Battery pack upper cover assembly, battery pack and vehicle

Abstract

The battery pack upper cover assembly, the battery pack and the vehicle are provided by the present disclosure, the battery pack upper cover assembly comprises an upper cover plate, a plurality of first mounting holes are arranged at the edge of the upper cover plate in a circumferential direction, and the edge of the upper cover plate is connected with a battery pack box body through first connecting pieces which are correspondingly arranged in the first mounting holes; a plurality of second mounting holes are arranged on the upper cover plate, and the second mounting holes are located in an area surrounded by the first mounting holes, and first support sleeves are embedded in the second mounting holes; and the upper cover plate is connected with the battery pack box body through second connecting pieces which are correspondingly arranged in the first support sleeves. Double fixation can be formed between the upper cover plate and the box body, the fixation reliability between the body of the upper cover plate, the edge of the upper cover plate and the box body is effectively ensured, the first support sleeves are embedded in the second mounting holes, the second mounting holes can be supported, and deformation of the upper cover plate during use is prevented, thereby affecting the structural strength of the battery pack.

Description

Technical Field

[0001] This disclosure relates to the field of vehicle technology, and more particularly to a battery pack cover assembly, a battery pack, and a vehicle. Background Technology

[0002] Currently, the new energy vehicle industry is developing rapidly, and electric or hybrid vehicles are equipped with battery systems. These battery systems include battery packs, which typically provide power to the vehicle through the cells within the pack. Limited by the energy density of the cells and the installation space within the vehicle, the demand for longer driving ranges places increasingly higher demands on the design of the battery pack cover. The cover must possess strong sealing performance while maintaining structural strength. Current technology typically uses screws to fix the entire edge of the cover to the battery pack housing. However, when the battery pack cover is large, simply fixing the edge to the housing cannot guarantee reliable fixation between the large cover and the battery housing. Furthermore, large covers are prone to deformation during use, affecting the structural strength of the battery pack. Summary of the Invention

[0003] To address the aforementioned technical problems, this disclosure provides a battery pack cover assembly, a battery pack, and a vehicle.

[0004] The first aspect of this disclosure provides a battery pack cover assembly, including a cover plate, wherein a plurality of first mounting holes are provided circumferentially at intervals along the edge of the cover plate, and the edge of the cover plate is connected to the battery pack housing through first connectors that are correspondingly inserted into the plurality of first mounting holes.

[0005] The upper cover plate is provided with a plurality of second mounting holes, which are located in the area enclosed by a plurality of first mounting holes. A first support sleeve is embedded in the second mounting hole. The upper cover plate is connected to the battery pack housing through a pair of second connectors that are inserted into the plurality of first support sleeves.

[0006] Optionally, the first support sleeve includes a support base and a support boss disposed on the support base. The support boss protrudes from one side surface of the support base and is embedded in the second mounting hole. The side surface of the support base facing the support boss abuts against one side surface of the upper cover plate. The first support sleeve has a mounting through hole that passes through the support base and the support boss for the second connector to pass through.

[0007] Optionally, an annular protrusion is provided circumferentially at the outer periphery of the support boss, and a sealing ring is fitted on the annular protrusion. One side surface of the sealing ring abuts against the surface of the support base facing the upper cover plate, and the other side surface of the sealing ring abuts against the plate surface of the upper cover plate facing the support base.

[0008] Optionally, a flange surface is formed at the edge of the upper cover plate to contact and mate with the battery pack housing, and a plurality of first mounting holes are spaced apart on the flange surface.

[0009] Optionally, a second support sleeve is embedded in the first mounting hole, the height of the second support sleeve is greater than or equal to the thickness of the upper cover plate where the first mounting part is located, and the first connector passes through the second support sleeve.

[0010] Optionally, the second support sleeve is an annular sleeve with an outer diameter greater than or equal to the inner diameter of the first mounting hole. An opening is formed on the wall of the annular sleeve, and the opening penetrates the wall of the annular sleeve along the height direction. The walls of the annular sleeve on both sides of the opening deform towards each other under the action of external force, so that the annular sleeve is embedded in the first mounting hole.

[0011] Optionally, the upper cover plate is made of PCM material;

[0012] And / or, a centrally raised protrusion is formed on the upper cover plate, and a plurality of protrusions are formed on the surface of the upper cover plate, a drainage channel is formed between the plurality of protrusions, and the outlet of the drainage channel is disposed toward the edge of the upper cover plate.

[0013] Optionally, it also includes a first mica plate, an aerogel insulation sheet, and a second mica plate. The first mica plate, the aerogel insulation sheet, and the second mica plate are sequentially disposed on one side of the upper cover plate, and the first mica plate, the aerogel insulation sheet, and the second mica plate are respectively provided with clearance holes corresponding to the second mounting holes.

[0014] A second aspect of this disclosure provides a battery pack including a battery pack housing and a battery pack cover assembly as described above, the battery pack cover assembly being mounted on the battery pack housing.

[0015] A third aspect of this disclosure provides a vehicle including the battery pack described above.

[0016] The battery pack cover assembly disclosed herein includes a top cover plate. Multiple first mounting holes are spaced circumferentially along the edge of the top cover plate. The edge of the top cover plate is connected to the battery pack housing via first connectors that pass through the multiple first mounting holes. Multiple second mounting holes are also distributed on the top cover plate, located within the area enclosed by the multiple first mounting holes. First support sleeves are embedded in the second mounting holes. The top cover plate is connected to the battery pack housing via second connectors that pass through the multiple first support sleeves. This arrangement provides a double fixation between the top cover plate and the housing, effectively ensuring the reliability of the fixation between the top cover plate body, the edge of the top cover plate, and the housing. Furthermore, the first support sleeves embedded in the second mounting holes ensure the strong connection between the middle of the top cover plate and the housing, provide support for the top cover plate at the second mounting holes, and enhance the structural strength of the top cover plate at the second mounting holes, thereby preventing deformation of the top cover plate during use and affecting the structural strength of the battery pack. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0018] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0019] Figure 1 This is an exploded view of the battery pack cover assembly in one embodiment of the present disclosure;

[0020] Figure 2 This is a partial cross-sectional view of a battery pack cover assembly in one embodiment of the present disclosure;

[0021] Figure 3 This is a schematic diagram of the structure of the second support sleeve in one embodiment of this disclosure;

[0022] Figure 4 This is a cross-sectional view of the upper cover plate and the second support sleeve in one embodiment of the present disclosure;

[0023] Figure 5 This is a schematic diagram of the structure of the first support sleeve in one embodiment of this disclosure;

[0024] Figure 6 This is an exploded view of the first support sleeve and sealing ring in one embodiment of this disclosure;

[0025] Figure 7This is a cross-sectional view of the upper cover plate and the first support sleeve in one embodiment of this disclosure.

[0026] Figure label:

[0027] 1. Top cover plate; 11. First mounting hole; 12. Second mounting hole; 13. Flange face; 14. Protrusion; 15. Raised portion; 2. First support sleeve; 20. Mounting through hole; 21. Support base; 22. Support boss; 23. Annular raised portion; 3. Sealing ring; 4. Second support sleeve; 40. Opening; 5. First mica plate; 6. Aerogel insulation sheet; 7. Second mica plate. Detailed Implementation

[0028] To better understand the above-mentioned objectives, features, and advantages of this disclosure, the solutions disclosed herein will be further described below. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0029] Numerous specific details are set forth in the following description in order to provide a full understanding of this disclosure, but this disclosure may also be implemented in other ways different from those described herein; obviously, the embodiments in the specification are only some, and not all, of the embodiments of this disclosure.

[0030] Reference Figures 1 to 7 As shown, some embodiments of this disclosure provide a battery pack cover assembly, including a top cover plate 1. Multiple first mounting holes 11 are spaced circumferentially along the edge of the top cover plate 1. The shape of the top cover plate 1 is adapted to the shape of the battery pack housing. The edge of the top cover plate 1 is connected to the battery pack housing via first connectors that are correspondingly inserted into the multiple first mounting holes 11. Multiple second mounting holes 12 are distributed on the top cover plate 1. The multiple second mounting holes 12 are located within the area enclosed by the multiple first mounting holes 11. First support sleeves 2 are embedded in the second mounting holes 12. The top cover plate 1 is connected to the battery pack housing via second connectors that are correspondingly inserted into the multiple first support sleeves 2.

[0031] With the above-described configuration, in this embodiment, the edge of the upper cover plate 1 is connected to the battery pack housing through a first connector that passes through a plurality of first mounting holes 11. The upper cover plate 1 is connected to the battery pack housing through a second connector that passes through a plurality of first support sleeves 2. This allows the upper cover plate 1 and the housing to form a double fixation, effectively ensuring the reliability of the fixation between the body of the upper cover plate 1, the edge of the upper cover plate 1, and the housing. Furthermore, the first support sleeve 2 is embedded inside the second mounting hole 12, which not only ensures the firmness of the connection between the body of the upper cover plate and the housing, but also provides support for the upper cover plate 1 at the second mounting hole 12 and enhances the structural strength of the upper cover plate 1 at the second mounting hole 12, thereby preventing the upper cover plate 1 from deforming during use and affecting the structural strength of the battery pack.

[0032] In actual installation, the number and location of the second mounting holes 12 can be flexibly set according to the connection strength requirements between the upper cover plate 1 and the housing. For example, the number of second mounting holes 12 can be 2, 4, or more, as shown in the reference. Figure 1 As shown, in this embodiment, there are four second mounting holes 12. Two second mounting holes 12 are located in the middle of the upper cover plate 1, and the other two second mounting holes 12 are located near the edge of the upper cover plate 1. This allows the first mounting holes 11 and the second mounting holes 12 to be distributed evenly across the entire upper cover plate 1, ensuring that the upper cover plate 1 is subjected to uniform force and preventing the connection points on the upper cover plate 1 from being too concentrated, thereby reducing the load-bearing capacity of the upper cover plate 1.

[0033] Reference Figures 5 to 7 As shown, in this embodiment, the first support sleeve 2 includes a support base 21 and a support boss 22 disposed on the support base 21. The support boss 22 protrudes from one side surface of the support base 21 and is embedded in the second mounting hole 12. In actual application, the outer diameter of the support boss 22 is greater than or equal to the inner diameter of the second mounting hole 12, thereby providing a certain support for the second mounting hole 12 and preventing the upper cover plate 1 from being easily deformed due to insufficient strength near the connection position. The side surface of the support base 21 facing the support boss 22 abuts against one side surface of the upper cover plate 1, and the first support sleeve 2 has a mounting through hole 20 that passes through the support base 21 and the support boss 22 for the second connector to pass through. In actual application, the second connector can be a screw, bolt, or pin. The above connection method can be flexibly selected according to actual connection requirements. It should be noted that if the second connector is a screw or bolt, the inner wall of the mounting through hole 20 is provided with an internal thread for connection with the screw or bolt.

[0034] Furthermore, referring to Figure 6An annular protrusion 23 is provided circumferentially at the outer periphery of the supporting boss 22. A sealing ring 3 is fitted onto the annular protrusion 23. The sealing ring 3 can be made of sealing foam, foamed silicone, UV elastic adhesive, or other materials. (Refer to...) Figure 7 As shown, in the assembled state, the support boss 22 is embedded inside the second mounting hole 12, the outer wall of the support boss 22 is in close contact with the inner wall of the second mounting hole 12, the side surface of the support base 21 facing the support boss 22 abuts against the side surface of the upper cover plate 1, one side surface of the sealing ring 3 abuts against the surface of the support base 21 facing the upper cover plate 1, and the other side surface of the sealing ring 3 abuts against the surface of the upper cover plate 1 facing the support base 21. Through the cooperation of the first support member 2, the sealing ring 3 and the upper cover plate 1, the fixed reliability between the upper cover plate 1 and the box is ensured, the deformation of the upper cover plate 1 is prevented, and the sealing effect of the upper cover plate 1 is effectively improved.

[0035] Specifically, refer to Figure 1 As shown, a flange surface 13 is formed at the edge of the upper cover plate 1 to contact and mate with the battery pack housing. The upper cover plate 1 and the flange surface 13 are integrally manufactured, for example, using prepreg molding technology. This processing method is simple, has low requirements for molds, causes little damage to the molds during production, can improve the service life of the molds, and reduce production costs. Multiple first mounting holes 11 are spaced apart on the flange surface 13. The flange surface 13 is formed by the edge of the upper cover plate 1 sinking downwards along the height direction. When water accidentally enters the battery pack, the water on the upper cover plate 1 can be quickly discharged along the flange surface 13, preventing water from accumulating on the top of the battery pack system for a long time and causing a short circuit. During assembly, a sealing strip can be installed between the flange face 13 and the housing. The sealing strip is a ring-shaped structure adapted to the flange face 13. Specifically, it can be made of elastic materials such as single-layer rubber strips or sealing foam. During installation, the flange face 13 of the upper cover plate 1 is placed on the housing, and the upper cover plate 1 is fastened to the housing using the first connector. The sealing strip is then fitted to the flange face 13 to achieve a sealed connection between the upper cover plate 1 and the housing. The sealing strip effectively seals the outer periphery of the housing and the upper cover plate 1, thereby ensuring that the battery pack housing can achieve a sealing rating of IP67 or higher, ensuring the safety of the battery pack.

[0036] In this embodiment, a second support sleeve 4 is embedded in the first mounting hole 11. The height of the second support sleeve 4 is greater than or equal to the thickness of the portion of the upper cover plate 1 where the first mounting hole 11 is located. The first connector passes through the second support sleeve 4 to ensure the sealing performance between the edge of the upper cover plate 1 and the housing. In actual implementation, the second support sleeve 4 can adopt the same or different structure as the first support sleeve 2. Specifically, refer to... Figure 3 and Figure 4As shown, the second support sleeve 4 is an annular sleeve. The outer diameter of the annular sleeve is greater than or equal to the inner diameter of the first mounting hole 11. Placing the annular sleeve inside the first mounting hole 11 provides a certain degree of support for the first mounting hole 11, improving the structural strength of the upper cover plate 1 and preventing the upper cover plate 1 from being too weak near the first mounting hole 11, which could easily lead to cracks or deformation under large connecting forces. An opening 40 is formed on the cylindrical wall of the annular sleeve, penetrating the cylindrical wall of the annular sleeve along its height direction. The cylindrical walls on both sides of the opening 40 deform towards each other under external force, causing the annular sleeve to be embedded in the first mounting hole 11. Specifically, the annular sleeve can be made of rubber or UV elastic rubber, etc. During the installation of the annular sleeve, it is pressed towards the opening 40 to reduce its outer diameter, thus placing the annular sleeve inside the first mounting hole 11. This creates an interference fit between the annular sleeve and the first mounting hole 11. The outer wall of the annular sleeve abuts against the inner wall of the first mounting hole 11 to withstand the tightening force when fastening the upper cover plate 1, preventing the upper cover plate 1 from being crushed or worn by the first connecting member. In practical applications, the first connecting member can be a screw, bolt, or pin. The above connection method can be flexibly selected according to actual connection requirements. It should be noted that if the first connecting member is a screw or bolt, the inner wall of the annular sleeve is provided with internal threads for connection with the screw or bolt.

[0037] In practical applications, the top cover 1 can be made of metal or carbon fiber, etc. In this embodiment, the top cover 1 is made of PCM material through molding. Specifically, PCM material is a mixture of polycarbonate and plexiglass. This eliminates the need for the existing top cover that combines SMC and mica panels. Specifically, SMC is a composite material, a type of fiberglass, mainly composed of GF (special yarn), MD (filler), and various additives. This improves the existing top cover's weak resistance to flame impact during thermal runaway, which can easily lead to mica panel cracking and SMC top cover burn-through deformation. PCM material has strong electrical thermal protection performance, enabling protection during battery pack thermal runaway. Furthermore, this material has low density, flame retardancy, and good insulation and pressure resistance. (Refer to...) Figure 1As shown, a raised portion 14 is formed on the upper cover plate 1 to prevent a large amount of water from accumulating on the surface of the upper cover plate 1 after water enters the battery pack, thus affecting the normal operation of the battery pack. The raised portion 14 can be formed by the upper cover plate 1 itself rising upwards, or it can be a raised portion 14 covering the upper surface of the upper cover plate 1. While waterproofing, it can also improve the structural protection capability of the upper cover plate 1. Furthermore, multiple raised portions 15 are formed on the surface of the upper cover plate 1, and drainage channels are formed between the multiple raised portions 15. The outlet of the drainage channel is set towards the edge of the upper cover plate 1, so that water can flow quickly along the raised portions 14 and 15 into the drainage channel, and then be quickly discharged through the flange face 13.

[0038] Reference Figure 1 and Figure 2 As shown, the battery pack cover assembly also includes a first mica plate 5, an aerogel heat insulation sheet 6, and a second mica plate 7. The first mica plate 5, the aerogel heat insulation sheet 6, and the second mica plate 7 are sequentially disposed on one side surface of the cover plate 1, and the first mica plate 5, the aerogel heat insulation sheet 6, and the second mica plate 7 are respectively provided with clearance holes corresponding to the second mounting hole 12. Specifically, the shapes of the first mica plate 5, the aerogel heat insulation sheet 6, and the second mica plate 7 are adapted to the shape of the cover plate 1. The upper surface of the aerogel heat insulation sheet 6 is bonded to the lower surface of the first mica plate 5 with adhesive, and the lower surface of the aerogel heat insulation sheet 6 is bonded to the upper surface of the second mica plate 7 with adhesive. The lower surface of the second mica plate 7 is a surface that directly resists thermal shock.

[0039] In one specific embodiment, during assembly, the upper surface of the second mica plate 7 is adhered and fixed to the lower surface of the aerogel insulation sheet 6 using adhesive, and the upper surface of the aerogel insulation sheet 6 is adhered and fixed to the lower surface of the first mica paper 5 using adhesive; the first support sleeve 2 is assembled with the support boss 22 through the mounting through hole 20 to realize the assembly of the first support sleeve 2 and the sealing ring 3, and after the assembly is completed, the middle part of the upper cover plate 1 is installed with the box body through the support base 21 and the first connector; the second support sleeve 4 is accommodated in the first mounting hole 11 to achieve an interference fit, and the edge of the upper cover plate 1 is installed with the box body through the second connector.

[0040] With the above settings, the assembled battery pack cover assembly has the following effects: 1) Since the cover plate 1 is made of PCM material and cooperates with the protrusion 14, it can have a high structural protection function; 2) The flange face 13, the first mounting hole 11 and the second support sleeve 4 ensure the sealing function between the cover plate 1 and the box; 3) The second mounting hole 12, the first support sleeve 2 and the sealing ring 3 together ensure the fixed reliability of the large-size cover plate 1 and reduce the deformation of the cover plate 1; 4) Furthermore, the combination of the first mica plate 5, the aerogel heat insulation sheet 6 and the second mica plate 7 realizes the thermal protection and thermal barrier of the entire battery pack, and the aerogel heat insulation sheet 6 has good flame impact resistance, which can effectively reduce or even block thermal shock, thereby ensuring the stability of the battery pack system during thermal runaway and reducing the loss during thermal runaway. Furthermore, by assembling the PCM material top cover 1, the first mica plate 5, the aerogel heat insulation sheet 6, and the second mica plate 7 to form the battery pack top cover assembly, the battery pack system effectively protects the metal parts inside the battery pack through composite materials with good electrical protection performance, ensuring the electrical and mechanical protection capabilities of the top cover 1.

[0041] This disclosure also provides a battery pack, including a battery pack housing and the aforementioned battery pack cover assembly. The battery pack cover assembly is mounted on the battery pack housing. The technical features of the battery pack cover assembly used in this battery pack can be found in the battery pack cover assembly in the above embodiments, which enables the battery pack to have strong electrical protection performance and flame impact resistance, which will not be described in detail here.

[0042] This disclosure also provides a vehicle including the above-described battery pack. The vehicle can use a power battery system. The battery pack cover assembly can be used for sealing, structural protection, electrical protection, etc. of the power battery system. It not only meets the requirements of strong thermal protection and thermal shock resistance of the battery pack cover assembly under thermal runaway in large sizes, but also takes into account the lightweight requirements, power performance and driving range requirements of the whole vehicle.

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the term "comprising" or any other variations thereof is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0044] The above are merely specific embodiments of this disclosure, enabling those skilled in the art to understand or implement this disclosure. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this disclosure. Therefore, this disclosure is not to be limited to these embodiments, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A battery pack cover assembly, characterized in that, Includes an upper cover plate, wherein a plurality of first mounting holes are provided circumferentially at intervals along the edge of the upper cover plate, and the edge of the upper cover plate is connected to the battery pack housing through first connectors that are correspondingly inserted into the plurality of first mounting holes. The upper cover plate is provided with a plurality of second mounting holes, which are located in the area enclosed by a plurality of first mounting holes. A first support sleeve is embedded in the second mounting hole. The upper cover plate is connected to the battery pack box through a pair of second connectors that are inserted into the plurality of first support sleeves. The first support sleeve includes a support base and a support boss disposed on the support base. The support boss protrudes from one side surface of the support base and is embedded in the second mounting hole. The side surface of the support base facing the support boss abuts against the upper side of one side plate of the upper cover plate. The first support sleeve has a mounting through hole that passes through the support base and the support boss for the second connector to pass through. It also includes a first mica plate, an aerogel insulation sheet, and a second mica plate. The first mica plate, the aerogel insulation sheet, and the second mica plate are arranged downwards in sequence on the lower side of one side of the upper cover plate, and the first mica plate, the aerogel insulation sheet, and the second mica plate are respectively provided with clearance holes corresponding to the second mounting holes.

2. The battery pack cover assembly according to claim 1, characterized in that, An annular protrusion is provided along the circumferential direction at the outer periphery of the support boss. A sealing ring is fitted on the annular protrusion. One side surface of the sealing ring abuts against the surface of the support base facing the upper cover plate, and the other side surface of the sealing ring abuts against the plate surface of the upper cover plate facing the support base.

3. The battery pack cover assembly according to claim 1, characterized in that, The edge of the upper cover plate has a flange surface that contacts and mates with the battery pack housing, and a plurality of first mounting holes are spaced apart on the flange surface.

4. The battery pack cover assembly according to claim 1, characterized in that, A second support sleeve is embedded in the first mounting hole. The height of the second support sleeve is greater than or equal to the thickness of the portion of the upper cover plate where the first mounting hole is located. The first connector passes through the second support sleeve.

5. The battery pack cover assembly according to claim 4, characterized in that, The second support sleeve is an annular sleeve with an opening formed on its cylindrical wall. The opening penetrates the cylindrical wall of the annular sleeve along its height direction. The cylindrical walls of the annular sleeve on both sides of the opening deform towards each other under the action of external force, so that the annular sleeve is embedded in the first mounting hole.

6. The battery pack cover assembly according to claim 1, characterized in that, The top cover is made of PCM material; And / or, a centrally raised protrusion is formed on the upper cover plate, and a plurality of protrusions are formed on the surface of the upper cover plate, a drainage channel is formed between the plurality of protrusions, and the outlet of the drainage channel is disposed toward the edge of the upper cover plate.

7. A battery pack, characterized in that, include: The battery pack housing and the battery pack cover assembly as described in any one of claims 1 to 6, wherein the battery pack cover assembly is mounted on the battery pack housing.

8. A vehicle, characterized in that, Includes the battery pack as described in claim 7.

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