A tray frame, a tray, a battery pack, and an electrical device.

Abstract

This application provides a tray frame, a tray, a battery pack, and an electrical device, relating to the field of battery pack technology. The tray frame includes a first side beam, which comprises a first side beam body, a collision protection part, and at least two first connecting members. The collision protection part extends in the same direction as the first side beam body and is fixed to one side of the first side beam body via the first connecting members. At least a portion of the collision protection part has a gap with the first side beam body. Multiple lifting lug modules are provided on the collision protection part, arranged sequentially along its extension direction. This gap creates a certain crumple zone between the collision protection part and the first side beam body, providing good energy absorption in the event of a side column collision, thus effectively protecting the battery module installed in the tray.

Description

Technical Field

[0001] This application relates to the field of battery pack technology, and in particular to a tray frame, a tray, a battery pack, and an electrical device. Background Technology

[0002] A power battery pack is a key component in electric vehicles, hybrid vehicles, power tools, and other electric equipment used to store and provide electrical energy. A power battery pack generally includes battery modules, a tray, and a cover. The tray mainly consists of a base plate and a frame. The frame is fixed to the base plate to form a cavity. The cover is connected to the frame to seal this cavity, thereby protecting the battery modules located within it.

[0003] Additionally, the frame includes a side beam with welded lifting lug modules, which can be connected to the device using the battery pack. The lifting lug modules are typically welded directly to the outside of the side beam. During use, if the lifting lug modules are subjected to pressure, the side beam will deform, compressing the internal battery modules and damaging them. Summary of the Invention

[0004] This application provides a tray frame, a tray, a battery pack, and an electrical device to reduce the probability of damage to the battery module caused by deformation of the side beam squeezing the battery module.

[0005] In a first aspect, embodiments of this application provide a pallet frame, including a first side beam. The first side beam includes a first side beam body, an anti-collision part, and at least two first connecting members. The anti-collision part extends in the same direction as the first side beam body. The anti-collision part is fixed to one side of the first side beam body by the first connecting members, and at least a portion of the anti-collision part has a gap with the first side beam body. The anti-collision part is provided with a plurality of lifting lug modules, which are arranged sequentially along the extension direction of the anti-collision part.

[0006] In some possible implementations, the lug module is integrally die-cast with the first side beam.

[0007] In some possible implementations, one end of the first connector is provided with a support portion, which extends below the anti-collision portion and is connected to the anti-collision portion.

[0008] In some possible implementations, the first connector is further provided with a limiting part, which is connected to the side of the anti-collision part away from the supporting part.

[0009] In some possible implementations, the supporting portion has an inclined surface on the side opposite to the main body of the first side beam.

[0010] In some possible implementations, the first side beam further includes a second connector connected to the main body of the first side beam, with the end of the first connector opposite to the support portion connected to the second connector.

[0011] In some possible implementations, the distance between the second connector and the first side beam body on the side facing away from the first side beam body is less than or equal to the width of the gap.

[0012] In some possible implementations, at least one of the first connectors is provided on each side of each of the lug modules, and the angle between the first connector and the anti-collision part is 0°-60°.

[0013] In some possible implementations, the lifting lug module includes a first lifting lug sleeve with a first through hole, and the first lifting lug sleeve is inserted into the anti-collision part.

[0014] In some possible implementations, the lug module further includes at least two first lug reinforcing ribs disposed on the outside of the first lug sleeve. The first lug reinforcing ribs are located on the side of the anti-collision part away from the second connector. The support part adjacent to the lug module is connected to at least one of the first lug reinforcing ribs. The first lug reinforcing ribs are also connected to the anti-collision part.

[0015] In some possible implementations, the anti-collision part includes a second connecting plate and a reinforcing part, the reinforcing part being disposed on the side of the second connecting plate opposite to the second connecting member, and the reinforcing part being located between two adjacent lifting lug modules.

[0016] In some possible implementations, the reinforcing portion includes a third connecting plate and two fourth connecting plates. The extension direction of the third connecting plate is the same as that of the second connecting plate. Both ends of the third connecting plate are connected to the supporting portion, and the third connecting plate is connected to the side of the second connecting plate away from the first side beam body. One end of the two fourth connecting plates is connected to the third connecting plate, and the other end is connected to the two supporting portions respectively.

[0017] In some possible implementations, the two fourth connecting plates are arranged opposite each other, and the included angle between the two fourth connecting plates is 60-150°.

[0018] In some possible implementations, a second side beam integrally formed with the first side beam and a middle cross beam are also included. There are two first side beams and two second side beams. The two first side beams are arranged opposite each other, and the two second side beams are respectively arranged at both ends of the first side beams. The two ends of the second side beams are connected to the ends of the two first side beams. There is at least one middle cross beam. The two ends of the middle cross beam are respectively connected to the two first side beams. At least one cross beam lug is provided on the middle cross beam.

[0019] In some possible implementations, the second side beam is provided with a mounting part located on one side of the two second side beams facing away from each other, and the mounting part is provided with at least one lifting lug hole that penetrates the mounting part.

[0020] In some possible implementations, the intermediate crossbeam includes a first main rib, a second main rib, and at least two secondary ribs extending in the same direction. The first main rib and the second main rib are arranged opposite to each other. One side of each secondary rib is connected to the first main rib, and the other side is connected to the second main rib. The crossbeam lugs are arranged between adjacent secondary ribs, and the first main rib, the second main rib, and the secondary ribs are all connected to the crossbeam lugs.

[0021] In some possible implementations, the beam lifting lug includes a second lifting lug sleeve and at least four second lifting lug reinforcing ribs disposed on the second lifting lug sleeve. The second lifting lug sleeve is provided with a second through hole. Of the four second lifting lug reinforcing ribs, one is connected to the first main rib plate, one is connected to the second main rib plate, and the other two are respectively connected to the secondary rib plates located on both sides of the second lifting lug sleeve.

[0022] In some possible implementations, a third lifting lug sleeve is also provided below the beam lifting lug. The third lifting lug sleeve is connected to the first main rib plate and the second main rib plate respectively. The third lifting lug sleeve is provided with a third through hole coaxial with the second through hole. The inner diameter of the third through hole is larger than the inner diameter of the second through hole.

[0023] In some possible implementations, the first main rib and the second main rib are provided with mutually cooperating clearance notches, and at least one clearance notch is provided at the middle and one at both ends of the first main rib or the second main rib. The shape of the secondary rib is adapted to the shape of the first main rib and the second main rib.

[0024] In some possible implementations, both the first main rib and the second main rib are provided with a connecting platform at the end opposite to the secondary rib. The connecting platform is located on the opposite side of the first main rib and the second main rib, and the connecting platform is used to connect to one of the pallet bottom plates of the pallet.

[0025] Secondly, embodiments of this application also provide a pallet, including a pallet base and a pallet frame as described in any of the first aspects, wherein the pallet frame is connected to the pallet base.

[0026] Thirdly, embodiments of this application also provide a battery pack, including a battery pack body and the tray described in the second aspect, wherein the tray is connected to the battery pack body.

[0027] Fourthly, embodiments of this application provide an electrical device, including a device body and a battery pack as described in the third aspect, wherein the battery pack is fixed to the device body.

[0028] In the pallet frame, pallet, battery pack, and electrical equipment provided in this application embodiment, the first side beam of the pallet frame includes a first side beam body, an anti-collision part, and a first connecting member. The lifting lug module is disposed on the anti-collision part, and the anti-collision part is connected to the first side beam body through the first connecting member, and at least a part of the anti-collision part has a gap with the first side beam body. This makes there a certain crumple space between the anti-collision part and the first side beam body, so that the anti-collision part has a better energy absorption effect in the event of a side column collision, reducing the probability of deformation of the first side beam body, thereby providing better protection for the battery module installed in the pallet and reducing the probability of damage to the battery module. Attached Figure Description

[0029] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0030] Figure 1 This is a schematic diagram of the structure of the tray provided in the embodiments of this application;

[0031] Figure 2 This is a schematic diagram of the structure of the first side beam in the pallet frame provided in an embodiment of this application;

[0032] Figure 3 for Figure 2 An enlarged schematic diagram of the structure within the circle;

[0033] Figure 4 for Figure 2 The front view of the first side beam in the middle;

[0034] Figure 5 for Figure 4 AA section view in the middle;

[0035] Figure 6 for Figure 2 A top view of the first side beam in the pallet frame;

[0036] Figure 7 for Figure 6 An enlarged schematic diagram of the structure within the circle;

[0037] Figure 8 for Figure 1 An enlarged schematic diagram of the structure within the circle;

[0038] Figure 9 A top view of the middle crossbeam of the pallet frame provided in an embodiment of this application;

[0039] Figure 10 for Figure 9 BB cross-section view in the middle;

[0040] Figure 11 for Figure 9 An enlarged schematic diagram of the structure within the circle;

[0041] Figure 12 for Figure 9 The front view of the middle crossbeam;

[0042] Figure 13 for Figure 12 CC cross-section view in the middle;

[0043] Figure 14 for Figure 1 A schematic diagram of the connection structure between the middle crossbeam and the bottom plate of the pallet.

[0044] Figure 15 for Figure 14 DD cross-section diagram.

[0045] Figure label:

[0046] 100-First side beam; 110-First side beam body; 120-Anti-collision part; 121-Second connecting plate; 122-Third connecting plate; 123-Fourth connecting plate; 130-First connecting piece; 131-Supporting part; 132-Limiting part; 133-Sloping surface; 140-Second connecting piece; 141-First mounting hole; 142-First sealing groove;

[0047] 200 - Lifting lug module; 210 - First lifting lug sleeve; 211 - First through hole; 220 - First lifting lug reinforcing rib;

[0048] 300 - Second side beam; 310 - Lifting lug hole; 320 - Mounting part;

[0049] 400 - Intermediate crossbeam; 410 - First main rib plate; 420 - Second main rib plate; 430 - Secondary rib plate; 440 - Crossbeam lifting lug; 441 - Second lifting lug sleeve; 442 - Second through hole; 443 - Second lifting lug reinforcing rib; 450 - Third lifting lug sleeve; 451 - Third through hole; 460 - Connecting platform; 470 - Clearance notch; 480 - Crossbeam reinforcing rib;

[0050] 500 - Pallet bottom plate.

[0051] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0052] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0053] Battery packs are one of the core components commonly used in electric vehicles, hybrid vehicles, and other electric devices. They mainly consist of battery modules, a battery management system (BMS), a cooling system, trays, and covers.

[0054] Pallets are generally composed of multiple components, such as the pallet base, side beams, middle crossbeams, lifting lug modules, and reinforcing structures, which are assembled by welding or riveting. Since there are many components that make up a pallet, welding or riveting them one by one requires a lot of manpower and resources. As a result, when mass-producing pallets, not only is the cost high, but it is also difficult to effectively control product quality.

[0055] Meanwhile, the pallet frame is mainly composed of side beams, middle crossbeams, and lifting lug modules. When assembling the pallet frame, multiple side beams are generally welded together to form a frame that wraps around the bottom plate of the pallet. Then, the middle crossbeam is welded to the frame, and the lifting lug modules are directly welded to the outside of the side beams.

[0056] With this structure, if the side pillar of the lifting lug module is hit during use, the side beam is easily deformed due to compression. The deformation of the side beam will then compress the battery module located inside the frame, thereby damaging the battery module.

[0057] To avoid the aforementioned problems, this application provides a tray frame, a tray, a battery pack, and electrical equipment. The structure of the first side beam of the tray frame is optimized, and there is a gap between the anti-collision part of the first side beam and the main body of the first side beam. In the event of a side column collision, the probability of damage to the battery module can be effectively reduced. At the same time, the tray frame can be integrally molded, the processing technology is simple, and the mechanical properties and weight of the tray are optimized, effectively reducing the cost of the tray and having a significant cost advantage in mass production. In addition, the connection and disassembly of the tray and the electrical equipment are convenient, improving the convenience of maintenance.

[0058] It is understood that the tray frame, tray, and battery pack provided in this application embodiment can be applied not only to electric vehicles and hybrid vehicles, but also to other devices that require the use of battery packs. This application embodiment does not limit them.

[0059] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0060] In some embodiments, see Figure 1 As shown, the tray includes a tray frame and a tray base plate 500. The tray frame is disposed around the tray base plate 500 to form a receiving cavity for placing the battery module between the tray base plate 500 and the tray frame.

[0061] The pallet frame may include a first side beam 100 and a second side beam 300. There are two first side beams 100 and two side beams 300. The two first side beams 100 are arranged opposite each other, and the two second side beams 300 are respectively located at both ends of the first side beams 100. The two ends of the second side beams 300 are connected to the ends of the two first side beams 100 respectively.

[0062] The first side beam 100 and the second side beam 300 can be integrally formed or separately formed and then connected. The upper surface of the pallet bottom plate 500 can be connected to the bottom of the first side beam 100 and the second side beam 300.

[0063] In some embodiments, see Figure 1 , Figure 2 and Figure 3As shown, the first side beam 100 includes a first side beam body 110, a collision avoidance portion 120, and at least two first connecting members 130. The collision avoidance portion 120 extends in the same direction as the first side beam body 110, and is fixed to one side of the first side beam body 110 by the first connecting members 130, i.e., located on the side of the first side beam body 110 opposite to the receiving cavity. At least a portion of the collision avoidance portion 120 has a gap with the first side beam body 110, meaning that at least a portion of the collision avoidance portion 120 will not contact the first side beam body 110.

[0064] For example, the anti-collision part 120 may not be connected to the first side beam body 110 as a whole, but may be directly connected to the first connector 130, and may be completely connected to the first side beam body 110 through the first connector 130.

[0065] For example, the anti-collision part 120 can be connected to the ends of the first side beam body 110 at both ends, while the middle part is only connected to the first side beam body 110 through the first connector 130.

[0066] It is understood that this is merely an example and not a limitation, as long as there is a gap between at least a portion of the first side beam body 110 and the anti-collision part 120 to protect the battery module.

[0067] Of course, the number of first connectors 130 and the distance between adjacent first connectors 130 can also be designed according to the support requirements of the anti-collision part 120. This embodiment does not limit them here.

[0068] Meanwhile, the anti-collision part 120 is provided with multiple lifting lug modules 200, which are arranged sequentially along the extension direction of the anti-collision part 120. The lifting lug modules 200 can be connected to electrical equipment, such as to the vehicle frame.

[0069] The distance between adjacent lifting lug modules 200 can be adjusted adaptively according to the installation of the tray and the electrical equipment, and this embodiment does not limit it.

[0070] Of course, the number of lug modules 200 is also the same and can be adjusted according to the actual situation. Two, three or more are all possible, and this embodiment does not limit it.

[0071] Specifically, the anti-collision part 120 protrudes outward from the outer side of the first side beam body 110, and the lifting lug module 200 is disposed on the anti-collision part 120. When the battery pack is involved in a side pillar collision, the gap can serve as a collapse space between the anti-collision part 120 and the first side beam body 110, thereby reducing the probability of the first side beam body 110 deforming and concave due to the side pillar collision, thus providing better protection for the battery module.

[0072] In some embodiments, the first side beam 100 and the lifting lug module 200 can be integrally formed by die casting, that is, the first side beam body 110, the anti-collision part 120, the connector and the lifting lug module 200 are all integrally formed. Die casting is a metal forming process that uses high pressure to inject molten metal into a mold cavity, and after cooling, it is demolded to obtain the desired part. It is a processing method well known to those skilled in the art, and will not be described in detail in this embodiment.

[0073] The first side beam 100 and the lifting lug module 200 are integrally formed, which can eliminate multiple complex processes such as welding and riveting, improve the convenience of pallet processing, and at the same time improve the consistency of structural strength at different positions of the first side beam 100.

[0074] In some embodiments, see Figure 4 and Figure 5 As shown, one end of the first connector 130 is provided with a support portion 131, which extends to the bottom of the anti-collision portion 120 and is connected to the anti-collision portion 120.

[0075] After the support part 131 is provided on the first connector 130, the connection strength between the first connector 130 and the anti-collision part 120 can be strengthened by the support part 131, so that the load can be effectively distributed after the lifting lug module 200 is connected to the electrical equipment.

[0076] In some embodiments, the first connector 130 is further provided with a limiting part 132, which is connected to the side of the anti-collision part 120 away from the supporting part 131.

[0077] Specifically, the first connecting member 130 can be configured as a first connecting plate. Of its two opposing side walls, one is attached to and connected to the main body 110 of the first side beam, and the other side wall has a limiting part 132 and a supporting part 131. The anti-collision part 120 is locked between the limiting part 132 and the supporting part 131. At the same time, one side wall of the anti-collision part 120 is connected to the side of the first connecting plate near the anti-collision part 120. Thus, the position of the anti-collision part 120 is restricted by the supporting part 131 and the limiting part 132, and the load is transferred with the help of the supporting part 131 and the limiting part 132, thereby improving the deformation resistance.

[0078] In some embodiments, see Figure 5 As shown, the support part 131 is provided with an inclined surface 133 on the side away from the first side beam body 110, that is, a draft angle is provided at the end of the support part 131 away from the first side beam body 110, thereby forming the inclined surface 133.

[0079] Specifically, the upper surface of the support portion 131, facing away from the main body 110 of the first side beam, can be flush with the end of the anti-collision portion 120, so that the support portion 131 can effectively contact the anti-collision portion 120. The projection of the lower surface of the support portion 131 in the vertical direction is located inside the upper surface of the support portion 131, thereby forming a slope 133 at the end of the support portion 131.

[0080] The angle between the inclined plane 133 and the horizontal plane can be 30°-60°. In production, after multiple topology optimization simulation experiments, it was found that this angle not only does not affect the strength of the first side beam 100, but also helps to achieve the goal of lightweighting.

[0081] That is, setting the inclined plane 133 facilitates demolding and also helps to reduce the weight of the first side beam 100, thus aiding in the lightweight design.

[0082] In some embodiments, see Figure 5 As shown, the first side beam 100 also includes a second connector 140 connected to the first side beam body 110. The end of the first connector 130 facing away from the support portion 131 is connected to the second connector 140. That is, the second connector 140 is located on the upper part of the first side beam body 110 and is connected to the side of the first side beam body 110 facing away from the receiving cavity. The top of the first connector 130 is connected to the second connector 140. The first connector 130 and the second connector 140 are used as force transmission paths in the Z-axis vibration process, so that the first side beam 100 has good Z-axis stiffness and helps to improve the Z-axis modal frequency of the battery pack.

[0083] In some embodiments, see Figure 5 As shown, the distance between the second connector 140 and the first side beam body 110 is less than or equal to the width of the gap.

[0084] That is, the width of the second connector 140 in the X direction is less than or equal to the minimum distance between the main body 110 of the first side beam and the anti-collision part 120, so that the projection of the second connector 140 in the Z direction will not overlap with the anti-collision part 120 at all. When the first side beam 100 and the lifting lug module 200 are integrally molded, demolding can be performed directly by moving the mold in the positive and negative directions of the Z direction, which improves the convenience of processing the first side beam 100 and the lifting lug module 200, and can also effectively reduce mold design and processing costs, improve die casting efficiency, and reduce the cost of mass production of the first side beam 100.

[0085] In some embodiments, such as Figure 5As shown, the lifting lug module 200 includes a first lifting lug sleeve 210, which has a first through hole 211. The first lifting lug sleeve 210 is inserted into the anti-collision part 120, that is, the first lifting lug sleeve 210 penetrates the anti-collision part 120. Bolts can be directly inserted into the first through hole 211 to connect the lifting lug module 200 to the electrical equipment.

[0086] The first through hole 211 extends along the Z direction, and there are no obstructions above or below it, which facilitates demolding. Furthermore, the first lifting lug sleeve 210 can be placed below the connection point of the electrical equipment, and bolts can be inserted into the first through hole 211 from below to lock the first lifting lug sleeve 210 and the electrical equipment. In traditional trays, bolts are typically inserted from top to bottom. For example, when using it in a vehicle, disassembling the battery pack requires first removing the seats, the vehicle floor, and other structures above the battery pack, making disassembly and installation extremely cumbersome. In this example, the lifting lug module 200 and the vehicle frame can be directly connected from the bottom, making battery pack disassembly and installation more convenient and improving maintenance efficiency.

[0087] In addition, the first lifting lug sleeve 210 can be extended to the outside of the anti-collision part 120 on the side facing the second connector 140, so as to facilitate the precision machining of the side of the first lifting lug sleeve 210 in contact with the frame.

[0088] In some embodiments, see Figure 6 and Figure 7 As shown, each lifting lug module 200 is provided with at least one first connector 130 on each side. The lifting lug module 200 is connected to the adjacent first connectors 130 on both sides, so that the load on the lifting lug module 200 can be distributed and transmitted through the anti-collision part 120 and the first connectors 130.

[0089] The included angle between the first connector 130 and the anti-collision part 120 can be set to 0°-60°. Production tests have shown that within this angle range, the first connector 130 can serve as an effective force transmission path between the lifting lug module 200 and the first side beam body 110. Especially in the vibration condition of the battery pack, the above-mentioned rib plate has good Z-direction stiffness, and the structure is simple and the lightweight effect is obvious. The battery pack designed based on this structure has a high Z-direction modal frequency.

[0090] For example, the lug module 200 also includes at least two first lug reinforcing ribs 220 disposed on the outside of the first lug sleeve 210. The end of the first lug sleeve 210 facing away from the second connector 140 also extends to the outside of the anti-collision part 120. The first lug reinforcing rib 220 is located on the side of the anti-collision part 120 facing away from the second connector 140. The support part 131 adjacent to the lug module 200 is connected to at least one of the first lug reinforcing ribs 220. The first lug reinforcing rib 220 is also connected to the anti-collision part 120.

[0091] For example, there are two first lifting lug reinforcing ribs 220, one connecting the first lifting lug sleeve 210 and the support portion 131 located on its left side, and the other connecting the first lifting lug sleeve 210 and the support portion 131 located on its right side.

[0092] For example, four first lifting lug reinforcing ribs 220 are provided and symmetrically arranged on both sides of the first lifting lug sleeve 210. The first lifting lug reinforcing ribs 220 on both sides can be connected to the support parts 131 on both sides respectively.

[0093] It is understood that the number of first lifting lug reinforcing ribs 220 can also be set, as long as the support portion 131 on both sides of the lifting lug module 200 is connected to at least one first lifting lug reinforcing rib 220. This embodiment does not limit it.

[0094] After the first lifting lug reinforcing rib 220 is set, the load can be transferred through the first lifting lug reinforcing rib 220, thereby improving the mechanical properties of the first side beam 100.

[0095] In some embodiments, see Figure 7 As shown, the anti-collision part 120 includes a second connecting plate 121 and a reinforcing part. The reinforcing part is disposed on the side of the second connecting plate 121 away from the second connecting member 140, and the reinforcing part is located between two adjacent lifting lug modules 200.

[0096] With the addition of reinforcement, some of the compressive force can be distributed and transmitted to the lifting lug modules 200 on both sides, thereby improving the anti-collision capability.

[0097] Specifically, the first connector 130 is only provided at the corresponding position of the lifting lug module 200, and two first connectors 130 are provided for each lifting lug module 200. The two first connectors 130 are respectively provided on both sides of the lifting lug module 200. At this time, the first connectors 130 located on both sides of the lifting lug module 200 can be symmetrically arranged with respect to the central axis of the lifting lug module 200 to better transfer the load. The reinforcing part includes a third connecting plate 122 and two fourth connecting plates 123. The extension direction of the third connecting plate 122 is the same as the extension direction of the second connecting plate 121. The two ends of the third connecting plate 122 are connected to the two support parts 131 between the two lifting lug modules 200. The third connecting plate 122 is connected to the side of the second connecting plate 121 away from the first side beam body 110. One end of the two fourth connecting plates 123 is connected to the third connecting plate 122, and the other end is connected to the two support parts 131 respectively.

[0098] The two fourth connecting plates 123 can be arranged opposite each other, and the included angle between the two fourth connecting plates 123 is 60°-150°. Within this angle range, the fourth connecting plates 123 can effectively transmit loads and have a good anti-deformation effect.

[0099] During use, the third connecting plate 122 and the fourth connecting plate 123 can assist in transmitting the compressive force and reduce the probability of deformation of the anti-collision part 120.

[0100] Understandably, during production, it was found that when using aluminum alloy for one-piece molding, setting the thickness of the first connecting plate, second connecting plate 121, third connecting plate 122, fourth connecting plate 123, and first lifting lug reinforcing rib 220 to 1.5-4mm can meet the usage requirements in most cases. Therefore, the thickness of the above components can be designed within this range, which can meet the usage requirements without increasing the thickness of the first side beam 100 due to excessive thickness. Of course, in some cases, they can also be set to be thicker or thinner, and this embodiment does not limit them.

[0101] In some embodiments, the second connector 140 can be a fifth connector plate, whose extension direction is the same as that of the first side beam body 110, and the angle between the fifth connector plate and the first side beam body 110 is 90°. The fifth connector plate is connected to the top of the first side beam body 110, the top of the first connector 130 is attached to and connected to the bottom of the fifth connector plate, and the bottom of the first connector 130 is flush with the bottom of the first side beam body 110, so that the connection area between the first connector 130 and the first side beam body 110 is large, so as to better transmit the load.

[0102] A first mounting hole 141 for mounting a cover plate of the battery pack and a first sealing groove 142 are provided on the top of the second connector 140. The extension direction of the first sealing groove 142 is the same as the extension direction of the second connector 140. When the cover plate of the battery pack is installed, a sealing strip can be placed in the first sealing groove 142 to make the cover plate and the first side beam 100 sealed together. A second mounting hole is provided at the bottom of the first side beam body 110 for mounting the bottom protective plate of the battery pack. This configuration eliminates the need for separate drilling and opening of the first sealing groove 142. Instead, the mold can be designed directly and formed in one piece, thereby reducing the number of processes and reducing losses caused by errors in the processing. It can effectively reduce the processing cost of the tray in mass production and improve the consistency of the first side beam 100.

[0103] Alternatively, a boss can be provided on the side of the first side beam body 110 near the receiving cavity, and the boss can be connected to the tray bottom plate 500.

[0104] In some embodiments, see Figure 1 and Figure 9 As shown, the pallet frame also includes at least one intermediate crossbeam 400. The two ends of the intermediate crossbeam 400 are respectively connected to two first side beams 100. At least one crossbeam lug 440 is provided on the intermediate crossbeam 400. The intermediate crossbeam 400 may be parallel to the second side beam 300 or not. This embodiment does not limit it. Of course, the bottom of the intermediate crossbeam 400 is connected to the pallet bottom plate 500.

[0105] The middle crossbeam 400, the first side beam 100, and the second side beam 300 are all integrally die-cast, thereby improving the mechanical properties of the tray frame and providing reliable mechanical protection for the battery module.

[0106] In addition, the middle crossbeam 400, the first side beam 100 and the second side beam 300 can all be die-cast from aluminum alloy, such as AlSi10MnMg, to reduce the weight of the pallet while ensuring that the strength of the pallet meets the requirements. Of course, the pallet can also be made of other materials that meet the usage requirements. This embodiment is only an example and not a limitation.

[0107] In some embodiments, see Figure 8 As shown, a mounting part 320 is provided on the second side beam 300. The mounting part 320 is located on the opposite side of the two second side beams 300. At least one lifting lug hole 310 is provided on the mounting part 320, and the lifting lug hole 310 penetrates the mounting part 320.

[0108] Specifically, the mounting part 320 protrudes outward from the outside of the second side beam 300, and the lifting lug hole 310 penetrates the mounting part 320, so that the upper and lower projection areas of the lifting lug hole 310 are not blocked by other tray structures, thus allowing bolts to be inserted into the lifting lug hole 310 from the bottom for installation. Compared with traditional trays, this can effectively improve the convenience of disassembly and maintenance.

[0109] It is understandable that one or more fourth lifting lug sleeves may be provided on the mounting part 320, with the lifting lug hole 310 penetrating through the fourth lifting lug sleeve, and the fourth lifting lug sleeve inserted on the mounting part 320, so that the top of the fourth lifting lug sleeve extends to the outside of the mounting part 320, so that the top of the fourth lifting lug sleeve can be precision machined.

[0110] In addition, a second sealing groove can be provided on the top of the second side beam 300. The extension direction of the second sealing groove is the same as the extension direction of the second side beam 300, and the second sealing groove is connected to the first sealing groove 142, so as to achieve a better sealing effect after the cover plate of the battery pack is connected.

[0111] In some embodiments, see Figure 9 , Figure 10 , Figure 12 and Figure 13 As shown, the intermediate crossbeam 400 includes a first main rib plate 410, a second main rib plate 420, and at least two secondary rib plates 430 extending in the same direction. The first main rib plate 410 and the second main rib plate 420 are arranged opposite to each other. One side of the secondary rib plate 430 is connected to the first main rib plate 410, and the other side is connected to the second main rib plate 420. The crossbeam lifting lug 440 is arranged between adjacent secondary rib plates 430, and the first main rib plate 410, the second main rib plate 420, and the secondary rib plate 430 are all connected to the crossbeam lifting lug 440.

[0112] It is understandable that the number of secondary ribs 430 can be determined based on the number of beam lugs 440. It is only necessary to ensure that each beam lug 440 has secondary ribs 430 on both sides, and the shape of the secondary ribs 430 is adapted to the shape of the first main rib 410 and the second main rib 420, and can be connected to the top of the first main rib 410 and the second main rib 420.

[0113] Specifically, such as Figure 1 As shown, the first main rib plate 410 and the second main rib plate 420 both extend along the X direction. They can be parallel to each other or inclined, so that the included angle between them is 0°-30°. The inclined arrangement here can be that the tops of the first main rib plate 410 and the second main rib plate 420 are inclined towards each other, or one end of the first main rib plate 410 and the second main rib plate 420 used to connect with the first side beam 100 is inclined towards each other. This embodiment does not limit this.

[0114] In addition, after multiple production tests, it was found that when using aluminum alloy to form the intermediate crossbeam 400, the thickness of the first main rib plate 410, the second main rib plate 420 and the secondary rib plate 430 is 2.5-4mm, which can meet the usage requirements in most cases while achieving lightweight design. Of course, this is just an example, and the thickness of the first main rib plate 410, the second main rib plate 420 and the secondary rib plate 430 can also be other values. This embodiment does not limit them.

[0115] In some embodiments, see Figure 10 and Figure 11 As shown, the beam lifting lug 440 includes a second lifting lug sleeve 441 and at least four second lifting lug reinforcing ribs 443 disposed on the second lifting lug sleeve 441. The second lifting lug sleeve 441 is provided with a second through hole 442 for connecting bolts. Among the four second lifting lug reinforcing ribs 443, one is connected to the first main rib plate 410, one is connected to the second main rib plate 420, and the other two are respectively connected to the secondary rib plates 430 located on both sides of the second lifting lug sleeve 441.

[0116] The connection strength between the second lifting lug sleeve 441 and the first main rib plate 410, the second main rib plate 420 and the secondary rib plate 430 can be improved by the second lifting lug reinforcing rib 443, and the load can be transferred by the second lifting lug reinforcing rib 443 to improve the performance of the intermediate crossbeam 400.

[0117] In some embodiments, see Figure 14 and Figure 15 As shown, a third lifting lug sleeve 450 is also provided below the crossbeam lifting lug 440. The third lifting lug sleeve 450 is connected to the first main rib plate 410 and the second main rib plate 420 respectively. The third lifting lug sleeve 450 is provided with a third through hole 451 coaxial with the second through hole 442. The inner diameter of the third through hole 451 is larger than the inner diameter of the second through hole 442.

[0118] Specifically, a third lifting lug sleeve 450 is provided below each second lifting lug sleeve 441. The top of the third lifting lug sleeve 450 is connected to the bottom of the second lifting lug reinforcing rib 443, and is also connected to the first main rib plate 410 and the second main rib plate 420 respectively. The third lifting lug sleeve 450 can help improve the strength of the intermediate crossbeam 400, and also facilitate the installation and positioning of the fastening nut. That is, the fastening nut can be inserted into the second through hole 442 from the bottom through the third through hole 451. The inner diameter of the third through hole 451 is larger than the inner diameter of the second through hole 442, which makes it easy to insert the fastening bolt. At the same time, after the fastening nut is screwed in, the end will be stuck at the end of the second lifting lug sleeve 441 and in the third through hole 451.

[0119] In addition, it was found in production that the wall thickness of the third lifting lug sleeve 450 can be set to 2.5-4mm, which has a good reinforcement effect without causing excessive weight.

[0120] In some embodiments, see Figure 15 As shown, a connecting platform 460 is provided at the end of the first main rib plate 410 and the second main rib plate 420 opposite to the secondary rib plate 430. The connecting platform 460 is located on the side of the first main rib plate 410 and the second main rib plate 420 opposite to each other. The connecting platform 460 is used to connect to one of the pallet bottom plates 500 of the pallet.

[0121] Specifically, the pallet bottom plate 500 can be divided into multiple pieces, and the specific number can be determined according to the number of intermediate crossbeams 400. As long as the intermediate crossbeams 400 are located between two adjacent pallet bottom plates 500, the intermediate crossbeams 400 can be welded to the pallet bottom plate 500 through the connecting platform 460 when connecting the intermediate crossbeams 400 and the pallet bottom plate 500.

[0122] In addition, it was found during the production process that the thickness of the connecting platform 460 can be 3-5mm, which is neither too thick nor too thin, and can also avoid the occurrence of solder burn-through.

[0123] The intermediate crossbeam 400 includes a first main rib plate 410, a second main rib plate 420, a secondary rib plate 430, and a crossbeam lifting lug 440. The components work together to achieve not only a simple structure and high strength, but also good lightweight effect, simple demolding process, and high production efficiency.

[0124] In addition, after the middle crossbeam 400 is welded to the pallet bottom plate 500 via the connecting platform 460, the second through hole 442 and the third through hole 451 are unobstructed from the top and bottom. The first through hole 211 on the first lifting lug sleeve 210 and the lifting lug hole 310 on the second side beam 300 are also unobstructed from the top and bottom. When connecting to electrical equipment, the fastening bolts can be inserted from the bottom of the third through hole 451, the first through hole 211, and the lifting lug hole 310 upwards. The connection part of the electrical equipment is located at the top of the second through hole 442, the first through hole 211, and the lifting lug hole 310. This not only makes installation convenient but also makes disassembly relatively convenient.

[0125] Meanwhile, the structure of the pallet frame allows the mold to be moved directly in both the positive and negative directions of the Z-axis after the pallet frame is integrally die-cast, which helps to reduce mold design and processing costs, improve the die-casting efficiency of the mold, and thus significantly reduce the cost of mass production of pallet frames.

[0126] In some embodiments, see Figure 10As shown, the first main rib plate 410 and the second main rib plate 420 are provided with mutually cooperating clearance notches 470. At least one clearance notch 470 is provided in the middle and at both ends of the first main rib plate 410 or the second main rib plate 420. The shape of the secondary rib plate 430 is adapted to the shape of the first main rib plate 410 and the second main rib plate 420.

[0127] Specifically, the height of the middle and both ends of the first main rib plate 410 and the second main rib plate 420 can be lower than the height of other positions, thereby forming a clearance gap 470 in the middle and both ends through the height difference. The secondary rib plate 430 is still connected to the top of the first main rib plate 410 and the second main rib plate 420 at the clearance gap 470, which increases the strength.

[0128] Meanwhile, end plates can be provided at both ends of the first main rib plate 410 and the second main rib plate 420, that is, at both ends for connecting with the first side beam 100, and the ends of the first main rib plate 410 and the second main rib plate 420 can be reinforced by connecting the end plates.

[0129] After setting clearance notches 470 on the first main rib plate 410 and the second main rib plate 420, the clearance notches 470 can be used to provide space for electrical wiring inside the battery pack, making it easier to route wiring inside the battery pack.

[0130] In addition, a crossbeam reinforcing rib 480 can be provided at the clearance gap 470 in the middle of the first main rib plate 410 and the second main rib plate 420, and the crossbeam reinforcing rib 480 can be connected and reinforced to the first main rib plate 410 and the second main rib plate 420 respectively.

[0131] The crossbeam reinforcing rib 480 can be configured as one or more, such as one at each end of the clearance notch 470; this embodiment does not limit this. Meanwhile, the thickness of the crossbeam reinforcing rib 480 can be relatively thin. In production, it has been found that a thickness of 1.5-3mm is sufficient to meet the usage requirements. Of course, the thickness of the crossbeam reinforcing rib 480 can also be set to other dimensions; this embodiment does not limit this.

[0132] The pallet frame structures in the embodiments of this application have all been verified through topology optimization calculations, and it has been found that they can meet the usage requirements of the pallet frame under various working conditions. During the optimization process, the main method is to change the material density of each unit to control the addition or removal of units, gradually achieving the optimal distribution of materials in space. Taking the first side beam 100 as an example, the simulation can be performed according to the following steps:

[0133] 1. Establishing a simulation model: First, the battery pack model is meshed, connection relationships are established, and material parameters are defined. Then, the first lifting lug sleeve 210, the first side beam body 110, the second connector 140, and other envelope structures are defined as non-design domains. The remaining areas within the outer envelope of the side beam are defined as design domains.

[0134] 2. Define design variables: Define design variables based on the design domain of the side beam, set the draft direction to be from top to bottom; and define the minimum and maximum thickness dimensions, minimum spacing, etc. of the design variables to control the generation effect of the rib plate; and set symmetrical constraints on the design domains of the two first side beams 100.

[0135] 3. Define load steps: Establish load analysis steps for calculating battery pack modes, compression, torsion, and other working conditions respectively.

[0136] 4. Define the response: Establish the modal frequencies of the first-order principal vibration mode of the battery pack, the deformation under the extrusion condition, the deformation under the torsion condition, and the response parameters of the volume fraction (or mass) of the pallet design domain; and define weighting coefficients according to the response parameters and importance of individual conditions, and establish the weighted response parameters of these conditions.

[0137] 5. Define constraints: Use the volume fraction (or mass) response of the pallet design domain as a constraint in the optimization process, and define the upper limit of the remaining volume fraction (or mass) after the design domain is optimized.

[0138] 6. Define optimization objectives: The weighted response parameters of multiple working conditions are used as optimization objectives. The ultimate goal is to maximize the modal frequency, minimize the extrusion deformation, and achieve the preset torsional stiffness.

[0139] 7. Submit the calculation. Once the optimization objective has reached the convergence condition, output the topology optimization results.

[0140] It is understandable that other components can also be simulated in a similar way, by modifying the corresponding conditions and parameters accordingly. This embodiment does not limit them.

[0141] In summary, the tray frame provided in this application embodiment is designed based on topology optimization results. It takes into account both the mechanical performance of the battery pack under conditions such as vibration and side pillar impact and the goal of lightweighting. It has obvious cost advantages in mass production, and the battery pack with this tray frame is easy to install and remove from electrical equipment such as vehicle frames, and has high maintenance efficiency.

[0142] This application also provides a tray, such as Figure 1 As shown, it includes the pallet frame and pallet base 500 in the above embodiments, and the pallet frame is connected to the pallet base 500.

[0143] That is, the first side beam 100, the second side beam 300, the middle cross beam 400 and other components can be welded onto the tray bottom plate 500 to cooperate with the tray bottom plate 500 to form a cavity for accommodating the battery module.

[0144] This application embodiment also provides a battery pack, which includes a battery pack body and a tray as described in the above embodiment. The battery pack body may include a cover plate, battery modules, a cooling system and other corresponding components. The tray can be connected to the cover plate of the battery pack to seal the receiving cavity. The battery modules are located in the receiving cavity and are protected by the cover plate and the tray.

[0145] It is understood that the structure of each component in the battery pack, the working principle of the battery pack, and the connection method of each component are well known to those skilled in the art, and will not be described in detail in this embodiment.

[0146] This application embodiment also provides an electrical device, which includes a device body and a battery pack. The battery pack is connected to the device body through components such as a lifting lug module 200 and a crossbeam lifting lug 440.

[0147] It is understood that the electrical equipment in this embodiment includes, but is not limited to, electric vehicles, hybrid vehicles, energy storage systems, consumer electronics, medical devices, drones, power tools, and other equipment that require the use of battery packs.

[0148] Finally, it should be noted that other embodiments of this application will readily conceive of by those skilled in the art upon consideration of the specification and practice of the application disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and alterations may be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A tray frame, characterized in that, The device includes a first side beam (100), which includes a first side beam body (110), a crash barrier (120), and at least two first connectors (130). The crash barrier (120) extends in the same direction as the first side beam body (110). The crash barrier (120) is fixed to one side of the first side beam body (110) by the first connectors (130). At least a portion of the crash barrier (120) has a gap with the first side beam body (110) due to the first connectors (130). The crash barrier (120) is provided with a plurality of lifting lug modules (200), which are arranged sequentially along the extension direction of the crash barrier (120). One end of the first connector (130) is provided with a support portion (131), which extends to the bottom of the anti-collision portion (120) and is connected to the anti-collision portion (120); The first side beam (100) further includes a second connector (140) connected to the first side beam body (110), and the first connector (130) is connected to the second connector (140) at one end away from the support part (131); The lug module (200) includes a first lug sleeve (210), and the lug module (200) further includes at least two first lug reinforcing ribs (220) disposed on the outside of the first lug sleeve (210). The first lug reinforcing ribs (220) are located on the side of the anti-collision part (120) away from the second connector (140). The support part (131) adjacent to the lug module (200) is connected to at least one of the first lug reinforcing ribs (220), and the first lug reinforcing ribs (220) are also connected to the anti-collision part (120).

2. The tray frame according to claim 1, characterized in that, The lifting lug module (200) is integrally die-cast with the first side beam (100).

3. The tray frame according to claim 1, characterized in that, The first connector (130) is also provided with a limiting part (132), which is connected to the side of the anti-collision part (120) away from the supporting part (131).

4. The tray frame according to claim 1, characterized in that, The supporting part (131) has an inclined surface (133) on the side away from the main body (110) of the first side beam.

5. The tray frame according to claim 1, characterized in that, The distance between the second connector (140) and the first side beam body (110) on the side facing away from the first side beam body (110) is less than or equal to the width of the gap.

6. The tray frame according to claim 1, characterized in that, Each of the lug modules (200) has at least one of the first connectors (130) on each side.

7. The tray frame according to claim 6, characterized in that, The first lifting lug sleeve (210) is provided with a first through hole (211), and the first lifting lug sleeve (210) is inserted into the anti-collision part (120).

8. The tray frame according to claim 1, characterized in that, The anti-collision part (120) includes a second connecting plate (121) and a reinforcing part. The reinforcing part is disposed on the side of the second connecting plate (121) away from the second connector (140) and is located between two adjacent lifting lug modules (200).

9. The tray frame according to claim 8, characterized in that, The reinforcing part includes a third connecting plate (122) and two fourth connecting plates (123). The extension direction of the third connecting plate (122) is the same as that of the second connecting plate (121). Both ends of the third connecting plate (122) are connected to the supporting part (131), and the third connecting plate (122) and the second connecting plate (121) are connected to the side away from the first side beam body (110). One end of the two fourth connecting plates (123) is connected to the third connecting plate (122), and the other end is connected to the two supporting parts (131) respectively.

10. The tray frame according to claim 9, characterized in that, The two fourth connecting plates (123) are arranged opposite to each other, and the included angle between the two fourth connecting plates (123) is 60-150°.

11. The tray frame according to any one of claims 1-10, characterized in that, It also includes a second side beam (300) integrally formed with the first side beam (100) and a middle cross beam (400). There are two of each of the first side beam (100) and the second side beam (300). The two first side beams (100) are arranged opposite each other. The two second side beams (300) are respectively arranged at both ends of the first side beam (100), and the two ends of the second side beams (300) are connected to the ends of the two first side beams (100). There is at least one middle cross beam (400). The two ends of the middle cross beam (400) are respectively connected to the two first side beams (100). At least one cross beam lug (440) is provided on the middle cross beam (400).

12. The tray frame according to claim 11, characterized in that, The second side beam (300) is provided with a mounting part (320), the mounting part (320) is located on the opposite side of the two second side beams (300), and the mounting part (320) is provided with at least one lifting lug hole (310), the lifting lug hole (310) penetrates the mounting part (320).

13. The tray frame according to claim 11, characterized in that, The intermediate crossbeam (400) includes a first main rib plate (410), a second main rib plate (420), and at least two secondary rib plates (430) extending in the same direction. The first main rib plate (410) and the second main rib plate (420) are arranged opposite to each other. One side of the secondary rib plate (430) is connected to the first main rib plate (410), and the other side is connected to the second main rib plate (420). The crossbeam lug (440) is arranged between adjacent secondary rib plates (430), and the first main rib plate (410), the second main rib plate (420), and the secondary rib plate (430) are all connected to the crossbeam lug (440).

14. The tray frame according to claim 13, characterized in that, The beam lifting lug (440) includes a second lifting lug sleeve (441) and at least four second lifting lug reinforcing ribs (443) disposed on the second lifting lug sleeve (441). The second lifting lug sleeve (441) is provided with a second through hole (442). Of the four second lifting lug reinforcing ribs (443), one is connected to the first main rib plate (410), one is connected to the second main rib plate (420), and the other two are respectively connected to the secondary rib plates (430) located on both sides of the second lifting lug sleeve (441).

15. The tray frame according to claim 14, characterized in that, A third lifting lug sleeve (450) is also provided below the crossbeam lifting lug (440). The third lifting lug sleeve (450) is connected to the first main rib plate (410) and the second main rib plate (420) respectively. A third through hole (451) coaxial with the second through hole (442) is provided on the third lifting lug sleeve (450). The inner diameter of the third through hole (451) is larger than the inner diameter of the second through hole (442).

16. The tray frame according to claim 13, characterized in that, The first main rib (410) and the second main rib (420) are provided with mutually cooperating clearance notches (470), and the clearance notches (470) are provided at least one in the middle and one at both ends of the first main rib (410) or the second main rib (420). The shape of the secondary rib (430) is adapted to the shape of the first main rib (410) and the second main rib (420).

17. The tray frame according to claim 13, characterized in that, Both the first main rib (410) and the second main rib (420) are provided with a connecting platform (460) at the end opposite to the secondary rib (430). The connecting platform (460) is located on the side opposite to each other of the first main rib (410) and the second main rib (420). The connecting platform (460) is used to connect to a pallet bottom plate (500) of the pallet.

18. A tray, characterized in that, It includes a pallet base plate (500) and a pallet frame as described in any one of claims 1-17, wherein the pallet frame is connected to the pallet base plate (500).

19. A battery pack, characterized in that, It includes a battery pack body and the tray as described in claim 18, the tray being connected to the battery pack body.

20. An electrical appliance, characterized in that, It includes a device body and a battery pack as described in claim 19, wherein the battery pack is fixed to the device body.

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