conductive plates are arranged at a distance from each other on the top of the first electrical housing, and each second conductive plate extends in the front-back direction.

[0022] One of the second conductive sheets has its rear end bent downwards and rests on the first positioning boss and is electrically connected to the fuse; the other second conductive sheet has its rear end bent downwards and rests on the second positioning boss and is electrically connected to the current sensor; the front ends of the two second conductive sheets are respectively connected to the battery pack via copper busbars.

[0023] The top cover is detachably attached to the top of the first electrical housing and covers the two second conductive plates.

[0024] Optionally, the current sensor has a first connector on the rear side, and the top cover has a first through hole facing the first connector.

[0025] Optionally, the top surface of the top cover is provided with a limiting groove that extends forward and backward, and the front end of the limiting groove is positioned directly opposite the first through hole;

[0026] The top cover is further provided with a limiting protrusion on at least one side of the limiting groove.

[0027] In some embodiments, the electronic control structure further includes a BMS master control board and a BMS slave control board, which are located on both sides of the first BDU module and are both positioned facing the side inspection port.

[0028] A vehicle according to an embodiment of the present invention includes: a vehicle body, wherein a passenger space is formed within the vehicle body; and a battery pack as described in the above embodiment, wherein the battery pack is mounted at the bottom of the vehicle body.

[0029] According to embodiments of the present invention, by employing the above-described battery pack, the vehicle's overall integration can be improved. Optimizing the battery pack structure facilitates the inspection and maintenance of battery pack malfunctions.

[0030] Specifically, a mounting opening is formed at the bottom of the vehicle body, and the battery pack is located inside the mounting opening;

[0031] The bottom of the vehicle body also has an upwardly recessed cavity, and the rear end of the battery pack is positioned directly opposite the upwardly recessed cavity.

[0032] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0033] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0034] Figure 1 This is an overall schematic diagram of a battery pack according to an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the positional relationship between the electrical module and the battery pack according to an embodiment of the present invention from one perspective;

[0036] Figure 3 This is an exploded view of a battery pack according to an embodiment of the present invention from one perspective;

[0037] Figure 4 This is a schematic diagram of the positional relationship between the electrical module and the battery pack according to an embodiment of the present invention from another perspective.

[0038] Figure 5 This is a structural diagram of a battery pack according to an embodiment of the present invention, showing components hidden from view.

[0039] Figure 6 This is a structural diagram of a battery pack according to an embodiment of the present invention, showing components hidden from another view.

[0040] Figure 7 This is a schematic diagram of the wiring harness structure of an electrical module according to an embodiment of the present invention;

[0041] Figure 8 This is a top view schematic diagram of an electrical module according to an embodiment of the present invention;

[0042] Figure 9 This is a front view schematic diagram of a portion of the structure of an electrical module according to an embodiment of the present invention;

[0043] Figure 10 This is a schematic diagram of the battery pack side access cover when it is opened according to an embodiment of the present invention;

[0044] Figure 11 This is a partial structural diagram of the battery pack with the wiring harness hidden and the side access cover opened according to an embodiment of the present invention.

[0045] Figure 12This is a top partial structural schematic diagram of the housing and support frame according to an embodiment of the present invention;

[0046] Figure 13 This is a top partial structural schematic diagram of the housing, support frame, and mounting plate according to an embodiment of the present invention;

[0047] Figure 14 This is a partial structural schematic diagram of the housing, support frame, and mounting plate according to an embodiment of the present invention;

[0048] Figure 15 This is a rear view schematic diagram of the housing and support frame according to an embodiment of the present invention;

[0049] Figure 16 This is a schematic diagram of the assembly structure of the BMS main control board according to an embodiment of the present invention from one perspective;

[0050] Figure 17 This is a schematic diagram of the assembly structure of the BMS main control board according to an embodiment of the present invention from another perspective;

[0051] Figure 18 This is a schematic diagram of the assembly structure of the BMS control board according to an embodiment of the present invention from one perspective;

[0052] Figure 19 This is a schematic diagram of the assembly structure of the BMS control board according to an embodiment of the present invention from another perspective;

[0053] Figure 20 This is a schematic diagram of the structure of the first BDU module according to an embodiment of the present invention from one viewpoint;

[0054] Figure 21 This is an exploded view of the first BDU module according to an embodiment of the present invention from another perspective.

[0055] Figure 22 This is an exploded view of the battery pack according to an embodiment of the present invention;

[0056] Figure 23 yes Figure 22 Enlarged view of a portion of the image;

[0057] Figure 24 This is a schematic diagram of the structure of the second electrical part according to an embodiment of the present invention;

[0058] Figure 25 This is an exploded view of the second electrical component according to an embodiment of the present invention;

[0059] Figure 26 This is a schematic diagram of the structure of the shock-absorbing column according to an embodiment of the present invention;

[0060] Figure 27This is a partial structural diagram of the second electrical housing according to an embodiment of the present invention;

[0061] Figure 28 This is a schematic diagram of the structure of the bottom protective plate and its buffer layer according to some embodiments of the present invention;

[0062] Figure 29 This is a partial structural diagram of the bottom protective plate according to other embodiments of the present invention;

[0063] Figure 30 According to some other embodiments of the present invention

[0064] Figure 31 This is an overall schematic diagram of a vehicle according to an embodiment of the present invention;

[0065] Figure 32 This is a diagram showing the positional relationship of the battery pack within the vehicle body according to an embodiment of the present invention.

[0066] Figure label:

[0067] 1000 vehicles;

[0068] Battery pack 100;

[0069] Shell 1, Frame 10, Front sidewall 11, Rear sidewall 12, Left sidewall 13, Right sidewall 14, Bottom protective plate 15, Thickened layer 151, Top plate 16, Mounting beam 17, Buffer layer 18

[0070] Side inspection port 101, first fixing hole 111, vent 102, frame side beam 103, frame body 1031.

[0071] Battery pack 2, battery group 20, battery cell 201, pressure relief component 202;

[0072] Electrical module 3

[0073] Electrical connection structure 31

[0074] First wire harness 311, first flexible conductor 3111, first plug connector 3112, second flexible conductor 3113, second plug connector 3114, third flexible conductor 3115, third plug connector 3116.

[0075] Second wiring harness 312, second signal transmission interface 3121

[0076] Third wiring harness 313, fourth wiring harness 314

[0077] High-voltage terminal block 315, low-voltage terminal block 316, copper busbar 317.

[0078] Electrical control structure 32,

[0079] First BDU module 321, first electrical housing 3211, first opening 3211a, second opening 3211b, first positioning boss 3211c, second threaded hole 3211d, first positioning cavity 3211e, second positioning boss 3211f, third threaded hole 3211g, second positioning cavity 3211h, fuse 3212, current sensor 3213, first connector 32131, first conductive sheet 3214, second conductive sheet 3215, top cover 3216, first through hole 3216a, limiting groove 3216b, limiting protrusion 3216c, first latching part 3216d, side cover 3217, second latching part 3217a, curved panel 3217b.

[0080] BMS main control board 322, second connector 3221

[0081] BMS slave control board 323, third connector 3231

[0082] Mounting plate 324, flange 3241, mounting hole 3242

[0083] Bolt 3291 (first bolt), Bolt 3292 (second bolt), Bolt 3293 (third bolt), Bolt 3294 (fourth bolt), Bolt 3295 (fifth bolt).

[0084] Second electrical component 33, fourth flexible conductor 331, second electrical housing 332, shock absorber column 333, thick column section 3331, thin column section 3332, center hole 3333, first extension plate 3351, second extension plate 3352, mating hook 33521, lower protrusion 336, second through hole 3361, wire fastener 3362, main relay 337, electrical strip 338, first signal transmission interface 339;

[0085] Support frame 4, support longitudinal rod 40, first longitudinal rod 401, second longitudinal rod 402, third longitudinal rod 403, fourth longitudinal rod 404, support cross rod 41, first threaded hole 411, clearance groove 412;

[0086] Divider assembly 5, crossbeam 51, lower crossbar 511, upper crossbar 512, first notch 5131, second notch 5132, third notch 5133, longitudinal beam 52, seat mounting nut 53, front cavity 54, rear cavity 55, receiving compartment 56, flow channel 561, width of flow channel x1.

[0087] 6. Liquid cooling plate, 601. Liquid cooling pipe, 602. Liquid cooling connector, 61. Bottom inspection port, 611. Fastening bolt, 62. Seating ring, 63. Bottom inspection cover, 64. Side inspection cover, 65. Air pressure balance valve, 66. Seat fixing fastener, 67. Fixing plate.

[0088] Vehicle body 200, passenger space 220, mounting port 230, upper concave cavity 240. Detailed Implementation

[0089] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0090] In the description of this invention, it should be understood that the terms "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and 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 a limitation of the invention. Furthermore, features defined with "first" or "second" 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.

[0091] 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 connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0092] The battery pack 100 according to an embodiment of the present invention will now be described with reference to the accompanying drawings. The battery pack 100 according to an embodiment of the present invention includes an electronic control structure 32, which extends along a first direction D1 or a second direction D2 of the battery pack 100. To facilitate understanding of the electronic control structure 32, the structure of the battery pack 100 according to some embodiments will be described below.

[0093] like Figures 1-6 As shown, the battery pack 100 according to an embodiment of the present invention includes: a housing 1, a battery pack 2, and an electrical module 3.

[0094] The housing 1 has a front side wall 11 and a rear side wall 12, and the rear side wall 12 is provided with a side inspection port 101. The battery pack 2 is located inside the housing 1.

[0095] Electrical module 3 is installed inside housing 1. Electrical module 3 includes an electrical connection structure 31 and an electrical control structure 32. In some designs, electrical module 3 is a split structure, that is, electrical module 3 includes electrical connection structure 31, electrical control structure 32, and a second electrical part 33, with electrical control structure 32 equivalent to the first electrical part. Electrical control structure 32 is located on the rear side of battery pack 2 and is positioned opposite the access port 101. The second electrical part 33 is located on the front side of battery pack 2. Electrical connection structure 31 is used for electrical connection with electrical control structure 32, second electrical part 33, and battery pack 2. Electrical module 3 also includes a high-voltage terminal 315 and a low-voltage terminal 316 provided on electrical connection structure 31. The high-voltage terminal 315 and the low-voltage terminal 316 are installed on housing 1.

[0096] It should be noted that the descriptions of "high voltage" and "low voltage" in this article do not limit their specific voltage values, but rather define their relative values. The high voltage value is typically the supply voltage of the battery pack 100 as a power source, while the low voltage value is typically the signal transmission voltage within the battery pack 100.

[0097] It is understandable that the application of the battery pack 100 is not limited. Depending on the installation location of the battery pack 100, the orientation of the battery pack 100 can be adaptively adjusted in the first direction D1 and the second direction D2. Both the first direction D1 and the second direction D2 are perpendicular to the height direction. The height direction of the battery pack 100 is... Figure 1 The vertical direction is shown. When installed on vehicle 1000, the first direction D1 is the front-to-back direction, and the second direction D2 is the left-to-right direction.

[0098] In existing technologies, the electrical modules of a battery pack include a BDU (Battery Disconnect Unit) and a BMS (Battery Management System). The BDU uses the BMS to control high-voltage switching and safety protection functions. In practical applications, the electrical modules are concentrated on one side of the battery pack, and long busbars are used to achieve electrical connections within the battery pack, with at least three long busbars.

[0099] This application divides the electrical module 3 into an electrical control structure 32 and a second electrical part 33, which can reduce the circuit connections that run through the front and back of the battery pack 100, thereby reducing the application cost of electrical connections and the weight of the battery pack 100, and optimizing the electrical layout within the battery pack 100.

[0100] According to an embodiment of the present invention, the battery pack 100, by configuring the electrical module 3 as the electronic control structure 32 and the second electrical part 33, facilitates the electrical layout within the battery pack 100 and optimizes the spatial arrangement of the electrical module 3 within the battery pack 100. In the prior art, the space occupied by the electrical module within the battery pack is smaller than the space occupied by the battery pack, and the height of some electrical modules is greater than the height of the battery pack. In order to accommodate the electrical module within the housing, the size of the housing needs to be increased, which also increases the size of the entire battery pack, reducing the utilization rate of the internal space of the battery pack. In this application, the optimized design makes it easier to reduce the height of the electrical module 3, for example, making the height of the battery pack 2 greater than or equal to the height of the electrical module 3, thereby avoiding the increase in the size of the battery pack 100 caused by the excessive height of the electrical module 3 and improving the utilization rate of the internal space of the battery pack 100.

[0101] The height dimensions of each part in this article refer to the height of the part (i.e., in the height direction). Figure 1 The dimensions in the vertical direction.

[0102] In some embodiments, such as Figure 1 and Figure 3 As shown, the housing 1 includes a frame 10 and a top plate 16 connected to the top of the frame 10, and a bottom protective plate 15 connected to the bottom of the frame 10.

[0103] Specifically, the shape of the frame 10 typically determines the overall shape of the battery pack 100. The frame 10 can be a square or hexagonal frame, etc. A common shape for the frame 10 is quadrilateral. Specifically, the frame 10 is formed by connecting the end-to-end side beams on its four sides. Each side beam constitutes one side wall of the housing 1, namely the front side wall 11, rear side wall 12, left side wall 13, and right side wall 14. Each side beam can be made of shaped steel or rolled steel. Furthermore, mounting beams 17 are connected to the frame 10. The mounting beams 17 can be installed on the side beams, for example, on the front side wall 11, rear side wall 12, left side wall 13, and right side wall 14. Furthermore, during the assembly of the battery pack 100, the side beams of the frame 10 are connected to the top plate 16 and the bottom protective plate 15 with bolts to improve the reliability of the connection.

[0104] Optionally, during assembly, the top of the battery pack 2 is directly glued to the top plate 16, making them an inseparable unit. Optionally, during assembly, the bottom of the battery pack 2 is directly glued to the bottom cover plate 15, making them an inseparable unit. Of course, the solution of this application is not limited to these. The bottom cover plate 15 can also be provided as a detachable connection structure to facilitate disassembly and maintenance of the battery pack 100 from the bottom. The top plate 16 can also be provided as a detachable connection structure to facilitate disassembly and maintenance of the battery pack 100 from the top.

[0105] In some embodiments, such as Figures 6-8As shown, the electrical control structure 32 includes a first BDU module 321, a BMS main control board 322, and a BMS slave control board 323. The first BDU module 321 is located between the BMS main control board 322 and the BMS slave control board 323. The second electrical part 33 includes a second BDU module.

[0106] Specifically, the BMS main control board 322 and the BMS slave control board 323 control the first BDU module 321 and the second BDU module to achieve high voltage switching and safety protection functions. The BMS main control board 322 and the BMS slave control board 323 are connected via a wiring harness in the electrical connection structure 31. The BMS main control board 322 and the BMS slave control board 323 are also connected to the first BDU module 321 and the second BDU module via the wiring harness in the electrical connection structure 31. The first BDU module 321 is located in the middle of the battery pack 2 in the second direction D2, and the second BDU module is connected to the battery pack 2 via a copper busbar 317. In the electrical control structure 32, the BMS main control board 322, the first BDU module 321, and the BMS slave control board 323 are arranged sequentially along the second direction D2. The wiring harness portion of the electrical connection structure 31 is as follows... Figure 7 As shown, it includes multiple wire harnesses.

[0107] Here, the first BDU module 321 is placed between the BMS main control board 322 and the BMS slave control board 323, which facilitates the central placement of the first BDU module 321 and ensures a symmetrical connection between the first BDU module 321 and the battery pack 2. When voltage divider protection is required for the battery pack 2, the first BDU module 321 and the two battery groups 20 of the battery pack 2 are symmetrical.

[0108] Specifically, the BMS main control board 322 and the BMS slave control board 323 are detachable via the side inspection port 101. It is understandable that the BMS main control board 322 and the BMS slave control board 323 have a higher failure rate in terms of failure frequency. Therefore, they are set to be detachable to facilitate direct removal for repair and inspection in case of failure.

[0109] For example, in the first electrical module 3, the BMS slave control board 323 includes at least one, which can collect and transmit data of individual battery cells in the battery pack 2, and transmit the data to the BMS master control board 322 via the electrical connection structure 31. Thus, the BMS slave control board 323 can be configured according to the number of individual battery cells 201 in the battery pack 2.

[0110] Specifically, the BMS slave control board 323 comprises two boards, which are stacked along the height direction. The dimensions of each BMS slave control board 323 are 86.5 mm in the first direction D1, 240 mm in the second direction D2, and 19.7 mm in height. The stacked height of the two BMS slave control boards 323 is 48.7 mm. The BMS master control board 322 has a dimension of 102 mm in the first direction D1, a dimension of 260 mm in the second direction, and a height of 24 mm. The first BDU module 321 has a dimension of 103 mm in the first direction D1, a dimension of 153 mm in the second direction D2, and a height of 85.5 mm. Along the second direction D2, the total dimensions of the BMS slave control board 323, the BMS master control board 322, and the first BDU module 321 in the electrical control structure 32 are at least 653 mm.

[0111] Combination Figure 10 and Figure 11 As shown, the height of the electronic control structure 32 and the second electrical part 33 is lower than that of the battery pack 2.

[0112] In some specific embodiments, such as Figure 17 , Figure 18 and Figure 11 As shown, the BMS slave control panels 323 are arranged along the left-right direction, and there are at least two BMS slave control panels 323 stacked along the height direction. The projections of all BMS slave control panels 323 on the rear side wall 12 are completely within the side access port 101. This allows the BMS slave control panels 323 to be pulled out horizontally during disassembly and assembly, reducing the risk of bumps caused by tilting. Moreover, when the side access port 101 is open, the status of the BMS slave control panels 323 can be observed more intuitively even without removing them.

[0113] like Figure 18 , Figure 19 and Figure 11 As shown, the BMS main control board 322 is positioned along the left-right direction, and its projection on the rear side wall 12 is entirely within the side inspection port 101. This allows the BMS main control board 322 to be pulled out horizontally during disassembly and assembly, reducing the risk of impact when tilted. Furthermore, when the side inspection port 101 is open, the status of the BMS slave control board 323 can be observed more directly even without removing the BMS main control board 322.

[0114] In some embodiments, such as Figures 12-14As shown, the battery pack 100 also includes a support frame 4, which is located inside the housing 1. The electronic control structure 32 is mounted on the support frame 4. The support frame 4 can provide support force to the electronic control structure 32, reducing the shaking of the electronic control structure 32 during the movement of the battery pack 100, thereby improving the safety of the battery pack 100. In addition, the support frame 4 can also raise the electronic control structure 32, making it easier to face the side inspection port 101.

[0115] The support frame 4 has multiple first threaded holes 411 on one side of the inspection port 101 facing the side, and the multiple first threaded holes 411 are distributed sequentially along the second direction D2. The BMS main control board 322 and the BMS slave control board 323 can be directly or indirectly connected to the support frame 4 by bolts, and are connected to the first threaded holes 411 for easy disassembly and assembly.

[0116] In some embodiments, the electronic control structure 32 includes two mounting plates 324, with the BMS main control board 322 and the BMS slave control board 323 respectively mounted on their respective mounting plates 324, and the mounting plates 324 being fixed in the housing 1 by first bolts 3291.

[0117] The first bolt 3291 is arranged in the front-to-back direction, with its head located at the rear end. The projection of the first bolt 3291 on the rear side wall 12 is located inside the side inspection port 101.

[0118] Specifically, such as Figure 16 As shown, the BMS main control board 322 is connected to a mounting plate 324, for example, by fixing it with vertically arranged bolts as shown.

[0119] Specifically, such as Figure 18 As shown, the BMS is connected from the control board 323 to another mounting plate 324, for example, by fixing the connection with vertically arranged bolts as shown.

[0120] Specifically, such as Figure 13 and Figure 14 As shown, during assembly, the mounting plate 324 with the BMS main control board 322 or BMS slave control board 323 is placed on the support frame 4. The side of the mounting plate 324 facing the inspection port 101 forms a downwardly extending flange 3241. The flange 3241 is provided with a mounting hole 3242 corresponding to the first threaded hole 411. The first bolt 3291 passes through the mounting hole 3242 and the first threaded hole 411 in sequence to fix it.

[0121] like Figures 12-14As shown, the support frame 4 includes four support crossbars 41 distributed along the first direction D1. Each support crossbar 41 extends along the second direction D2. Two support crossbars 41 are close to the side access port 101, and the other two support crossbars 41 are away from the side access port 101. Each support crossbar 41 is provided with a first threaded hole 411, and the support crossbar 41 close to the side access port 101 is provided with a relief groove 412, which corresponds to the first threaded hole 411 away from the side access port 101.

[0122] The mounting plate 324 has two flanges 3241 distributed along the first direction D1, and each flange 3241 has a mounting hole 3242. The mounting plate 324 is placed on the support frame 4. The side of the mounting plate 324 facing the side access port 101 forms a downward extending flange 3241. The flange 3241 has a mounting hole 3242 corresponding to the first threaded hole 411. The first bolt 3291 can pass through the mounting hole 3242 and the first threaded hole 411 in sequence to fix the mounting plate 324 to the support frame 4. Furthermore, the first bolt 3291 is set on the support frame 4 along the second direction D2, which can reduce interference during assembly and disassembly and improve the efficiency of installation or disassembly. In addition, the flange 3241 can also position the mounting plate 324 and assist in fixing the mounting plate 324 and the support frame 4. The flange 3241 of the mounting plate 324 faces the side inspection port 101 and extends downward. The flange 3241 is a single long strip, and a mounting hole 3242 is provided at the position corresponding to the first threaded hole 411. Alternatively, the flange 3241 is a long strip with a relief groove 412, and the flange 3241 is provided at the corresponding position of the first threaded hole 411.

[0123] In some specific embodiments, such as Figure 12 and Figure 13 As shown, the support frame 4 also includes four support longitudinal bars 40, each extending along a first direction D1. The four support longitudinal bars 40 are respectively arranged as a first longitudinal bar 401, a second longitudinal bar 402, a third longitudinal bar 403, and a fourth longitudinal bar 404. A support crossbar 41 connects the first longitudinal bar 401 and the second longitudinal bar 402, and a support crossbar 41 connects the third longitudinal bar 403 and the fourth longitudinal bar 404.

[0124] The electronic control structure 32 includes two detachable components, which are respectively located on the support crossbars 41 on both sides. Thus, the support longitudinal bar 40 and support crossbar 41 in the support frame 4 can support the detachable components. By setting the support frame 4 as a combination of support longitudinal bar 40 and support crossbar 41, compared to setting the support frame 4 as a single support plate, on the one hand, the support longitudinal bar 40 is lighter, meeting structural strength requirements while reducing the overall weight of the battery pack 100; on the other hand, the manufacturing process of the support longitudinal bar 40 is simpler, reducing production costs and improving production efficiency.

[0125] Specifically, a supporting crossbar 41 connects the first vertical bar 401 and the second vertical bar 402. There are two supporting crossbars 41, arranged along a first direction D1, each including a mounting hole 3242. The supporting crossbar 41 closer to the front of the first direction D1 is the first supporting crossbar, and the supporting crossbar 41 closer to the rear of the first direction D1 is the second supporting crossbar. The height of the second supporting crossbar is greater than that of the first supporting crossbar 41, and the mounting hole 3242 on the second supporting crossbar is fully exposed. At the mounting hole 3242, the heights of the first and second supporting crossbars are the same.

[0126] Furthermore, the BMS control board 323 is detachably connected to the first longitudinal bar 401 and the second longitudinal bar 402 via a mounting plate 324, and the BMS main control board 322 is detachably connected to the third longitudinal bar 403 and the fourth longitudinal bar 404 via another mounting plate 324.

[0127] Furthermore, the first BDU module 321 can be mounted on the second longitudinal bar 402 and the third longitudinal bar 403. For example, the first BDU module 321 includes a first electrical housing 3211, which is connected to the second longitudinal bar 402 and the third longitudinal bar 403 by vertically arranged bolts.

[0128] In some embodiments, such as Figure 10 , Figure 20 , Figure 21 As shown, the first BDU module 321 includes: a first electrical housing 3211 and a fuse 3212. The first electrical housing 3211 has a first opening 3211a on the rear side, and the fuse 3212 is detachably disposed inside the first electrical housing 3211.

[0129] Specifically, fuse 3212 is detachably connected to the first electrical housing 3211. After the electrical connection is severed in the event of a battery pack 100 failure, fuse 3212 needs to be replaced or manually reset.

[0130] Specifically, the first BDU module 321 also includes a side cover 3217, which is detachably sealed to the first opening 3211a. By providing the first electrical housing 3211 and the side cover 3217, the internal electrical components of the first BDU module 321, such as the fuse 3212, can be protected. Furthermore, the internal electrical components, such as the fuse 3212, are housed within the first electrical housing 3211, facilitating their fixation and installation, and improving the convenience and reliability of the fixed connection.

[0131] Furthermore, such as Figure 21As shown, the side cover 3217 has a second latching part 3217a at both ends, and the side cover 3217 can be latched to the first electrical housing 3211 through the second latching part 3217a.

[0132] In some specific embodiments, such as Figure 21 As shown, the side cover 3217 includes an arc-shaped panel 3217b located between the second snap-fit ​​portions 3217a on both sides. Its shape is adapted to the fuse 3212, improving compactness and constraint on the fuse 3212. The arc-shaped panel 3217b can be a circular arc plate; alternatively, it can be a grid plate to improve heat dissipation. The connection structure of the second snap-fit ​​portions 3217a improves the stability and convenience of the connection. By setting the side cover 3217 as a circular arc-shaped grid plate, the structural strength of the side cover 3217 can be improved.

[0133] Specifically, the first BDU module 321 further includes a current sensor 3213, which is connected in series with the fuse 3212. The current sensor 3213 is detachably disposed within the first electrical housing 3211. In this way, the current sensor 3213 can detect the current passing through the fuse 3212 in a timely manner, enabling the BMS slave control board 323 to determine in a timely manner whether the fuse 3212 needs to be blown.

[0134] Here, the internal circuit structure and specific working principle of the fuse 3212, current sensor 3213, BMS main control board 322, and BMS slave control board 323 are all existing technologies and will not be described in detail here.

[0135] Specifically, such as Figure 21 As shown, the fuse 3212 is fixed to the first electrical housing 3211 by the second bolt 3292. The head of the second bolt 3292 is set towards the side access port 101. The projection of the second bolt 3292 on the rear side wall 12 is located inside the side access port 101, thereby improving the reliability and stability of the fuse 3212 connected to the first electrical housing 3211.

[0136] When the fuse 3212 fails and needs to be replaced, first unlock the second latch 3217a to detach the side cover 3217 from the first electrical housing 3211 and expose the second bolt 3292. Then unscrew the second bolt 3292 to release the fixed connection between the fuse 3212 and the first electrical housing 3211. Finally, remove the faulty fuse 3212 through the side inspection port 101.

[0137] Similarly, the current sensor 3213 is fixed to the first electrical housing 3211 by the third bolt 3293. The head of the third bolt 3293 is set towards the side access port 101. The projection of the third bolt 3293 on the rear side wall 12 is located inside the side access port 101, thereby improving the reliability and stability of the current sensor 3213 connected to the first electrical housing 3211.

[0138] When the current sensor 3213 fails and needs to be replaced, first unlock the second latch 3217a to detach the side cover 3217 from the first electrical housing 3211 and expose the third bolt 3293. Then unscrew the third bolt 3293 to release the fixed connection between the current sensor 3213 and the first electrical housing 3211. Finally, remove the faulty current sensor 3213 through the side inspection port 101.

[0139] In some embodiments, such as Figure 21 As shown, the first electrical housing 3211 has a first positioning cavity 3211e and a second positioning cavity 3211h that open towards the side inspection port 101. The fuse 3212 is located in the first positioning cavity 3211e, and the current sensor 3213 is located in the second positioning cavity 3211h. In this way, the fuse 3212 and the current sensor 3213 are positioned separately using the first positioning cavity 3211e and the second positioning cavity 3211h, which facilitates assembly.

[0140] Specifically, a first positioning boss 3211c is formed on at least one side of the first positioning cavity 3211e within the first electrical housing 3211, and the end of the fuse 3212 is detachably connected to the first positioning boss 3211c. The fuse 3212 is fixedly connected to the side, minimizing obstruction to the fuse 3212.

[0141] A second positioning boss 3211f is formed on at least one side of the second positioning cavity 3211h within the first electrical housing 3211, and the end of the current sensor 3213 is detachably connected to the second positioning boss 3211f. The current sensor 3213 is fixedly connected to the side, minimizing obstruction to the current sensor 3213.

[0142] Furthermore, both the first positioning boss 3211c and the second positioning boss 3211f have threaded holes on their surfaces facing the side inspection port 101. The fuse 3212 is bolted to the first positioning boss 3211c, and the current sensor 3213 is bolted to the second positioning boss 3211f. Bolted connections are convenient, quick, and do not obstruct the view.

[0143] In some specific embodiments, such as Figure 21As shown, the first electrical housing 3211 has two first positioning bosses 3211c. The rear surface of the first positioning bosses 3211c has a second threaded hole 3211d. The two first positioning bosses 3211c define a first positioning cavity 3211e. The fuse 3212 is located in the first positioning cavity 3211e. The two ends of the fuse 3212 are connected to the two first positioning bosses 3211c by second bolts 3292. Each second bolt 3292 is threaded into the second threaded hole 3211d.

[0144] The first electrical housing 3211 is provided with two second positioning bosses 3211f. The rear surface of the second positioning bosses 3211f is provided with a third threaded hole 3211g. The two second positioning bosses 3211f define a second positioning cavity 3211h. The current sensor 3213 is located in the second positioning cavity 3211h. The two ends of the current sensor 3213 are connected to the two second positioning bosses 3211f by third bolts 3293. Each third bolt 3293 is threaded into the third threaded hole 3211g.

[0145] This allows for accurate positioning of both the fuse 3212 and the current sensor 3213, and also contributes to a more compact structure.

[0146] Optionally, the first positioning boss 3211c and the second positioning boss 3211f are staggered in height and are at different distances from the side inspection port 101.

[0147] Furthermore, two first positioning bosses 3211c are arranged in the left-right direction, and two second positioning bosses 3211f are arranged in the left-right direction. The two second positioning bosses 3211f are at different heights from the two first positioning bosses 3211c, and the rear surfaces of the first positioning bosses 3211c and the second positioning bosses 3211f are staggered in the front-back direction. This arrangement allows the fuse 3212 and current sensor 3213 to be staggered during assembly and disassembly, which helps to reduce the size of the first BDU module 321 in both the height and front-back directions.

[0148] Specifically, the first positioning boss 3211c is located below the second positioning boss 3211f, thus the fuse 3212 is installed below the current sensor 3213. Furthermore, the fuse 3212 is located behind the current sensor 3213, closer to the side access port 101. From a failure frequency perspective, this arrangement makes the fuse 3212, which has a higher failure rate, easier to remove.

[0149] Advantageously, such as Figure 21As shown, the first BDU module 321 further includes: a first conductive sheet 3214, which is located within the first positioning cavity 3211e and in front of the fuse 3212. A second positioning boss 3211f is located directly above a first positioning boss 3211c, and the left-right dimension of the current sensor 3213 is smaller than the left-right dimension of the fuse 3212. A portion of the side edge of the first conductive sheet 3214 extends laterally and then bends to connect to the first positioning boss 3211c for electrical connection with the fuse 3212. A portion of the upper edge of the first conductive sheet 3214 extends upward and then bends to connect to another second positioning boss 3211f for electrical connection with the current sensor 3213.

[0150] This configuration utilizes the first conductive piece 3214 to connect the fuse 3212 and the current sensor 3213 in series. Furthermore, the first conductive piece 3214 is not easily detached, ensuring high reliability. The width of the first conductive piece 3214 can be set to be relatively large, which is beneficial for reducing resistance, etc.

[0151] Specifically, such as Figure 21 As shown, the first electrical housing 3211 has a second opening 3211b at the top. The first BDU module 321 also includes a top cover 3216 and two second conductive plates 3215, which are spaced apart on the top of the first electrical housing 3211, and each second conductive plate 3215 extends in the front-back direction.

[0152] One of the second conductive pieces 3215 has its rear end bent downwards and rests on a first positioning boss 3211c, and is electrically connected to a fuse 3212. The rear end of the other second conductive piece 3215 is bent downwards and rests on a second positioning boss 3211f, and is electrically connected to a current sensor 3213. The front ends of the two second conductive pieces 3215 are respectively connected to the battery pack 2 via copper busbars 317. A top cover 3216 is detachably connected to the top of the first electrical housing 3211 and covers the two second conductive pieces 3215.

[0153] The top cover 3216 not only facilitates disassembly, assembly, and maintenance, but also provides a certain degree of positional constraint on the second conductive piece 3215. This design ensures high power connection reliability and allows for more flexible component replacement.

[0154] Optionally, such as Figure 20 and Figure 21 As shown, the current sensor 3213 has a first connector 32131 on the rear side, and the top cover 3216 has a first through hole 3216a facing the first connector 32131.

[0155] like Figure 7 and Figure 8As shown, the electrical connection structure 31 includes: a first flexible wire 3111 located on the rear side of the first BDU module 321, the end of the first flexible wire 3111 is provided with a first plug connector 3112, and the first plug connector 3112 is plugged into the first plug interface 32131 through a first through hole 3216a.

[0156] This allows for easy disassembly and assembly, as the first connector 3112 can be directly disconnected from the side inspection port 101. The first flexible wire 3111 can then be disconnected, allowing for inspection or disassembly of the internal structure of the first BDU module 321. Once assembled, the first connector 3112 can be directly inserted from the rear, making assembly very convenient and reducing interference from tangled wires.

[0157] Optionally, such as Figure 20 and Figure 21 As shown, the top surface of the top cover 3216 is provided with a limiting groove 3216b extending forward and backward. The front end of the limiting groove 3216b is positioned directly opposite the first through hole 3216a, and a portion of the first flexible wire 3111 is located within the limiting groove 3216b. The limiting groove 3216b can constrain the first flexible wire 3111, reducing the swaying of the first flexible wire 3111 during vibration and reducing the probability of loosening due to swaying. Moreover, compared with other wires, the first flexible wire 3111 is thinner and lighter, which can improve the connection reliability and improve the safety of the battery pack 100.

[0158] Optionally, the top cover 3216 may also have a limiting protrusion 3216c on at least one side of the limiting groove 3216b, which can further constrain the first flexible conductor 3111 and improve its safety in use. Further, as... Figure 21 As shown, the top cover 3216 is provided with two limiting protrusions 3216c, and the two limiting protrusions 3216c form barbs at the ends to facilitate hooking the first flexible wire 3111.

[0159] Furthermore, such as Figure 21 As shown, the top cover 3216 has first latching portions 3216d at both ends, and the top cover 3216 can be latched to the first electrical housing 3211 through the first latching portions 3216d. By setting the connection structure of the first latching portions 3216d, the stability and convenience of the connection are improved.

[0160] In some embodiments, such as Figure 7 , Figure 8 and Figure 10As shown, the BMS main control board 322 has a second connector 3221 on its rear side, and the BMS slave control board 323 has a third connector 3231 on its rear side. The electrical connection structure 31 also includes a second flexible wire 3113 located on the rear side of the BMS main control board 322, and a second connector 3114 at the end of the second flexible wire 3113, which fits into the second connector 3221.

[0161] The electrical connection structure 31 also includes a third flexible wire 3115 located on the rear side of the BMS slave control board 323, the end of the third flexible wire 3115 is provided with a third plug connector 3116, and the third plug connector 3116 is fitted into the third plug interface 3231.

[0162] This configuration allows for direct disconnection of the second connector 3114 and the third connector 3116 from the side inspection port 101 during assembly and disassembly. Disconnecting the second flexible wire 3113 allows for inspection or disassembly of the BMS main control board 322. Disconnecting the third flexible wire 3115 allows for inspection or disassembly of the BMS slave control board 323.

[0163] Once assembled, the second connector 3114 and the third connector 3116 can be directly inserted from the rear, making assembly very convenient and reducing interference from tangled wires.

[0164] like Figure 6 and Figure 8 As shown, in some embodiments, the electrical connection structure 31 includes a first wiring harness 311, which surrounds the electrical connection structure 31 and is electrically connected to the battery pack 2. The first wiring harness 311 has connectors that are respectively inserted into the BMS main control board 322, the BMS slave control board 323, and the first BDU module 321. The connectors are located on the side of the electrical control structure 31 facing the side access port 101. The fact that the first wiring harness 311 surrounds the electrical control structure 31 allows for changing the insertion direction of the connectors on the first wiring harness 311, directing the connectors towards the side access port 101. This makes it easier to open the first wiring harness 311 through the side access port 101, further improving the convenience of maintenance.

[0165] Specifically, the first flexible conductor 3111, the second flexible conductor 3113, and the third flexible conductor 3115 are all led out from the first wire harness 311.

[0166] Specifically, the first wire harness 311 is provided with a plurality of wire harness clips spaced apart along the extension direction of the first wire harness 311, and the wire harness clips are oriented towards the side inspection port 101 for installation and removal. The plurality of wire harness clips can fix the first wire harness 311, reduce the swing of the first wire harness 311 and reduce the probability of the plug-in connectors on the first wire harness 311 being loose.

[0167] In some embodiments, such as Figure 1 and Figure 3 As shown, the battery pack 100 also includes a side access cover 64, which can cover the side access port 101 and is detachably connected to the rear side wall 12. The side access cover 64 can protect the internal structure of the battery pack 100 and prevent dust, moisture, etc. from entering the battery pack 100 through the side access port 101.

[0168] Specifically, such as Figure 15 As shown, the rear sidewall 12 has a plurality of first fixing holes 111, which are arranged at intervals along the circumference of the side access port 101. The side access cover 64 can cover the side access port 101, and the side access cover 64 includes a plurality of through holes corresponding to the positions of the first fixing holes 111. The first fixing holes 111 and the through holes are connected by fasteners to improve the stability of the connection.

[0169] Alternatively, the side access cover 64 is connected to the rear side wall 12. One side of the side access cover 64 can be flipped relative to the rear side wall 12, and the other sides of the side access cover 64 are provided with through holes corresponding to the fixing holes of the rear side wall 12, and are connected by fasteners.

[0170] Specifically, the side access port 101 has a dimension of 720mm in the second direction D2 and a height of 70mm. The height of the electronic control structure 32 is smaller than that of the side access port 101, so that the BMS main control board 322, the BMS slave control board 323 and the first BDU module 321 in the electronic control structure 32 can be passed through the side access port 101 respectively.

[0171] Specifically, when it is necessary to replace one of the BMS main control board 322, BMS slave control board 323 and the first BDU module 321, the fasteners in the first fixing hole 111 are released, the side inspection cover 64 is removed, and the wire harness buckles 91 can be disassembled one by one through the first fixing hole 111. The plug connector is removed and the faulty electrical component is allowed to pass through the side inspection port 101.

[0172] In some embodiments, such as Figure 7 and Figure 8 As shown, the electrical connection structure 31 includes a second wiring harness 312, a third wiring harness 313, and a fourth wiring harness 314. The second wiring harness 312 is arranged along the length direction of the second electrical part 33, and the second wiring harness 312 is detachably connected to at least one end of the second electrical part 33, thereby electrically connecting the electrical connection structure 31 to the second electrical part 33.

[0173] The third wiring harness 313 is connected between the first wiring harness 311 and the second wiring harness 312, thereby enabling communication between the electronic control structure 31 and the second electrical component 33. The fourth wiring harness 314 is connected to the third wiring harness 313, and the end of the fourth wiring harness 314 is provided with a low-voltage terminal 316. Through the low-voltage terminal 316 of the fourth wiring harness 314, the battery pack 100 can transmit signals with external devices.

[0174] In some embodiments, such as Figure 13 and Figure 6 As shown, the battery pack 100 also includes a partition component 5 disposed within the housing 1. The partition component 5 includes at least three crossbeams 51, which extend in the left-right direction and are spaced apart in the front-back direction.

[0175] Battery pack 2 is located between the foremost crossbeam 51 and the last crossbeam 51. The foremost crossbeam 51 and the front sidewall 11 define a front cavity 54, and the second electrical component 33 is located within the front cavity 54. The last crossbeam 51 and the rear sidewall 12 define a rear cavity 55, and the electronic control structure 32 is located within the rear cavity 55.

[0176] The arrangement of at least three crossbeams 51 divides the interior of the battery pack 100 housing 1 into zones, which not only improves the structural strength of the battery pack 100 but also provides mounting positions for internal structures. Furthermore, the arrangement of at least three crossbeams 51 can also restrict the direction of internal fluid discharge.

[0177] Specifically, the partition assembly 5 further includes at least two longitudinal beams 52, which extend in the front-rear direction, and a longitudinal beam 52 is connected between each two adjacent crossbeams 51. A receiving compartment 56 is defined between the two adjacent crossbeams 51, the longitudinal beam 52, and the side wall of the housing 1. The battery pack 2 includes a plurality of battery groups 20, and each receiving compartment 56 contains one battery group 20.

[0178] exist Figure 3 and Figure 4 In the battery pack 2, there are four battery groups 20, each of which is located in a receiving compartment 56.

[0179] In some specific embodiments, such as Figure 14 and Figure 6 As shown, each crossbeam 51 includes a lower crossbeam 511 and an upper crossbeam 512. The lower crossbeam 511 extends in the left-right direction, and its two ends are connected to the left side wall 13 and the right side wall 14 of the housing 1, respectively. The upper crossbeam 512 extends in the left-right direction and is fixedly connected above the lower crossbeam 511. At least two spaced-apart upper crossbeams 512 are connected to each lower crossbeam 511.

[0180] On the same crossbeam 51, a first notch 5131 is defined between the upper crossbeam 512 on the left and the left side wall 13 of the shell 1, a second notch 5132 is defined between the upper crossbeam 512 on the right and the right side wall 14 of the shell 1, a third notch 5133 is defined between two adjacent upper crossbeams 512, and a third notch 5133 is provided above the junction of two adjacent longitudinal beams 52.

[0181] This crossbeam and longitudinal beam overlap design facilitates installation and provides support for the third wiring harness 313 when it passes through the battery pack 2. It not only improves the orderliness of the wiring but also eliminates the need for the third wiring harness 313 to be inserted into the receiving cavity 56, reducing the likelihood of the pressure relief component 202 spraying internal electrolyte towards the third wiring harness 313, thereby reducing the risk of short circuits or open circuits in the third wiring harness 313.

[0182] Specifically, the third wiring harness 313 is fastened to the longitudinal beam 52 to reduce the shaking of the third wiring harness 313 during vibration and reduce the chance of loosening caused by shaking.

[0183] In some specific embodiments, such as Figure 6 and Figure 8 As shown, the first wiring harness 311 is located within the rear cavity 55 and surrounds the electronic control structure 32. The first wiring harness 311 is electrically connected to the battery pack 2 and is detachably electrically connected to the electronic control structure 32. The second wiring harness 312 is located within the front cavity 54 and is arranged along the left-right direction on the rear side of the second electrical part 33. The second wiring harness 312 is detachably electrically connected to the second electrical part 33. In this way, both the first wiring harness 311 and the second wiring harness 312 are constrained, reducing shaking and the risk of loosening of connections due to shaking.

[0184] Furthermore, such as Figure 6 As shown, the battery pack 100 also includes at least one seat mounting nut 53 for connecting an external seat. The seat mounting nut 53 is fixedly connected to at least one crossbeam 51, which has at least two seat mounting nuts 53 spaced apart in the left-right direction. Thus, when the battery pack 100 is applied to the vehicle 1000, the seats in the passenger compartment 220 can be fitted with seat mounting nuts 53 using fasteners. This eliminates the need for a separate seat mounting crossbeam in the passenger compartment 220, improving structural compactness and reducing the number of parts.

[0185] Optionally, such as Figure 6 and Figure 1As shown, the height of the crossbeam 51 is less than the height of the housing 1. The seat mounting nuts 53 are welded to the top of the crossbeam 51. The top plate 16 of the housing 1 is provided with seat fixing fasteners 66 directly opposite each seat mounting nut 53. In this way, the seat can be connected to both the seat fixing fasteners 66 and the seat mounting nuts 53 through the fasteners, thereby extending the vertical length of the mating parts. Moreover, when the seat is under stress, it will transmit the force to the entire battery pack 100, using the battery pack 100 as a whole to disperse the impact force.

[0186] In some specific embodiments, such as Figure 2 As shown, the battery cells 201 in the battery group 20 are arranged in a left-right direction, and each battery cell 201 has a pressure relief component 202 at its left and / or right ends. Figure 2 In the example, each battery cell 201 in each battery group 20 is provided with a pressure relief component 202 to improve its safety. The number of pressure relief components 202 on each battery cell 201 can be one or more, and there is no limit here.

[0187] Specifically, the battery cell 201 is sheet-shaped and extends along the second direction D2. Multiple battery cells 201 are stacked along the first direction D1 to form a battery group 20, which helps to increase the arrangement density of the battery group 20 and increase the energy density of the battery pack 100.

[0188] In this design, the battery pack 20 forms flow channels 561 between its left and right ends and the inner walls of the receiving cavity 56. This eliminates the need for additional channels, allowing the high-pressure gas discharged from the pressure relief component 202 to be released through the channels between the ends of the battery pack 20 and the inner walls of the receiving cavity 56, thus improving the utilization of internal space. These flow channels 561 can also function as buffer channels for the battery pack 20.

[0189] Optionally, the width x1 of the flow channel 561 can be 5-50mm, thereby effectively ensuring the flowability of the flow channel 561 without being too wide and occupying too much volume. Optionally, the width x1 of the flow channel 561 can be 35mm. Here, the width x1 of the flow channel 561 refers to its dimension in the second direction D2.

[0190] Optionally, such as Figure 5 As shown, an exhaust port 102 is provided on the rear side wall 12 of the housing 1, so that the high-pressure gas can be discharged from the exhaust port 102. Further optionally, as... Figure 5 As shown, a pressure balance valve 65 is installed at the exhaust port 102. When there is high-pressure airflow inside, the pressure balance valve 65 is opened to exhaust the air, and it remains sealed when the air pressure is normal.

[0191] In some embodiments, such as Figure 6As shown, the high-voltage terminal 315 and the low-voltage terminal 316 are mounted on the front side wall 11 of the housing 1 and are spaced apart from the second electrical part 33 in the left-right direction. An exhaust port 102 is provided on the rear side wall 12 of the housing 1. This arrangement ensures that the location of the battery pack 100 for external power communication and the side inspection port 101 are located on the front and rear sides of the battery pack 100, without interference. When installed on the vehicle 1000, the low failure rate of the power communication part, by placing it at the front and protecting it within the vehicle body 200, further reduces its failure rate.

[0192] The second electrical component 33 is located adjacent to and along the front sidewall 11. The high-voltage terminal 315 of the electrical module 3 can output high-voltage electricity to the outside of the battery pack 100 to provide electrical energy; the low-voltage terminal 316 of the electrical module 3 can output low-voltage electricity to the outside of the battery pack 100 to transmit signals. The electrical connection structure 31 connects the second electrical component 33, the low-voltage terminal 316, and the high-voltage terminal 315. Its installation position is close to the front sidewall 11, which can reduce the arrangement of the electrical connection structure 31 and reduce the application cost of electrical connections.

[0193] In some embodiments, such as Figure 3 As shown, the bottom plate of the housing 1 is a removable bottom cover 15, so that the second electrical part 33 can be disassembled and assembled when the bottom cover 15 is removed.

[0194] The second electrical component 33 can be installed or removed from the housing 1. The bottom plate of the housing 1 is a removable bottom cover 15, which allows the second electrical component 33 to be installed or removed when the bottom cover 15 is removed. When the second electrical component 33 needs to be repaired, the bottom cover 15 is removed from the battery pack 100, and then the second electrical component 33 is taken out.

[0195] Specifically, such as Figure 22 and Figure 23 As shown, the battery pack 100 also includes a liquid cooling plate 6, which is located below the battery pack 2 and the electrical module 3. A bottom protective plate 15 is detachably connected to the bottom of the liquid cooling plate 6. The liquid cooling plate 6 is provided with a bottom access port 61 corresponding to the second electrical part 33. The bottom protective plate 15 covers the bottom access port 61.

[0196] The liquid cooling plate 6 has a bottom access port 61, which is located at the bottom of the battery pack 100 and corresponds to the second electrical part 33. The bottom protective plate 15 can cover the bottom access port 61. The liquid cooling plate 6 can be used to cool the battery pack 2 and keep it within a safe temperature range.

[0197] A bottom access port 61 is provided on the liquid cooling plate 6, which does not affect the disassembly of the second electrical part 33. Moreover, the liquid cooling plate 6 can be connected to the bottom of the frame 10 on all four edges, further improving the overall structural strength.

[0198] When applied to vehicle 1000, the underbody protection plate 15 serves as the base of electric vehicle 1000, bearing the weight of the vehicle 1000's interior; on the other hand, the underbody protection plate 15 protects the internal structure of battery pack 100, reducing damage.

[0199] Specifically, such as Figure 6 As shown, the liquid cooling plate 6 has a liquid flow channel for the flow of cooling liquid. The liquid cooling plate 6 has liquid cooling pipes 601 for liquid to flow in or out, and each liquid cooling pipe 601 has a liquid cooling connector 602 at its end for connection to an external water tank. The liquid cooling connector 602 can be mounted on the frame 10, for example, on the front side wall 11.

[0200] Furthermore, such as Figure 22 As shown, a sealing ring 62 needs to be installed around the bottom access port 61 to improve the sealing performance of the bottom access port 61 during use.

[0201] The location of the bottom access port 61 is quite flexible, for example, in... Figure 22 In the middle, the liquid cooling plate 6 is provided with a sealing ring 62 surrounding the bottom inspection port 61. For example... Figure 29 In the middle, the bottom guard plate 15 is provided with a sealing ring 62 surrounding the bottom inspection port 61.

[0202] In other embodiments, such as Figure 22 As shown, the battery pack 100 also includes a bottom access cover 63 covering the bottom access port 61. The bottom access cover 63 is detachably connected to the liquid cooling plate 6 and is located above the bottom protective plate 15. The bottom access cover 63 can protect the internal structure of the battery pack 100 and prevent dust, moisture, etc. from entering the battery pack 100 through the bottom access port 61.

[0203] Optionally, the bottom access cover 63 is provided with a sealing ring 62 surrounding the bottom access port 61 to further improve the sealing protection of the bottom access port 61.

[0204] Furthermore, such as Figure 29 As shown, the battery pack 100 includes fastening bolts 611 connecting the bottom protective plate 15 and the liquid cooling plate 6, with multiple fastening bolts 611 distributed around the bottom access port 61. The fastening bolts 611 secure the bottom protective plate 15 and the liquid cooling plate 6 at the bottom access port 61, improving the connection reliability and sealing at the bottom access port 61.

[0205] In some alternative embodiments, such as Figure 29As shown, the upper surface of the bottom protective plate 15 is provided with an upwardly protruding thickened layer 151, and the projection surface of the thickened layer 151 on the liquid cooling plate 6 completely covers the bottom access port 61. In this way, after the bottom protective plate 15 is connected and fixed to the upper frame 10, the thickened layer 151 is squeezed upward, thereby pressing the bottom access port 61 and improving the sealing performance.

[0206] In some alternative embodiments, as shown in 28, a buffer layer 18 may be provided on the upper surface of the bottom cover 15 to improve the buffer protection of the internal battery pack 2 and electrical module 3.

[0207] In some embodiments, such as Figure 13 and Figure 6 As shown, a fixing plate 67 is provided inside the housing 1, and the fixing plate 67 is located above the second electrical part 33. The second electrical part 33 is detachably connected to the fixing plate 67 by a fourth bolt 3294. The head of the fourth bolt 3294 is located at the lower end, that is, the installation direction of the fourth bolt 3294 is away from the fixing plate 67 and towards the bottom access port 61. The projection of the fourth bolt 3294 on the liquid cooling plate 6 is located inside the bottom access port 61, thereby allowing the fourth bolt 3294 to be removed or installed through the bottom access port 61, improving the convenience of removal or installation.

[0208] like Figures 23-24 As shown, in some embodiments, the second electrical portion 33 includes a second electrical housing 332 for accommodating electrical components. Specifically, the second electrical portion 33 further includes a first extension plate 3351 connected to at least one side of the second electrical housing 332, and the first extension plate 3351 has a mating groove that extends through the side away from the second electrical housing 332. The battery pack 100 also includes a shock-absorbing column 333, which is vertically arranged.

[0209] like Figure 26 As shown, the damping column 333 includes two thick column segments 3331 and a thin column segment 3332 located between the two thick column segments 3331. Figure 24 and Figure 25 As shown, the thin column segment 3332 fits into the mating groove, and the two thick column segments 3331 are sandwiched between the upper and lower sides of the first outer extension plate 3351. The damping column 333 has a central hole 3333, and the fourth bolt 3294 passes through the central hole 3333 and connects to the fixing plate 67. By setting the damping column 333, on the one hand, the fixing plate 67 can be connected, improving the reliability of the connection; on the other hand, it absorbs the vibration of the second electrical part 33 to protect the electrical components housed inside the second electrical housing 332.

[0210] For easy disassembly, the electrical connection structure 31 is electrically connected to the second electrical part 33 via a flexible wire harness. For example, the connector of the second electrical part 33 for communication is a first signal transmission interface 339, and the second wire harness 312 of the electrical connection structure 31 is connected to a second signal transmission interface 3121, and the two are plugged into each other.

[0211] like Figure 23 As shown, the first signal transmission interface 339 is located at the bottom of the second electrical housing 332, so the interface status can be easily observed when the bottom access port 61 is opened. Specifically, the second signal transmission interface 3121 is plugged into the first signal transmission interface 339 from the side. This facilitates manual plugging and unplugging of the second signal transmission interface 3121 while reducing shaking by utilizing the weight of the wires supported by the interface.

[0212] Specifically, the first signal transmission interface 339 is connected to the interior of the second electrical housing 332 via multiple fourth flexible wires 331, thereby allowing the second electrical part 33 to be connected to the electrical control structure 32 via the first transmission interface 319.

[0213] In some specific embodiments, such as Figure 25 As shown, the second electrical housing 332 of the second electrical component 33 is detachably connected to the housing 1. The second electrical component 33 includes a main relay 337, a current-connecting strip 338, and a first transmission interface 319. The main relay 337 is located inside the housing 1, one end of the current-connecting strip 338 is connected to the main relay 337, and the other end of the current-connecting strip 338 is located outside the second electrical housing 332. The current-connecting strip 338 is used to connect high-voltage electricity, and the main relay 337 can control the high-voltage electricity.

[0214] Specifically, the electrical connection structure 32 includes a copper busbar 317 and a second transmission interface 37. One end of the copper busbar 317 is connected to the other end of the electrical connector 338 via a fifth bolt 3295. The second signal transmission interface 3121 is plugged into the first signal transmission interface 339, thereby realizing the electrical connection between the second electrical part 33 and the electrical connection structure 32.

[0215] For example, the copper busbar 317 is elongated and has a certain degree of flexibility, allowing it to be bent. The connection between the copper busbar 317 and the connecting strip 338 has an insulating cover, which is attached to the second electrical housing 332. When it is necessary to remove the second electrical component 33, first disconnect the power to the second electrical component 33, remove the insulating cover, release the fixing structure between the copper busbar 317 and the connecting strip 338, and then the fifth bolt 3295 can be loosened. By unplugging the second transmission interface 37, the fourth bolt 3294 is exposed and can be loosened.

[0216] like Figure 27As shown, in some embodiments, the second electrical part 33 further includes a second extension plate 3352 connected to the second electrical housing 332. The second extension plate 3352 has mating hooks 33521 on both sides. There are two first signal transmission interfaces 339, which are located on opposite sides of the second extension plate 3352. Each first signal transmission interface 339 has a mating groove that mates with the mating hooks 33521. The first signal transmission interface 339 can be fixed on the second electrical housing 332 by means of a snap-fit ​​connection, which can reduce the connection cost and improve the reliability of the connection.

[0217] like Figure 25 As shown, in some embodiments, two main relays 337 are spaced apart. The bottom of the second electrical housing 332 forms a downwardly protruding portion 336, which covers the bottom of the two main relays 337 respectively. The bottom of the second electrical housing 332 is provided with a second through hole 3361 near the two downward protrusions 336. Part of the fourth flexible wire 331 extends into the second electrical housing 332 through the second through hole 3361, and part extends into the second electrical housing 332 through another second through hole 3361. In this way, the second electrical housing 332 can be used to define the placement position of the fourth flexible wire 331, reduce the probability of interference with other parts, and reduce the adverse effects on signal generation.

[0218] Optionally, such as Figure 25 and Figure 27 Therefore, at least one side of the lower protrusion 336 is provided with a wire fastener 3362 for limiting the movement of the fourth flexible conductor 331. This restricts the movement of the wire fastener 3362 and reduces its swaying.

[0219] In some embodiments, the frame 10 is formed by connecting multiple frame side beams 103 sequentially along the length direction to form an annular frame, referred to as frame 10. Specifically, the front side wall 11 is composed of at least one frame side beam 103, the rear side wall 12 is composed of at least one frame side beam 103, the left side wall 13 is composed of at least one frame side beam 103, and the right side wall 14 is composed of at least one frame side beam 103.

[0220] Each frame edge beam 103 includes at least two frame sections 1031 distributed along the height direction, with each frame section 1031 forming a closed edge beam cavity. Each frame edge beam 103 may include two frame sections 1031, which are stacked sequentially along the height direction. In some embodiments, adjacent frame sections 1031 are connected by connecting ribs.

[0221] Each frame edge beam 103 is formed by integral roll forming of steel plate, or by integral extrusion of aluminum profile. This ensures that all frame sections 1031 of each frame edge beam 103, or all frame sections 1031 and all connecting ribs, are continuous. Furthermore, each side of each frame section 1031 is roll-formed or extruded, not formed by stretching ordinary profiles. This reduces welding between the sides of the same frame section 1031 and between adjacent frame sections 1031, thus reducing processing steps. Additionally, adjacent frame sections 1031 are not only stacked but also connected by interlocking edges, resulting in stronger overall integrity and significantly improved overall structural strength.

[0222] Furthermore, the mounting beam 17 is formed by integral roll forming of steel plate, or the mounting beam 17 is an integrally formed extruded aluminum profile.

[0223] The vehicle 1000 according to an embodiment of the present invention, such as Figure 31 As shown, it includes: a vehicle body 200 and a battery pack 100 as described in the above embodiment. The structure of the battery pack 100 will not be described in detail here. Figure 32 As shown, a passenger space 220 is formed inside the vehicle body 200, and the battery pack 100 is installed at the bottom of the vehicle body 200.

[0224] By adopting the aforementioned battery pack 100, the internal structure of the vehicle 1000 can be protected, the integrated design of the battery pack 100 and the vehicle 1000 can be improved, the number of parts can be reduced, and the cost and weight can be lowered.

[0225] Specifically, a mounting opening 230 is formed at the bottom of the vehicle body 200, and the battery pack 100 is located within the mounting opening 230. An upwardly recessed cavity 240 is also formed at the bottom of the vehicle body 200, with the rear end of the battery pack 100 positioned directly opposite the upwardly recessed cavity 240. This allows for maintenance of the electronic control structure 32 within the side inspection port 101 via the lower upwardly recessed cavity 240, without requiring disassembly of the entire vehicle, thus minimizing damage to the vehicle.

[0226] Other configurations and operations of the vehicle 1000 according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here.

[0227] In the description of this specification, references to terms such as "embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0228] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A battery pack, characterized in that, include: A housing, wherein a side inspection port is provided on the housing; An electrical control structure is disposed within the housing and facing the side access port. The electrical control structure includes a first BDU module, which includes a first electrical housing, a fuse, and a current sensor. The first electrical housing has a first opening facing the side access port. The fuse and the current sensor are detachably disposed within the first electrical housing, and the current sensor is connected in series with the fuse. The first electrical housing has a first positioning cavity and a second positioning cavity that open toward the side inspection port. The fuse is located in the first positioning cavity and the current sensor is located in the second positioning cavity. A first positioning boss is formed on at least one side of the first positioning cavity within the first electrical housing, and the end of the fuse is detachably connected to the first positioning boss; A second positioning boss is formed on at least one side of the second positioning cavity within the first electrical housing, and the end of the current sensor is detachably connected to the second positioning boss; Both the first positioning boss and the second positioning boss have threaded holes on their surfaces facing the side inspection port. The fuse is bolted to the first positioning boss, and the current sensor is bolted to the second positioning boss.

2. The battery pack according to claim 1, characterized in that, The first positioning boss and the second positioning boss are staggered in height and are at different distances from the side inspection port.

3. The battery pack according to claim 2, characterized in that, The first BDU module further includes: a first conductive sheet, which is located in the first positioning cavity and on the side of the fuse away from the side access port; A portion of the side edge of the first conductive sheet is bent and connected to a first positioning boss after extending laterally, so as to be electrically connected to the fuse; The upper edge of a portion of the first conductive sheet extends upward and is then bent and connected to a second positioning boss for electrical connection with the current sensor.

4. The battery pack according to claim 1, characterized in that, The first electrical housing has a second opening at the top. The first BDU module also includes a top cover and two second conductive plates. The two second conductive plates are arranged at a distance from each other on the top of the first electrical housing, and each second conductive plate extends in the front-back direction.

5. The battery pack according to claim 4, characterized in that, One of the second conductive sheets has its rear end bent downwards and rests on the first positioning boss and is electrically connected to the fuse; the other second conductive sheet has its rear end bent downwards and rests on the second positioning boss and is electrically connected to the current sensor; the front ends of the two second conductive sheets are respectively connected to the battery pack via copper busbars. The top cover is detachably attached to the top of the first electrical housing and covers the two second conductive plates.

6. The battery pack according to claim 4, characterized in that, The current sensor has a first connector on the rear side, and the top cover has a first through hole facing the first connector.

7. The battery pack according to claim 6, characterized in that, The top surface of the top cover is provided with a limiting groove that extends forward and backward, and the front end of the limiting groove is positioned directly opposite the first through hole. The top cover is further provided with a limiting protrusion on at least one side of the limiting groove.

8. The battery pack according to any one of claims 1-7, characterized in that, The electronic control structure also includes a BMS master control board and a BMS slave control board, which are located on both sides of the first BDU module and are both positioned directly opposite the side inspection port.

9. A vehicle, characterized in that, It also includes the battery pack according to any one of claims 1-8.

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