Assembly method of power battery pack, vehicle and power battery pack

Abstract

This invention discloses a power battery pack, including a housing assembly and a module assembly. The housing assembly is a one-piece die-cast, hollow structure. The module assembly is located within the inner cavity of the housing assembly, and a bottom protective plate is provided at the bottom of the housing assembly. The power battery pack of this invention features a one-piece housing assembly, eliminating the need for a top cover and sealing gasket, reducing system weight, improving production efficiency, and lowering housing material costs. The module assembly and BDU adopt an inverted design, facilitating disassembly and assembly, and simplifying maintenance. This invention also discloses a method for assembling a vehicle and the power battery pack.

Description

Technical Field

[0001] This invention belongs to the field of automotive power battery system technology. Specifically, this invention relates to a power battery pack, a vehicle, and a method for assembling the power battery pack. Background Technology

[0002] Currently, the power battery pack assembly consists of an upper cover, a sealing gasket, and a lower housing. The lower housing is made of extruded aluminum profiles and involves many production steps, complex processes, high costs, and low forming efficiency through cutting, welding, riveting, and other techniques.

[0003] The top cover of the battery pack assembly is made of carbon steel stretching die or composite material. A sealing gasket is added between the top cover and the lower battery pack for sealing. The top cover is located above the lower battery pack. During use, there may be a problem of sealing failure. Later maintenance requires the entire power battery pack to be disassembled, which is inconvenient.

[0004] The aim is to provide an improved power battery housing assembly, particularly regarding improvements to the structure of the power battery housing assembly and increased production efficiency. Summary of the Invention

[0005] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention provides a power battery pack with an optimized structure that facilitates production and maintenance.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a power battery pack, including a housing assembly and a module assembly, wherein the housing assembly is an integral die-cast and hollow structure, the module assembly is located in the inner cavity of the housing assembly, and a bottom protective plate is provided at the bottom of the housing assembly.

[0007] The housing assembly includes a top wall and a plurality of side walls disposed on the top wall and extending downward toward the top wall. The bottom guard plate is located below the side walls and connected to the side walls. The module assembly is located between the top wall and the bottom guard plate.

[0008] A fixing device is provided in the inner cavity of the housing assembly. The module assembly is mounted on the fixing device by a first bolt, which passes through the module assembly from below and is inserted into the first mounting hole on the fixing device.

[0009] The fixing device is provided with a first nut that cooperates with the first bolt, and the first nut is located between the fixing device and the top wall.

[0010] A high-voltage power distribution module is installed in the inner cavity of the enclosure assembly. The high-voltage power distribution module is mounted on the fixing device by a second bolt, which passes through the high-voltage power distribution module from below and is inserted into the second mounting hole on the fixing device.

[0011] The fixing device is provided with a second nut that mates with the second bolt, and the second nut is located between the fixing device and the top wall.

[0012] The fixing device includes longitudinal beams, and multiple longitudinal beams are provided. The longitudinal beams are fixedly connected to the box assembly.

[0013] A protective coating is provided on the bottom surface of the bottom protective plate.

[0014] The present invention also provides a vehicle including the aforementioned power battery pack.

[0015] The present invention also provides a method for assembling a power battery pack, comprising the following steps:

[0016] S1. Install the aforementioned housing assembly;

[0017] S2. Insert the module assembly into the housing assembly from below;

[0018] S3. Install the bottom guard plate at the bottom of the housing assembly.

[0019] The power battery pack of the present invention has an integrally molded structure for the housing, eliminating the need for a top cover and sealing gasket, thereby reducing system weight, improving production efficiency, and reducing housing material costs; the module assembly and BDU adopt an inverted design, which facilitates disassembly and assembly and makes maintenance convenient. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the power battery pack of the present invention;

[0021] Figure 2 This is a top view of the power battery pack of the present invention;

[0022] Figure 3 This is an exploded view of the power battery pack of the present invention;

[0023] Figure 4 This is an inverted view of the internal modules of the battery system.

[0024] Figure 5 This is a block diagram of a power battery system;

[0025] The markings in the above figures are as follows: 1. Housing assembly; 2. Front adapter bracket; 3. Longitudinal beam; 4. Rear adapter bracket; 5. High voltage power distribution module (BDU) and power battery management system (BMS); 6. Module assembly; 7. Bottom guard plate; 8. Cooling inlet; 9. Cooling outlet; 10. First bolt; 11. Second bolt; 12. First nut; 13. Protective coating. Detailed Implementation

[0026] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solutions of the present invention, and to facilitate its implementation.

[0027] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," and similar expressions used in this document are for illustrative purposes only.

[0028] It should be noted that in the following embodiments, the terms "first," "second," and "third" do not represent an absolute distinction in structure and / or function, nor do they represent the order of execution; they are merely for the convenience of description.

[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly associated with those skilled in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0030] like Figures 1 to 4 As shown, the present invention provides a power battery pack, including a power battery management system (BMS), a housing assembly 1 and a module assembly 6. The housing assembly 1 is an integral die-cast and hollow structure. The module assembly 6 is located in the inner cavity of the housing assembly 1. A bottom guard plate 7 is provided at the bottom of the housing assembly 1.

[0031] Specifically, this invention relates to a design method for a new energy vehicle power battery system without a top cover or sealing gasket. The battery box uses an integrated die-casting design and an inverted internal design for the battery pack installation. This reduces the cost of the new energy vehicle power battery system, decreases the number of parts, and avoids numerous complex connection and sealing processes. From an efficiency perspective, the reduction in the number of parts and welding processes improves production efficiency and also facilitates after-sales maintenance of the battery pack. During maintenance, only the bottom guard plate 7 needs to be removed and installed, without disassembling the entire battery pack system. A battery system specifically designed for new energy vehicle applications is provided. The box is formed by integrated die-casting and carbon steel stretching molding of the bottom guard plate 7, and then sealed to form the box assembly 1, without a top cover or sealing gasket. The internal modules and high-voltage power distribution modules are inverted and installed on the battery box. The entire battery system is then inverted and installed on the vehicle body using a lift.

[0032] Compared with existing battery system designs for new energy vehicles, this invention reduces the number of top cover and sealing gasket components, and uses one-piece die casting for the housing, which reduces the weight of the housing, improves production efficiency, and reduces material costs. The internal modules of the battery system feature an inverted design for the high-voltage power distribution module, and the module adopts large-area liquid cooling, which increases the cooling area and thermal runaway exhaust channels, greatly reducing thermal runaway.

[0033] like Figures 1 to 3 As shown, the housing assembly 1 includes a top wall and a plurality of side walls disposed on the top wall and extending downward toward the top wall. The bottom guard plate 7 is located below the side walls and connected to the side walls. The module assembly 6 is located between the top wall and the bottom guard plate 7. The bottom guard plate 7 is used to close the bottom opening of the module assembly 6.

[0034] like Figures 1 to 3 As shown, the housing assembly 1 is a rectangular shell structure made of aluminum alloy. It has four side walls, each fixedly connected to one of the four sides of the top wall. The top wall is horizontal, while the side walls are vertical, arranged in pairs opposite each other. The top and side walls are integrally formed. The bottom protective plate 7 is parallel to the top wall, and the two are arranged opposite each other, with the top wall sealing the top of the housing assembly 1. After the bottom protective plate 7 is fixedly installed to the housing assembly 1, the bottom of the housing assembly 1 is sealed.

[0035] The battery pack assembly 1 utilizes integrated die-casting technology. The advantages of integrated die-casting battery packs are: the welding process for aluminum profiles is lengthy and inefficient, while integrated die-casting allows for rapid molding and higher efficiency; the weld quality issues associated with profile welding are also effectively resolved by integrated die-casting. From a production cost perspective, there is no need to invest in equipment for multiple aluminum profiles; only one die-casting machine is required, simplifying the overall production process. In the future, with the improvement of the performance of various alloy materials and the increased production capacity of large die-casting machines, high-energy battery packs for pure electric vehicles are also expected to achieve integrated die-casting molding.

[0036] like Figure 3 and Figure 4As shown, a fixing device is installed in the inner cavity of the housing assembly 1. The module assembly 6 is mounted on the fixing device by a first bolt 10. The first bolt 10 passes through the module assembly 6 from below and is inserted into the first mounting hole on the fixing device. A first nut 12 is provided on the fixing device to mate with the first bolt 10. The first nut 12 is located between the fixing device and the top wall. The first nut 12 is welded to the fixing device. The first bolt 10 is vertically arranged, and the first bolt 10 and the first nut 12 are threaded together. There are multiple first bolts 10, and the number of first nuts 12 is the same as the number of first bolts 10. Each first bolt 10 mates with one first nut 12. The first bolt 10 is a hexagonal head bolt, which includes a threaded part and a hexagonal head. The threaded part has external threads and is threaded to the first nut 12. The threaded part passes through a through hole on the module assembly 6 and is inserted into the first mounting hole. The first nut 12 is located above the first mounting hole, and the hexagonal head is located below the module assembly 6. During assembly, the module assembly 6 can be inserted into the inner cavity of the housing assembly 1 from below. The first bolt 10 is inserted into the through hole of the module assembly 6 from below, then into the first mounting hole, and finally tightened with the first nut 12 to achieve the fixed installation of the module assembly 6.

[0037] like Figure 3 and Figure 4 As shown, a high-voltage power distribution module is installed in the inner cavity of the housing assembly 1. The high-voltage power distribution module is mounted on a fixing device via a second bolt 11. The second bolt 11 passes through the high-voltage power distribution module from below and is inserted into a second mounting hole on the fixing device. A second nut is provided on the fixing device to mate with the second bolt 11. The second nut is located between the fixing device and the top wall. The second nut is welded to the fixing device. The second bolt 11 is vertically positioned, and the second bolt 11 and the second nut are threaded together. Multiple second bolts 11 are provided, and the number of second nuts is the same as the number of second bolts 11. Each second bolt 11 mates with one second nut. The second bolt 11 is a hexagonal head bolt, consisting of a threaded shank and a hexagonal head. The threaded shank has external threads and is threadedly connected to the second nut. The threaded shank passes through a through hole on the high-voltage power distribution module and is inserted into the second mounting hole. The second nut is located above the second mounting hole, and the hexagonal head is located below the high-voltage power distribution module. During assembly, the high-voltage power distribution module can be installed into the inner cavity of the housing assembly 1 from below. The second bolt 11 is inserted into the through hole of the high-voltage power distribution module from below, then into the second mounting hole, and finally tightened with the second nut to achieve the fixed installation of the high-voltage power distribution module.

[0038] like Figure 3As shown, the fixing device mainly includes longitudinal beams 3, multiple longitudinal beams 3 are provided, the longitudinal beams 3 are fixedly connected to the box assembly 1, and the first nut 12 and the second nut are fixedly connected to the longitudinal beams 3.

[0039] The power battery system employs an inverted design, with the module assembly 6 and the high-voltage power distribution module mounted upside down on the housing assembly 1 via longitudinal beams 3, facilitating future maintenance. Furthermore, the locking direction (Z-axis) of the tabs of the module assembly 6 and the high-voltage power distribution module is aligned with the ground direction.

[0040] like Figure 3 and Figure 4 As shown, a protective coating 13 is provided on the bottom surface of the bottom guard plate 7. In this embodiment, the guide plate is made of carbon steel, and the protective coating 13 is made of PVC (polyvinyl chloride). By providing a protective coating 13 on the bottom of the battery pack, the protective performance of the battery pack can be enhanced, making it more wear-resistant and corrosion-resistant, thereby protecting the battery pack from damage from the external environment and ensuring that the battery pack can still maintain good condition in the event of an accident such as a collision.

[0041] like Figure 1 and Figure 2 As shown, a front adapter bracket 2 and a rear adapter bracket 4 are respectively provided at both ends of the housing assembly 1. The two front adapter brackets 2 are fixedly installed at one end of the housing assembly 1, and the two rear adapter brackets 4 are fixedly installed at the other end of the housing assembly 1. The power battery pack is fixedly installed on the vehicle body through the front adapter brackets 2 and the rear adapter brackets 4.

[0042] The aforementioned power battery pack mainly consists of a housing assembly 1, various metal supports, longitudinal beams 3, a bottom protective plate 7, and bolts, forming the "skeleton" of the power battery pack; it provides support and resists mechanical impact and vibration. The electrical system of the power battery pack consists of high-voltage jumpers or high-voltage wiring harnesses, low-voltage wiring harnesses, and relays. The thermal management system includes liquid cooling plates and cooling water pipes.

[0043] The power battery management system of a power battery pack consists of components such as sensors, actuators, and controllers (electronic control units), which collect data such as system voltage, current, and temperature. It effectively manages and controls the charging and discharging of the power battery pack and responds to functional requirements at the vehicle level.

[0044] The power battery pack with the above structure has the following advantages:

[0045] (1) The enclosure assembly 1 system design eliminates the top cover and sealing gasket, reduces the number of parts, and lowers the cost;

[0046] (2) Compared with aluminum profile welding, the integrated die-casting design of the box body aluminum alloy has the advantages of high production efficiency and low cost. It provides a new model for the lightweighting of power battery systems for new energy vehicles and the application of aluminum alloy die casting, which may subvert the automotive manufacturing process of aluminum profiles in power battery systems.

[0047] (3) The inverted battery system design facilitates convenient maintenance and disassembly; the large-area cooling of the module cells and the inverted installation facilitate the smooth exhaust and smoke discharge in the event of thermal runaway.

[0048] The present invention also provides a vehicle including a power battery pack with the above-described structure. The specific structure of this power battery pack can be found in [reference needed]. Figures 1 to 5 Further details will not be elaborated here. Since the vehicle of the present invention includes the power battery pack described in the above embodiments, it possesses all the advantages of the aforementioned power battery pack.

[0049] The present invention also provides a method for assembling a power battery pack, comprising the following steps:

[0050] S1. Install the enclosure assembly 1;

[0051] S2. Install the module assembly 6, BDU assembly and BMS management system into the housing assembly 1 from the bottom;

[0052] S3. Install the bottom guard plate 7 at the bottom of the housing assembly 1.

[0053] During assembly, the module assembly 6 can be inserted into the inner cavity of the housing assembly 1 from below. The first bolt 10 is inserted into the through hole of the module assembly 6 from below, then into the first mounting hole, and finally tightened with the first nut 12 to achieve the fixed installation of the module assembly 6.

[0054] In step S2 above, during assembly, the module assembly 6 can be installed into the inner cavity of the housing assembly 1 from below. The first bolt 10 is inserted into the through hole of the module assembly 6 from below, then into the first mounting hole, and finally tightened with the first nut 12 to achieve the fixed installation of the high voltage power distribution module.

[0055] In step S2 above, during assembly, the high-voltage power distribution module can be installed into the inner cavity of the housing assembly 1 from below. The second bolt 11 is inserted into the through hole of the high-voltage power distribution module from below, then inserted into the second mounting hole, and finally tightened with the second nut to achieve the fixed installation of the high-voltage power distribution module.

[0056] In step S3 above, during assembly, the bottom guard plate 7 is fixedly installed at the bottom of the housing assembly 1 using a third bolt.

[0057] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A power battery pack, comprising a housing assembly and a module assembly, characterized in that, The housing assembly is an integral die-cast and hollow structure. The module assembly is located in the inner cavity of the housing assembly, and a bottom protective plate is provided at the bottom of the housing assembly. The enclosure assembly includes a top wall and a plurality of side walls disposed on the top wall and extending downward toward the top wall, the bottom guard plate is located below the side walls and connected to the side walls, and the module assembly is located between the top wall and the bottom guard plate; A fixing device is provided in the inner cavity of the housing assembly. The module assembly is mounted on the fixing device by a first bolt, which passes through the module assembly from below and is inserted into the first mounting hole on the fixing device. The fixing device is provided with a first nut that cooperates with the first bolt, and the first nut is located between the fixing device and the top wall.

2. The power battery pack according to claim 1, characterized in that, A high-voltage power distribution module is installed in the inner cavity of the enclosure assembly. The high-voltage power distribution module is mounted on the fixing device by a second bolt, which passes through the high-voltage power distribution module from below and is inserted into the second mounting hole on the fixing device.

3. The power battery pack according to claim 2, characterized in that, The fixing device is provided with a second nut that mates with the second bolt, and the second nut is located between the fixing device and the top wall.

4. The power battery pack according to any one of claims 1 to 3, characterized in that, The fixing device includes longitudinal beams, and multiple longitudinal beams are provided. The longitudinal beams are fixedly connected to the box assembly.

5. The power battery pack according to any one of claims 1 to 3, characterized in that, A protective coating is provided on the bottom surface of the bottom protective plate.

6. A vehicle, characterized in that, Includes the power battery pack as described in any one of claims 1 to 5.

7. The assembly method of the power battery pack according to any one of claims 1 to 5, characterized in that, Including the following steps: S1. Install the aforementioned housing assembly; S2. Insert the module assembly into the housing assembly from below; S3. Install the bottom guard plate at the bottom of the housing assembly.

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