A high energy density battery pack

Abstract

The application discloses a high-energy-density battery box, which comprises a box frame, a liquid cooling plate is installed at the bottom of the box frame, and a plurality of protective plates are installed below the liquid cooling plate; a top cover plate is installed at the top of the box frame, and a box inner cavity for accommodating an electric core module is formed between the top cover plate and the liquid cooling plate; the box frame is composed of a plurality of frame edges, at least one side frame edge of the box frame is a side vertical assembly frame edge, at least one side of the top cover plate is provided with a side cover plate, and the side cover plate corresponds to the side vertical assembly frame edge; an outer side vertical surface of the side vertical assembly frame edge is an assembly surface matched with the side cover plate, and the side cover plate is attached to the outer side vertical surface. The box frame is a square frame, the left and right side frame edges of the box frame are side vertical assembly frame edges, and panels are installed at the front and back of the box frame; an upper profile surface of the panel is an assembly surface matched with the top cover plate, and a side profile surface of the panel is an assembly surface matched with the side cover plate. The application can improve the energy density of the battery box.

Description

Technical Field

[0001] This invention relates to the field of battery box technology, and more particularly to a high energy density battery box. Background Technology

[0002] The market is demanding increasingly higher range performance from new energy vehicles. With rising energy consumption and strict limitations on battery pack size, the maximum driving range of a single charge for a new energy vehicle primarily depends on the battery's energy density. High energy density means storing more energy in a smaller volume or with a lighter weight. Storing more electricity within the same volume results in higher efficiency and practicality in various applications.

[0003] Traditional battery packs typically have a sealed surface, i.e., the mounting surface of the top cover, on the upper end. To ensure proper installation, a large assembly surface needs to be reserved around the perimeter, resulting in a relatively small internal volume and limiting the number of cells within the module. Furthermore, to ensure the effective area for top cover installation and sealing gasket compression, the left and right side borders are generally wide, leading to an increase in the weight of the pack.

[0004] On the other hand, in order to prevent the liquid cooling plate from deforming greatly after bearing the load, a protective plate is generally required at the bottom of the liquid cooling plate. The general connection method is welding, but it is difficult to load and unload materials during welding, and welding is subject to thermal deformation. Summary of the Invention

[0005] Purpose of the invention: In order to overcome the shortcomings of the prior art, the present invention provides a high energy density battery box, which aims to improve the energy density of the battery box.

[0006] Technical Solution: To achieve the above objectives, the present invention provides a high-energy-density battery box, comprising a box frame, a liquid cooling plate installed at the bottom of the box frame, and several protective plates installed below the liquid cooling plate; a top cover plate installed at the top of the box frame, with an internal cavity for accommodating battery cell modules between the top cover plate and the liquid cooling plate; the box frame is composed of several side frames, at least one side frame of the box frame being a side-mounted mounting side frame, and at least one side of the top cover plate having a side cover plate corresponding to the side-mounted mounting side frame; the outer surface of the side-mounted mounting side frame is a mounting surface that mates with the side cover plate, and the side cover plate is correspondingly affixed to the outer surface; the box frame is a square frame, and the left and right side frames of the box frame are side-mounted mounting side frames. The front and rear sides of the box frame are equipped with panels; the upper contour surface of the panel is the assembly surface that mates with the top cover plate, and the side contour surface of the panel is the assembly surface that mates with the side cover plate; an assembly groove is provided on one side of the bottom of the side mounting frame; the two sides of the guard plate are respectively provided with snap-fit ​​structures, and the guard plate is snapped into the assembly grooves of the two side mounting frames through the snap-fit ​​structures on both sides, so that the side mounting frames can provide support for the guard plate; the two sides of the guard plate are rolled into a roll, and the roll is the snap-fit ​​structure; the length direction of the assembly groove is consistent with the length direction of the side mounting frame, and the cross-sectional shape of the assembly groove is consistent with the shape of the roll; the two ends of the assembly groove are insertion ports, and the roll can slide into the assembly groove from the insertion ports.

[0007] Furthermore, the outer facade is inclined from top to bottom in a direction away from the inner cavity of the box, and the side cover is also inclined from top to bottom in a direction away from the inner cavity of the box.

[0008] Furthermore, a certain gap is left between the rolled edge of the rolled circle and the body of the protective plate, so that the rolled circle can produce a certain degree of deformation; when the rolled circle is inserted into the assembly groove, the rolled circle is in a compressed state, so that the outer contour of the rolled circle fits against the inner wall of the assembly groove.

[0009] Furthermore, a glue storage tank is provided on the outer contour surface of the rolled circle, and the glue storage tank contains glue liquid. The rolled circle is fixed in the assembly groove by adhesive bonding.

[0010] Furthermore, a weight-reducing hole is provided inside the side-standing assembly frame, and the weight-reducing hole extends along the length direction of the side-standing assembly frame.

[0011] Furthermore, a plurality of air holes are provided between the weight-reducing hole and the assembly groove, and the air holes connect the weight-reducing hole and the assembly groove; a plurality of rolled balls are arranged in the assembly groove, the positions of the air holes correspond to the positions of the rolled balls, and the air holes are connected to the glue storage tanks on the rolled balls; external gas can be blown into the glue storage tank through the weight-reducing hole and the air holes, blowing the glue liquid in the glue storage tank onto the inner wall of the assembly groove.

[0012] Furthermore, the outer contour surface of the rolled-up surface is provided with a number of distribution grooves, which are all connected to the glue storage tank. The air holes can blow the glue in the glue storage tank into each distribution groove, so that the glue in each distribution groove overflows onto the inner wall of the assembly tank.

[0013] Beneficial effects: The high energy density battery box of the present invention has the following beneficial effects:

[0014] 1) The mounting surface of the battery box side cover is the outer side of the side mounting frame, which releases the space in the width direction of the battery box cavity and increases the number of battery cells that can be accommodated in the battery box; under the same external dimensions of the battery box, the energy density of the battery box can be improved.

[0015] 2) The guard plate has rolled edges on both sides. During assembly, the rolled edges of the guard plate are simply inserted into the assembly slot to ensure the left and right position of the guard plate. The rolled edges on both sides can ensure the load-bearing capacity of the guard plate. Therefore, the connection method can be glued instead of welding. Glue does not have thermal deformation.

[0016] 3) The rolled cylinder is under compression deformation in the assembly slot, which makes the rolled cylinder and the assembly slot fit tightly together, and the guard plate is not easy to loosen. A glue storage tank is provided on the outer contour surface of the rolled cylinder. Air is blown into the glue storage tank through the weight reduction hole and air hole, which can blow the glue in the glue storage tank onto the inner wall of the assembly slot. Thus, even when the rolled cylinder and the assembly slot are tightly fitted together, the outer contour surface of the rolled cylinder and the inner wall of the assembly slot can be connected together by adhesive. Attached Figure Description

[0017] Appendix Figure 1 This is a schematic diagram of the overall structure of the battery box;

[0018] Appendix Figure 2 This is an exploded view of the battery box components;

[0019] Appendix Figure 3 This is a schematic diagram of the structure of the protective panels and front panels on the box frame;

[0020] Appendix Figure 4 A structural diagram of the side-mounted assembly frame;

[0021] Appendix Figure 5 This is a schematic diagram showing the fit between the side cover and the outer facade;

[0022] Appendix Figure 6 This is a schematic diagram of the pores and the glue storage tank. Detailed Implementation

[0023] The invention will now be further described with reference to the accompanying drawings.

[0024] As attached Figures 1 to 6The high-energy-density battery box includes a box frame 1. A liquid cooling plate 2 is installed at the bottom of the box frame 1 to liquid cool the battery cell modules 5 inside the battery box. Several protective plates 3 are installed below the liquid cooling plate 2. The liquid cooling plate 2 will deform to a certain extent after bearing weight, and the protective plates 3 can support the liquid cooling plate 2 to prevent excessive deformation. A top cover plate 4 is installed on the top of the box frame 1. The top cover plate 4 is opposite to the liquid cooling plate 2, and the space between the top cover plate 4 and the liquid cooling plate 2 is the internal cavity of the box to accommodate the battery cell modules 5. That is, the battery cell modules 5 are installed inside the battery box and located between the top cover plate 4 and the liquid cooling plate 2.

[0025] The housing frame 1 is composed of several welded and assembled side frames, and at least one side frame of the housing frame 1 is a side-mounted assembly frame 6. At least one side of the top cover plate 4 is provided with a side cover plate 7, which corresponds to the side-mounted assembly frame 6. The outer surface 8 of the side-mounted assembly frame 6 is the assembly surface that mates with the side cover plate 7, and the side cover plate 7 is correspondingly attached to the outer surface 8.

[0026] Traditional battery boxes typically consist of a frame plate mounted on the box frame 1, with the box cover sealed to the upper surface of the frame plate. To ensure proper installation, a large mounting surface needs to be reserved on the frame plate, resulting in a relatively small internal volume of the battery box. This limits the number of cells in the cell module 5 and leads to a lower energy density. Furthermore, to ensure an effective mounting area for the box cover, the frame plate is generally wide, increasing the weight of the battery box and hindering its lightweight design.

[0027] In this invention, the battery box omits the frame plate on the side where the side mounting frame 6 is located. Instead, a side cover plate 7 is connected to the top cover plate 4, allowing the side cover plate 7 to directly adhere to the outer surface 8 of the side mounting frame 6. This transforms the traditional upper mounting surface into a lateral mounting surface, freeing up space in the width direction of the battery box cavity and increasing the number of battery cells that can be accommodated. This improves the energy density of the battery box while maintaining the same external dimensions.

[0028] As attached Figure 3 As shown, the box frame 1 is a square frame, with side mounting frames 6 on the left and right sides, and vertical panels 9 installed on the front and rear sides of the box frame 1. (See attached image) Figure 2 As shown, the top cover plate 4 is integrally connected to the two sides of the side cover plate 7. The upper contour surface of the panel 9 is the assembly surface that mates with the top cover plate 4, and the side contour surface of the panel 9 is the assembly surface that mates with the side cover plate 7.

[0029] As attached Figure 5As shown, the outer facade 8 is inclined from top to bottom in a direction away from the inner cavity of the battery box. Correspondingly, the side cover 7 is also inclined from top to bottom in a direction away from the inner cavity of the battery box, so that the left and right sides of the battery box gradually narrow from bottom to top, the overall size of the battery box is smaller, and the energy density of the battery box is improved.

[0030] As attached Figure 5 As shown, a mounting groove 10 is provided on one side of the bottom of the side-standing mounting frame 6. A snap-fit ​​structure is provided on both sides of the protective plate 3. The protective plate 3 is snapped into the mounting grooves 10 of the two side-standing mounting frames 6 through the snap-fit ​​structures on both sides, so that the side-standing mounting frame 6 can provide support for the protective plate 3, and the protective plate 3 in turn provides support for the liquid cooling plate 2, preventing excessive deformation of the liquid cooling plate 2 under load.

[0031] The two sides of the protective plate 3 are rolled into rolled circles 11, which serve as the snap-fit ​​structure. The length direction of the mounting groove 10 is consistent with the length direction of the side-mounted mounting frame 6. The cross-sectional shape of the mounting groove 10 is consistent with the shape of the rolled circle 11, and the outer contour of the rolled circle 11 is circular. The cross-sectional shape of the mounting groove 10 is also circular. Both ends of the mounting groove 10 are insertion ports, through which the rolled circle 11 can slide into the mounting groove 10. One side of the mounting groove 10 is open, and the rolled circle 11 is connected to the body of the protective plate 3 through the opening on one side of the mounting groove 10.

[0032] A certain gap is left between the rolled edge of the rolled circle 11 and the body of the protective plate 3, so that the rolled circle 11 can undergo a certain degree of deformation, that is, the degree of winding of the rolled circle 11 can change to a certain extent. When the rolled circle 11 is inserted into the assembly groove 10, the rolled circle 11 is in a compressed state, so that the outer contour of the rolled circle 11 fits against the inner wall of the assembly groove 10, and the rolled circle 11 can be locked in the assembly groove 10, so that the protective plate 3 and the side-standing assembly frame 6 are stably connected, the protective plate 3 is not easy to loosen, and the protective plate 3 provides good support for the liquid cooling plate 2.

[0033] Generally, the connection between the protective plate 3 and the housing frame 1 is welding, but welding is difficult due to loading and unloading, and it also results in thermal deformation. In this invention, since the protective plate 3 has rolled cylinders 11 on both sides, during assembly, it is only necessary to snap the rolled cylinders 11 of the protective plate 3 into the assembly groove 10 to ensure the left and right position of the protective plate 3, and then adjust the front and back position of the protective plate 3. After the rolled cylinders 11 on both sides are snapped together, the load-bearing capacity of the protective plate 3 can be guaranteed, so the connection method can be adhesive instead of welding, and adhesive does not have thermal deformation. Therefore, in this invention, the rolled cylinders 11 are fixed in the assembly groove 10 by adhesive. However, since the rolled cylinders 11 are under compression in the assembly groove 10, the outer contour of the rolled cylinders 11 fits against the inner wall of the assembly groove 10, making it difficult to add adhesive between the rolled cylinders 11 and the assembly groove 10. Therefore, a glue reservoir 12 is provided on the outer contour surface of the rolled cylinder 11, and glue liquid is stored in the glue reservoir 12. Before the rolled cylinder 11 is inserted into the assembly groove 10, a certain amount of glue liquid is added to the glue reservoir 12 in advance. In this way, after the rolled cylinder 11 is inserted into the assembly groove 10, the glue liquid in the glue reservoir 12 can be used to glue and fix the rolled cylinder 11 to a suitable position in the assembly groove 10.

[0034] As attached Figure 5 and 6 As shown, a weight reduction hole 13 is provided in the side mounting frame 6. The weight reduction hole 13 extends along the length direction of the side mounting frame 6. The setting of the weight reduction hole 13 can reduce the weight of the side mounting frame 6, which is beneficial to the lightweighting of the battery box.

[0035] As attached Figure 6 As shown, the weight-reducing hole 13 is parallel to the assembly groove 10. A plurality of air holes 14 are provided between the weight-reducing hole 13 and the assembly groove 10, arranged along the length of the side-mounted assembly frame 6. The upper end of each air hole 14 connects to the weight-reducing hole 13, and the lower end of each air hole 14 connects to the assembly groove 10. (See attached diagram) Figure 3 As shown, several protective plates 3 are arranged on the housing frame 1, and correspondingly, several rolled cylinders 11 are arranged in the assembly groove 10. The positions of the air holes 14 correspond to the positions of the rolled cylinders 11, and when the rolled cylinders 11 move with the protective plates 3 to the positions of the air holes 14, the air holes 14 and the glue storage tanks 12 on the rolled cylinders 11 are interconnected. Thus, external air can be blown into the glue storage tanks 12 through the weight reduction holes 13 and the air holes 14, thereby blowing the glue in the glue storage tanks 12 onto the inner wall of the assembly groove 10. If the glue storage tanks 12 are not blown with air, the bonding area between the glue in the glue storage tanks 12 and the assembly groove 10 is small, and the bonding effect between the rolled cylinders 11 and the assembly is poor. In practical applications, one end of the weight reduction hole 13 can be blocked, and air can be blown to the other end of the weight reduction hole 13 through the air supply device. The airflow is blown into the glue storage tanks 12 through the air holes 14, causing the glue in the glue storage tanks 12 to overflow onto the inner wall of the assembly groove 10.

[0036] The outer contour surface of the rolled cylinder 11 is also provided with a number of distribution support grooves, which are all connected to the glue storage tank 12. The air hole 14 can blow the glue in the glue storage tank 12 into each distribution support groove, so that the glue in each distribution support groove overflows onto the inner wall of the assembly tank 10. By setting the distribution support grooves, the adhesive area between the rolled cylinder 11 and the assembly tank 10 is larger, and the rolled cylinder 11 can be more firmly bonded to the assembly tank 10.

[0037] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high-energy-density battery box, characterized in that: The enclosure includes a housing frame (1), a liquid cooling plate (2) installed at the bottom of the housing frame (1), and several protective plates (3) installed below the liquid cooling plate (2); a top cover plate (4) is installed on the top of the housing frame (1), and the space between the top cover plate (4) and the liquid cooling plate (2) is the housing cavity for accommodating the battery cell module (5); the housing frame (1) is composed of several side frames, and at least one side frame of the housing frame (1) is a side-mounted mounting side frame (6), and at least one side of the top cover plate (4) is provided with a side cover plate (7), which corresponds to the side-mounted mounting side frame (6); the outer side surface (8) of the side-mounted mounting side frame (6) is a mounting surface that cooperates with the side cover plate (7), and the side cover plate (7) is correspondingly attached to the outer side surface (8). The box frame (1) is a square frame. The left and right side frames of the box frame (1) are side mounting frames (6). Panels (9) are installed on the front and rear sides of the box frame (1). The upper contour surface of the panel (9) is a mounting surface that matches the top cover plate (4), and the side contour surface of the panel (9) is a mounting surface that matches the side cover plate (7). The bottom side of the side-standing assembly frame (6) is provided with an assembly groove (10); the two sides of the guard plate (3) are respectively provided with snap-fit ​​structures, and the guard plate (3) is snapped into the assembly grooves (10) of the two side-standing assembly frames (6) through the snap-fit ​​structures on both sides, so that the side-standing assembly frame (6) can provide support for the guard plate (3). The two sides of the guard plate (3) are rolled into a roll circle (11), and the roll circle (11) is the snap-fit ​​structure; the length direction of the assembly groove (10) is consistent with the length direction of the side-standing assembly frame (6), and the cross-sectional shape of the assembly groove (10) is consistent with the shape of the roll circle (11); the two ends of the assembly groove (10) are insertion ports, and the roll circle (11) can slide into the assembly groove (10) from the insertion ports.

2. The high energy density battery box according to claim 1, characterized in that: The outer facade (8) is inclined from top to bottom in a direction away from the inner cavity of the box, and the side cover (7) is also inclined from top to bottom in a direction away from the inner cavity of the box.

3. A high-energy-density battery box according to claim 1, characterized in that: There is a certain gap between the rolled edge of the rolled circle (11) and the body of the guard plate (3) so that the rolled circle (11) can deform to a certain extent; when the rolled circle (11) is inserted into the assembly groove (10), the rolled circle (11) is in a squeezed state, so that the outer contour of the rolled circle (11) fits against the inner wall of the assembly groove (10).

4. A high-energy-density battery box according to claim 3, characterized in that: A glue storage tank (12) is provided on the outer contour surface of the rolled circle (11). The glue storage tank (12) contains glue liquid. The rolled circle (11) is fixed in the assembly groove (10) by adhesive bonding.

5. A high-energy-density battery box according to claim 4, characterized in that: The side-mounted assembly frame (6) is provided with a weight-reducing hole (13), which extends along the length direction of the side-mounted assembly frame (6).

6. A high-energy-density battery box according to claim 5, characterized in that: A plurality of air holes (14) are provided between the weight reduction hole (13) and the assembly groove (10), and the air holes (14) connect the weight reduction hole (13) and the assembly groove (10); a plurality of rolled balls (11) are arranged in the assembly groove (10), the positions of the air holes (14) correspond to the positions of the rolled balls (11), and the air holes (14) are connected to the glue storage tanks (12) on the rolled balls (11); external gas can be blown into the glue storage tank (12) through the weight reduction hole (13) and the air holes (14), and blow the glue liquid in the glue storage tank (12) onto the inner wall of the assembly groove (10).

7. A high-energy-density battery box according to claim 6, characterized in that: The outer contour surface of the rolled circle (11) is also provided with several distribution support grooves, which are all connected to the glue storage tank (12). The air hole (14) can blow the glue in the glue storage tank (12) into each distribution support groove, so that the glue in each distribution support groove overflows onto the inner wall of the assembly tank (10).

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