A battery pack housing structure

Abstract

This invention relates to a battery pack housing structure, belonging to the field of power batteries. It includes a roll-formed steel frame, with welded nuts on both sides of the frame. These nuts are screwed onto extruded aluminum alloy lifting lugs. A liquid cooling plate is connected to the roll-formed steel frame via blind rivets. A rivet nut penetrates the liquid cooling plate on the roll-formed steel frame. This invention utilizes rivet nuts to connect the bottom protective plate and blind rivets to connect the liquid cooling plate, and fully welds the roll-formed steel frame and bottom protective plate. This avoids ribs and bolt marks on the bottom protective plate and prevents interference with the sensors at the battery swapping station. The supporting aluminum block and foam ensure the bottom protective plate meets strength requirements during transport. The welded nuts on both sides of the roll-formed steel frame enhance the overall rigidity of the housing. The extruded aluminum alloy lifting lugs allow for secondary CNC machining after welding. The installation holes and surfaces of the lifting lugs on the roll-formed steel housing do not need to be pre-machined, avoiding splicing errors and welding deformation.

Description

Technical Field

[0001] This invention belongs to the field of power battery technology, and specifically relates to a battery pack housing structure. Background Technology

[0002] With the rapid development of new energy vehicles, the demand in the battery swapping field is also growing. Currently, the battery pack enclosures used in the battery swapping field are mainly made of aluminum alloy, which is relatively expensive. In comparison, battery pack enclosures manufactured by conventional sheet metal stamping and roll forming processes have lower dimensional accuracy and rigidity, but are more cost-effective.

[0003] The mounting holes and surfaces of the lifting lugs in battery pack enclosures manufactured using roll forming steel technology need to be machined before welding. Errors in enclosure splicing and welding deformation result in low dimensional accuracy of the finished enclosure. Furthermore, due to the process factors of roll forming steel and the need for lightweighting, roll forming steel enclosures typically use thin-walled, simple-section roll forming steel profiles as frames or beams, leading to insufficient overall rigidity. To address this, high-strength steel is used to enhance the overall rigidity, but its thin wall thickness prevents secondary CNC machining during welding. The bottom protective plate of the battery pack enclosure is usually thin-walled, but it must withstand the pressure of the conveyor belt during battery swapping. A thin-walled bottom protective plate cannot meet the strength requirements during transport. Moreover, the presence of punching ribs and bolt marks on the bottom protective plate can easily cause interference with sensors at the battery swapping station, making it difficult to apply in different swapping scenarios. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a battery pack housing structure, comprising a roll-formed steel frame, with welded nuts on both sides of the roll-formed steel frame, and extruded aluminum alloy lifting lugs screwed onto the welded nuts. A liquid cooling plate is connected to the roll-formed steel frame via blind rivets. A rivet nut penetrating the liquid cooling plate is provided on the roll-formed steel frame. A bottom protective plate is fully welded to one end of the roll-formed steel frame located on the liquid cooling plate. A supporting aluminum block is provided on the liquid cooling plate, which contacts the bottom protective plate. The bottom protective plate is plug-welded to the rivet nut. The space between the bottom protective plate and the liquid cooling plate is a filling cavity, and the filling cavity is filled with expanding foam.

[0005] Furthermore, the roll-formed steel frame includes a roll-formed steel frame, a crossbeam, and a longitudinal beam. The crossbeam is connected inside the roll-formed steel frame, and the longitudinal beam connected to the crossbeam is provided inside the roll-formed steel frame. Welded nuts are provided on both sides of the roll-formed steel frame.

[0006] Furthermore, the crossbeam includes a beam body and a transition plate, with transition plates provided at both ends of the beam body, and the transition plates are riveted to the roll-formed steel frame by blind rivets.

[0007] Furthermore, the extruded aluminum alloy lifting lug includes a connecting plate, a lifting plate, and bolts. The connecting plate is connected to the roll-formed steel frame by bolts, and the bolts are connected to welding nuts. The end of the connecting plate away from the roll-formed steel frame is provided with a lifting plate, and the lifting plate is provided with lifting holes.

[0008] Furthermore, the rivet nut includes a flange portion, a raised portion, and a collapsible portion connected in sequence along the vertical direction. The flange portion has a through hole that passes through the raised portion and the flange portion in sequence. The bottom guard plate is plug-welded to the flange portion. The collapsible portion passes through the crossbeam, and the raised portion passes through the liquid cooling plate.

[0009] Furthermore, the crossbeam is provided with mounting holes, and the liquid cooling plate is provided with through holes coaxial with the mounting holes. A portion of the collapsible portion is accommodated in the mounting holes, and a portion of the heightening portion is accommodated in the through holes.

[0010] Furthermore, the diameter of the flange is 15-35 mm.

[0011] Furthermore, the height of the raised portion is 3-20mm.

[0012] Furthermore, the liquid cooling plate is provided with a glue injection hole that communicates with the filling cavity.

[0013] Furthermore, the liquid cooling plate is provided with an exhaust hole that communicates with the filling cavity.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] 1) This invention utilizes rivet nuts to connect the bottom protective plate and blind rivets to connect the liquid cooling plate, and fully welds the roll-formed steel frame and the bottom protective plate. This avoids ribs and bolt marks on the bottom protective plate and does not interfere with the sensors of the battery swapping station, making it adaptable to different battery swapping scenarios. The supporting aluminum block and the filling foam ensure that the bottom protective plate meets the strength requirements during the transfer process. The welded nuts on both sides of the roll-formed steel frame enhance the overall rigidity of the box. The extruded aluminum alloy lifting lugs enable secondary CNC machining after splicing and welding. The extruded aluminum alloy lifting lugs are screwed to the roll-formed steel frame, eliminating the need to process the mounting holes and mounting surfaces of the roll-formed steel box lifting lugs before welding, avoiding splicing errors and welding deformation of the box, and improving the dimensional accuracy of the finished box.

[0016] 2) This invention uses rivet nuts to connect the bottom guard plate and the roll-formed steel frame of the box, which realizes the support and fixation of the bottom guard plate without concave ribs of the box, avoiding ribs and bolt marks.

[0017] 3) The flange portion of the rivet nut in this invention can increase the contact area and reduce stress. The raised portion can increase the distance between the collapsible portion and the flange portion, enabling rivet installation when the flange portion is far from the rivet mounting surface.

[0018] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description, claims and drawings. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the battery pack housing structure is shown;

[0021] Figure 2 A schematic diagram of the structure connecting the bottom guard plate and the roll-formed steel frame with rivet nuts is shown;

[0022] Figure 3 A schematic diagram showing the connection between the liquid cooling plate and the roll-formed steel frame using blind rivets is shown.

[0023] Figure 4 A schematic diagram showing the connection between the extruded aluminum alloy lifting lug and the roll-formed steel frame is shown;

[0024] Figure 5 A schematic diagram of the roll-formed steel frame is shown.

[0025] Figure 6 A schematic diagram showing the connection between the crossbeam and the roll-formed steel frame is shown;

[0026] Figure 7 A schematic diagram of the injection hole and vent hole is shown;

[0027] Figure 8 A schematic diagram of the rivet nut structure is shown.

[0028] Reference numerals: 1. Rolled steel frame; 11. Rolled steel frame edge; 111. Welded nut; 12. Crossbeam; 121. Beam body; 122. Adapter plate; 123. Mounting hole; 13. Longitudinal beam; 2. Liquid cooling plate; 21. Through hole; 22. Glue injection hole; 23. Vent hole; 3. Extruded aluminum alloy lifting lug; 31. Connecting plate; 32. Lifting plate; 321. Lifting hole; 33. Bolt; 4. Supporting aluminum block; 5. Bottom guard plate; 51. Filling cavity; 6. Rivet nut; 61. Flange; 62. Heightened part; 63. Collapsed part; 64. Through hole; 7. Blind rivet. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] Figure 1 A schematic diagram of the battery pack housing structure is shown. Figure 1 As shown, a battery pack housing structure includes a roll-formed steel frame 1, with welded nuts 111 on both sides of the roll-formed steel frame 1. Figure 4 A schematic diagram showing the connection between the extruded aluminum alloy lifting lug 3 and the roll-formed steel frame 11 is shown, as follows. Figure 4 As shown, the welded nut 111 is screwed with an extruded aluminum alloy lifting lug 3. Figure 2 A schematic diagram showing the structure of the rivet nut 6 connecting the bottom guard plate 5 and the roll-formed steel frame 1 is shown, as follows. Figure 2 As shown, a liquid cooling plate 2 is connected to the roll-formed steel frame 1 by a pop rivet 7. A rivet nut 6 is provided on the roll-formed steel frame 1 that penetrates the liquid cooling plate 2. A bottom guard plate 5 is fully welded to one end of the roll-formed steel frame 1 located at the liquid cooling plate 2. A supporting aluminum block 4 is provided on the liquid cooling plate 2 that contacts the bottom guard plate 5. The bottom guard plate 5 is plug-welded to the rivet nut 6. The space between the bottom guard plate 5 and the liquid cooling plate 2 is a filling cavity 51, and the filling cavity 51 is filled with expanding foam.

[0031] The battery pack housing structure utilizes blind rivets 7, rivet nuts 6, supporting aluminum blocks 4, extruded aluminum alloy lifting lugs 3, roll-formed steel frame 1, and welded nuts 111 connecting the extruded aluminum alloy lifting lugs 3 to the roll-formed steel frame 1. This solves the problem that the bottom protective plate 5 of the existing roll-formed steel housing is difficult to apply in different battery swapping scenarios; it solves the problem that the thin-walled bottom protective plate 5 cannot meet the strength requirements during transportation; it solves the problem that the roll-formed steel housing has a thin wall thickness, making it impossible to perform secondary CNC machining after welding; it solves the problem of the roll-formed steel housing having insufficient overall rigidity; and it solves the problem that the finished housing has low dimensional accuracy due to housing splicing errors and welding deformation.

[0032] Specifically, the foaming adhesive may be selected from, but is not limited to, polyurethane foaming adhesive.

[0033] Figure 5 A schematic diagram of the structure of the roll-formed steel frame 1 is shown. (See attached diagram.) Figure 5As shown, in some embodiments, the roll-formed steel frame 1 includes a roll-formed steel frame 11, a crossbeam 12, and a longitudinal beam 13. The crossbeam 12 is connected inside the roll-formed steel frame 11, and the longitudinal beam 13 connected to the crossbeam 12 is provided inside the roll-formed steel frame 11. Welded nuts 111 are provided on both sides of the roll-formed steel frame 11. The crossbeam 12 and the longitudinal beam 13 provide installation conditions for the liquid cooling plate 2 and provide support for the liquid cooling plate 2.

[0034] Figure 3 A schematic diagram showing the connection between the blind rivet 7 and the liquid cooling plate 2 and the roll-formed steel frame 1 is shown. Figure 3 As shown, in some embodiments, the roll-formed steel frame 11, the crossbeam 12 and the longitudinal beam 13 are all connected to the liquid cooling plate 2 by pop rivets 7; this ensures the connectivity between the liquid cooling plate 2 and the roll-formed steel frame 11 and provides reliability.

[0035] In some embodiments, the crossbeam 12 is connected to the liquid cooling plate 2 by a blind rivet 7; with the connection of the rivet nut 6, the blind rivets 7 are then used to rivet the adjacent positions to ensure the connection between the liquid cooling plate 2 and the crossbeam 12.

[0036] Figure 6 A schematic diagram showing the connection between the crossbeam 12 and the roll-formed steel frame 11 is provided. Figure 6 As shown, in some embodiments, the crossbeam 12 includes a beam body 121 and a transition plate 122. Both ends of the beam body 121 are provided with transition plates 122. The transition plates 122 are riveted to the roll-formed steel frame 11 by pop rivets 7. The riveting of the transition plates 122 and the roll-formed steel frame 11 by pop rivets 7 can reduce weld stress and welding deformation.

[0037] In some embodiments, the extruded aluminum alloy lifting lug 3 includes a connecting plate 31, a lifting plate 32, and bolts 33. The connecting plate 31 is connected to the roll-formed steel frame 11 by bolts 33, and the bolts 33 are connected to welding nuts 111. The end of the connecting plate 31 away from the roll-formed steel frame is provided with a lifting plate 32, and the lifting plate 32 is provided with a lifting hole 321. The connecting plate 31 serves to connect the roll-formed steel frame 11; the bolts 33 serve to connect the roll-formed steel frame 11 and the connecting plate 31; the lifting plate 32 is used as a load-bearing component for lifting; and the lifting hole 321 is used as a connection hole for lifting.

[0038] Figure 8 A schematic diagram of the rivet nut 6 is shown. Figure 8As shown, in some embodiments, the rivet nut 6 includes a flange portion 61, a raised portion 62, and a collapsible portion 63 connected vertically in sequence. The flange portion 61 has a through hole 64 that passes through the raised portion 62 and the flange portion 61 in sequence. The bottom guard plate 5 is plug-welded to the flange portion 61. The collapsible portion 63 passes through the crossbeam 12, and the raised portion 62 passes through the liquid cooling plate 2. The bottom guard plate 5 and the roll-formed steel frame 1 are connected by the rivet nut 6, that is, the collapsible portion 63 of the rivet nut 6 passes through the crossbeam 12, the raised portion 62 passes through the liquid cooling plate 2, and the bottom guard plate 5 is then plug-welded to the flange portion 61 of the rivet nut 6. This breaks the limitations of the connection. The bottom guard plate 5 can be directly connected to the roll-formed steel frame 1 without the need for concave ribs, avoiding the need for punching ribs and bolt marks 33.

[0039] In some embodiments, the through hole 64 is threaded at the location of the collapsible portion 63; this facilitates the use of the screw on an external rivet gun to pull the collapsible portion 63 of the rivet nut 6.

[0040] In some embodiments, the crossbeam 12 is provided with mounting holes 123, and the liquid cooling plate 2 is provided with through holes 21 coaxial with the mounting holes 123. A portion of the collapsible portion 63 is accommodated in the mounting holes 123, and a portion of the raised portion 62 is accommodated in the through holes 21. The mounting holes 123 and through holes 21 provide installation conditions for the rivet nuts 6 and also provide connection conditions for the liquid cooling plate 2 and the crossbeam 12.

[0041] Specifically, the beam 121 is provided with a plurality of evenly distributed mounting holes 123.

[0042] Specifically, the liquid cooling plate 2 is provided with a plurality of evenly distributed through holes 21.

[0043] In some embodiments, the flange portion 61 has a diameter of 15-35 mm; a flange portion 61 with a diameter of 15-35 mm can increase the contact area, reduce stress, and prevent deformation.

[0044] In some embodiments, the flange portion 61 has a diameter of 20 mm; a flange portion 61 with a diameter of 20 mm can increase the contact area, reduce stress, and avoid deformation; a flange portion 61 with a diameter of 20 mm and a raised portion 62 can enable riveting when the flange portion 61 is far from the riveting mounting surface.

[0045] In some embodiments, the height of the raised portion 62 is 3-20mm; the raised portion 62 with a height of 3-20mm and the flange portion 61 with a diameter of 15-35mm can achieve riveting when the flange portion 61 is far from the riveting mounting surface.

[0046] In some embodiments, the height of the raised portion 62 is 10 mm; the raised portion 62 with a height of 10 mm can increase the distance between the collapsible portion 63 and the flange portion 61; the raised portion 62 with a height of 10 mm and the flange portion 61 with a diameter of 20 mm can enable riveting when the flange portion 61 is far from the riveting mounting surface.

[0047] Figure 7 A schematic diagram of the injection hole 22 and the vent hole 23 is shown. Figure 7 As shown, in some embodiments, the liquid cooling plate 2 is provided with a glue injection hole 22 communicating with the filling cavity 51; glue is injected into the filling cavity 51 through the glue injection hole 22.

[0048] Specifically, the liquid cooling plate 2 is provided with a glue injection hole 22 that communicates with the filling cavity 51.

[0049] In some embodiments, the liquid cooling plate 2 is provided with an exhaust hole 23 communicating with the filling cavity 51; the exhaust hole 23 is used for venting the glue during injection.

[0050] Specifically, the liquid cooling plate 2 is provided with a plurality of exhaust holes 23 that communicate with the filling cavity 51.

[0051] The working principle of the battery pack housing structure is as follows:

[0052] By utilizing different materials, different connection methods, and adding supporting aluminum blocks 4, the adaptability to various scenarios is increased, enabling secondary CNC machining after welding, increasing overall rigidity, and improving the dimensional accuracy of the finished box. Specifically, the two ends of the crossbeam 12 are connected to the roll-formed steel frame 11 using blind rivets 7, and then the longitudinal beam 13 is welded to the roll-formed steel frame 11 and simultaneously welded to the crossbeam 12. The roll-formed steel frame 1 and the liquid cooling plate 2 are then connected using blind rivets 7, and the crossbeam 12 and the bottom guard plate 5 are connected using rivet nuts 6. The bottom guard plate 5 and the roll-formed steel frame 11 are then fully welded, and foaming adhesive is injected into the filling cavity 51 through the glue injection hole 22. During the glue application process, the vent hole 23 releases air.

[0053] Using rivet nuts 6 to connect the bottom guard plate 5 and the liquid cooling plate 2, and fully welding the roll-formed steel frame 1 and the bottom guard plate 5, can avoid the punching ribs and bolt marks 33 on the bottom guard plate 5, and will not interfere with the sensors of the battery swapping station, and can adapt to different battery swapping scenarios; the supporting aluminum block 4 and the filling foam can ensure that the bottom guard plate 5 meets the strength requirements during the transmission process; the welded nuts 111 on both sides of the roll-formed steel frame 1 can enhance the overall rigidity of the box; the extruded aluminum alloy lifting lugs 3 can realize secondary CNC machining after splicing and welding; the extruded aluminum alloy lifting lugs 3 are screwed to the roll-formed steel frame 1, eliminating the need to complete the processing of the mounting holes and mounting surfaces of the roll-formed steel box lifting lugs before welding, avoiding splicing errors and welding deformation of the box, and improving the dimensional accuracy of the finished box.

[0054] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A battery pack housing structure, characterized in that, The system includes a roll-formed steel frame (1), with welded nuts (111) on both sides of the roll-formed steel frame (1). The welded nuts (111) are screwed with extruded aluminum alloy lifting lugs (3). A liquid cooling plate (2) is connected inside the roll-formed steel frame (1) by a blind rivet (7). A rivet nut (6) penetrating the liquid cooling plate (2) is provided on the roll-formed steel frame (1). A bottom guard plate (5) is fully welded to one end of the roll-formed steel frame (1) located on the liquid cooling plate (2). A supporting aluminum block (4) is provided on the liquid cooling plate (2) and contacts the bottom guard plate (5). The bottom guard plate (5) is plug-welded to the rivet nut (6). The space between the bottom guard plate (5) and the liquid cooling plate (2) is a filling cavity (51). The filling cavity (51) contains a... The foaming adhesive, the rivet nut (6) includes a flange (61), a raised part (62) and a collapsible part (63) connected in sequence along the vertical direction. The flange (61) is provided with a through hole (64) that passes through the raised part (62) and the flange (61) in sequence. The bottom guard plate (5) is plug-welded to the flange (61). The collapsible part (63) is installed on the crossbeam (12). The raised part (62) is installed on the liquid cooling plate (2). The crossbeam (12) is provided with a mounting hole (123). The liquid cooling plate (2) is provided with a through hole (21) coaxial with the mounting hole (123). A part of the collapsible part (63) is accommodated in the mounting hole (123), and a part of the raised part (62) is accommodated in the through hole (21).

2. The battery pack housing structure according to claim 1, characterized in that, The roll-formed steel frame (1) includes a roll-formed steel frame (11), a crossbeam (12) and a longitudinal beam (13). The roll-formed steel frame (11) is connected to the crossbeam (12), and the roll-formed steel frame (11) is provided with a longitudinal beam (13) connected to the crossbeam (12). Welded nuts (111) are provided on both sides of the roll-formed steel frame (11).

3. The battery pack housing structure according to claim 2, characterized in that, The crossbeam (12) includes a beam body (121) and a transition plate (122). Both ends of the beam body (121) are provided with transition plates (122). The transition plates (122) are riveted to the roll-formed steel frame (11) by pop rivets (7).

4. The battery pack housing structure according to claim 1, characterized in that, The extruded aluminum alloy lifting lug (3) includes a connecting plate (31), a lifting plate (32) and a bolt (33). The connecting plate (31) is connected to the roll-formed steel frame (11) by the bolt (33). The bolt (33) is connected to the welding nut (111). The end of the connecting plate (31) away from the roll-formed steel frame is provided with a lifting plate (32). The lifting plate (32) is provided with a lifting hole (321).

5. The battery pack housing structure according to claim 1, characterized in that, The diameter of the flange (61) is 15-35 mm.

6. The battery pack housing structure according to claim 1, characterized in that, The height of the raised part (62) is 3-20mm.

7. The battery pack housing structure according to any one of claims 1 to 6, characterized in that, The liquid cooling plate (2) is provided with a glue injection hole (22) that communicates with the filling cavity (51).

8. The battery pack housing structure according to any one of claims 1 to 6, characterized in that, The liquid cooling plate (2) is provided with an exhaust hole (23) that communicates with the filling cavity (51).

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