Battery box assembly and processing method of water cooling plate of battery box assembly

Abstract

The invention discloses a battery box assembly and a processing method of a water cooling plate of the battery box assembly. The battery box assembly comprises a box body, a plurality of battery modules, a copper bar assembly, a signal line assembly and a cooling pipeline. The box body is provided with a cavity and a side opening communicated with the cavity, each battery module is arranged in the cavity, the copper bar assembly is located on one side of the side opening and electrically connected with the battery modules, the signal line assembly is located on one side, away from the battery modules, of the copper bar assembly and electrically connected with the battery modules, and the cooling pipeline is located on the side opening. The cooling pipeline is located on the side, away from the copper bar assembly, of the signal line assembly. At least part of structures of any two of the copper bar assembly, the signal line assembly and the cooling pipeline are arranged in a staggered mode. The layout of the copper bar assembly, the signal line assembly, the cooling pipeline and the like in the battery box assembly avoids each other, so that the maintenance of each structural member in the battery box assembly is very convenient, and the rationality of process disassembly and assembly is stronger.

Description

Technical Field

[0001] The present invention relates to the field of battery technology, and in particular to a processing method of a battery box assembly and a water cooling plate thereof. Background Art

[0002] The battery box usually has a box body, a battery module, a copper busbar assembly, a signal line assembly and a cooling pipeline. The box body has a cavity and a side opening. Each battery module is stacked in the cavity. The copper busbar assembly, the signal line assembly and the cooling pipeline are all located on the side opening and are arranged in sequence from the inside to the outside. The three are stacked on each other, the signal line assembly usually covers the copper busbar assembly, and the cooling pipe covers the top of the signal line assembly and the copper busbar assembly. That is, the setting positions and extension tracks of the copper busbar assembly, the signal line assembly and the cooling pipeline have a lot of overlap or proximity, which makes it difficult to repair the inside of the battery box.

[0003] For example, when a copper busbar is damaged and needs to be repaired, the cooling pipeline must usually be removed first and the coolant must be released. Then the signal line assembly can be removed before the copper busbar can be repaired or replaced. This does not meet the convenience of process disassembly and assembly, and the maintenance cost and labor cost are high.

[0004] In view of this, the present invention is proposed. Summary of the invention

[0005] In order to solve one of the above technical problems, the present invention provides a processing method of a battery box assembly and a water cooling plate thereof.

[0006] The present invention adopts the following technical solutions:

[0007] The first object of the present application is to provide a battery box assembly, comprising:

[0008] A box body, the box body having a cavity and a side opening communicating with the cavity;

[0009] A plurality of battery modules, each of which is disposed in the cavity;

[0010] A copper busbar assembly, the copper busbar assembly is located at one side of the side opening, and the copper busbar assembly electrically connects the battery modules;

[0011] A signal line assembly, the signal line assembly is located on a side of the copper busbar assembly away from the battery module, and the signal line assembly is electrically connected to each of the battery modules;

[0012] A cooling pipeline, the cooling pipeline is located at the side port, and the cooling pipeline is located at a side of the signal line assembly away from the copper busbar assembly;

[0013] Wherein, at least part of the structures of any two of the copper busbar assembly, the signal line assembly and the cooling pipeline are staggered.

[0014] Optionally, the battery modules are arranged in multiple rows, and in two upper and lower adjacent rows of battery modules, the battery modules in one are all first battery modules, and the battery modules in the other row are all second battery modules;

[0015] In the first battery module and the second battery module that are adjacent to each other vertically, the positive electrode interface of one and the negative electrode interface of the other are located on the same longitudinal line;

[0016] The copper bar assembly includes a plurality of longitudinal copper bars and a plurality of transverse copper bars;

[0017] The longitudinal copper bar extends in the longitudinal direction, and the positive electrode interface and the negative electrode interface of two upper and lower adjacent battery modules are electrically connected through the longitudinal copper bar;

[0018] The transverse copper bar extends in a direction perpendicular to the longitudinal copper bar, and at least two adjacent battery modules in the same row of battery modules are connected via the transverse copper bar.

[0019] Optionally, a BMS slave board is provided in each row of battery modules, and the BMS slave board data is connected to multiple battery modules;

[0020] The signal line assembly includes a plurality of low-voltage collection harness groups, one end of each of the low-voltage collection harness groups is connected to a plurality of battery modules, and the other end is connected to a corresponding BMS slave board;

[0021] Among them, each low-voltage collection harness group and the longitudinal copper busbar are staggered.

[0022] Optionally, the signal line assembly further includes a main line harness;

[0023] The main wire harness is located in the middle of the side opening and extends in the longitudinal direction.

[0024] Optionally, the cooling pipeline includes a water inlet main pipeline, a water outlet main pipeline, a plurality of first slave pipelines, a plurality of second slave pipelines and a plurality of third slave pipelines;

[0025] One end of each of the first slave pipelines is connected to the corresponding battery module on the first side of each row of battery modules, and the other end of each of the first slave pipelines is connected to the water inlet main pipeline;

[0026] One end of each of the second slave pipelines is connected to the corresponding battery module on the second side of each row of battery modules, and the other end of each of the second slave pipelines is connected to the water outlet main pipeline;

[0027] Two adjacent battery modules in the same row are connected via a third slave pipeline;

[0028] Wherein, each of the water inlet main pipeline, the water outlet main pipeline, the first slave pipeline, the second slave pipeline and the third slave pipeline are staggered with respect to the signal line assembly and the copper busbar assembly.

[0029] Optionally, both the main water inlet pipeline and the main water outlet pipeline are located on one side of the middle part of the side port and extend longitudinally.

[0030] The main water inlet pipeline and the main water outlet pipeline are respectively arranged on both sides of the main wire harness.

[0031] Optionally, the box body includes a top frame, a bottom frame and a peripheral frame.

[0032] The peripheral frame is arranged on the edge of the bottom frame, and the top frame is connected to the peripheral frame.

[0033] The top frame, the bottom frame and the peripheral frame enclose to form the side port.

[0034] A plurality of aviation connectors are arranged on the bottom frame, and each aviation connector is selected from a main positive plug, a main negative plug, a wire harness plug and a water nozzle.

[0035] Among them, the main positive plug is electrically connected to the copper row assembly, the wire harness plug is connected to the signal wire assembly, and the water nozzle is connected to the cooling pipeline.

[0036] Optionally, the battery module includes a water cooling plate and a plurality of battery cells, and each battery cell is attached to the water cooling plate.

[0037] The water cooling plate includes:

[0038] A water cooling plate body, the water cooling plate body includes two first main boards, a second main board and two side blocking strips, the first main board and the second main board are arranged at intervals and in parallel, the two side blocking strips are respectively arranged on both sides of the first main board, and the side blocking strips respectively connect the first main board and the second main board, the first main board, the second main board and the two side blocking strips enclose to form an inner cavity and a front port and a rear port communicating with the inner cavity.

[0039] A plurality of rib strips, each rib strip is located in the inner cavity, each rib strip respectively connects the first main board and the second main board, and the rib strip extends from one front port to the rear port.

[0040] A front plug and a rear plug, the front plug and the rear plug are respectively arranged at both ends of the water cooling plate body and respectively seal the front port and the rear port of the water cooling plate body.

[0041] Among them, the endpoints on the same side of at least some adjacent rib strips are located on the same locus circle.

[0042] The second object of the present application is to provide a processing method for the water cooling plate of the battery box assembly, including: controlling the large turning tool to extend into the inner cavity to cut each rib strip so that the endpoints of at least some rib strips are located on the same locus circle.

[0043] Optionally, the processing method of the water cooling plate includes:

[0044] Controlling the large disc cutter to extend into the inner cavity from the front port and cutting each of the ribs so that the endpoints of at least some adjacent ribs close to the front port are located on the same locus circle;

[0045] Controlling the large disc cutter to extend into the inner cavity from the rear port and cutting each of the ribs so that the endpoints of at least some adjacent ribs close to the rear port are located on the same locus circle.

[0046] Optionally, the step of controlling the large disc cutter to extend into the inner cavity from the front port and cutting each of the ribs so that the endpoints of at least some adjacent ribs close to the front port are located on the same locus circle includes: first controlling the large disc cutter to extend into the inner cavity from the front port and cutting each of the flow dividing ribs on one side of the isolation rib so that the corresponding endpoints of each of the flow dividing ribs on one side of the isolation rib are located on the first locus circle, and then controlling the large disc cutter to extend into the inner cavity from the front port and cutting each of the flow dividing ribs on the other side of the isolation rib so that the corresponding endpoints of each of the flow dividing ribs on the other side of the isolation rib are located on the second locus circle;

[0047] The step of controlling the large disc cutter to extend into the inner cavity from the rear port and cutting each of the ribs so that the endpoints of at least some adjacent ribs close to the rear port are located on the same locus circle includes: controlling the large disc cutter to extend into the inner cavity from the rear port and cutting the isolation rib and each of the flow dividing ribs so that the endpoints on the corresponding sides of the isolation rib and each of the flow dividing ribs are located on the third locus circle.

[0048] By adopting the above technical solutions, the present application has the following beneficial effects:

[0049] The layouts of the copper row assembly, signal line assembly, cooling pipeline, etc. in the battery box assembly of the present application avoid each other and do not affect each other, making the maintenance of each structural member in the battery box assembly very convenient and the rationality of process disassembly and assembly stronger. When a certain part in the box needs to be repaired or replaced, for example, when the copper row is damaged and needs to be replaced, there is no need to remove the signal line assembly and the cooling pipeline, and the copper row is directly exposed at the side port without obstruction, facilitating the operator to directly operate and replace the copper row. When the terminal of the signal line assembly is damaged and the wiring harness terminal needs to be repaired, there is no need to remove the cooling pipeline or the copper row assembly, and the wiring harness is directly exposed at the side port without obstruction, facilitating the staff to directly operate and replace the wiring harness. For another example, when the water pipe is damaged and needs to be replaced, it does not affect the copper row assembly and the signal line assembly either, and it can be directly replaced.

[0050] The following further describes in detail the specific embodiments of the present invention with reference to the accompanying drawings. Description of the Drawings

[0051] The accompanying drawings, as part of this application, are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention, but do not constitute an improper limitation to the present invention. Obviously, the accompanying drawings in the following description are only some embodiments. For those of ordinary skill in the art, other accompanying drawings can be obtained based on these drawings without creative efforts. In the accompanying drawings:

[0052] Figure 1 It is a schematic three-dimensional structure diagram of the battery box assembly provided by the embodiment of this application;

[0053] Figure 2 It is a schematic structure diagram of each battery module of the battery box assembly provided by the embodiment of this application;

[0054] Figure 3 It is a state diagram of each battery module of the battery box assembly provided by the embodiment of this application connected by a copper busbar assembly;

[0055] Figure 4 It is a schematic layout diagram of the signal line assembly and the copper busbar assembly in the battery box assembly provided by the embodiment of this application;

[0056] Figure 5 It is a schematic layout diagram of the signal line assembly, the copper busbar assembly and the cooling pipeline in the battery box assembly provided by the embodiment of this application;

[0057] Figure 6 It is a bottom view of the battery box assembly provided by the embodiment of this application;

[0058] Figure 7 It is a schematic layout diagram of the support sheet metal assembly in the battery box assembly provided by the embodiment of this application;

[0059] Figure 8 It is a perspective view of the water-cooled plate in the battery box assembly provided by the embodiment of this application;

[0060] Figure 9 It is a cross-sectional view of the partial structure of the water-cooled plate in the battery box assembly provided by the embodiment of this application;

[0061] Figure 10 It is a schematic structure diagram of the box body of the battery box assembly provided by the embodiment of this application without connecting the door cover and the aluminum alloy skin;

[0062] Figure 11 It is a schematic structure diagram of the aluminum alloy frame and fasteners of the box body of the battery box assembly provided by the embodiment of this application;

[0063] Figure 12 It is a schematic structure diagram of the high-strength steel laminate of the box body of the battery box assembly provided by the embodiment of this application;

[0064] Figure 13 It is a schematic structural diagram of the aluminum alloy skin of the box body of the battery box assembly provided by the embodiment of the present application;

[0065] Figure 14 It is a schematic structural diagram of the door cover and the gasket of the box body of the battery box assembly provided by the embodiment of the present application;

[0066] Figure 15 It is an enlarged view of a partial structure of the aluminum alloy frame of the box body of the battery box assembly provided by the embodiment of the present application;

[0067] Figure 16 It is a cross-sectional view of the fastener connecting the high-strength steel laminate and the cross beam of the box body of the battery box assembly provided by the embodiment of the present application;

[0068] Figure 17 It is a partial enlarged view of the side of the high-strength steel laminate close to the disassembly and assembly port in the box body of the battery box assembly provided by the embodiment of the present application.

[0069] In the figure: aluminum alloy frame 1, bottom frame 11, rear frame 12, top frame 13, side frame 14, cross beam 141, rivet nut 1411, column 142, high-strength steel laminate 2, extension piece part 21, connection hole 211, avoidance notch 22, hollow strip groove 23, through hole 24, aluminum alloy skin 31, aluminum alloy laminate 32, door cover 4, fastener 5, stud 51, nut 52, gasket 6, battery module 7, first battery module 7a, second battery module 7b, water cooling plate 71, first main board 711a, second main board 711b, side baffle 712, front port 713, rear port 714, isolation rib 715, shunt rib 716, front plug 717, rear plug 718, end insertion cavity 719, inner cavity 720, residual rib 730, copper row assembly 8, longitudinal copper row 81, transverse copper row 82, signal line assembly 9, low-voltage acquisition wire harness group 91, main wire harness 92, cooling pipeline 10, water inlet main pipeline 101, water outlet main pipeline 102, first branch pipeline 103, second branch pipeline 104, BMS branch board a, total positive plug-in b1, total negative plug-in b2, wire harness plug-in c, water nozzle d, first track circle g, second track circle h, third track circle i, side port j, MSD100, support sheet metal assembly 200.

[0070] It should be noted that these drawings and text descriptions are not intended to limit the scope of the concept of the present invention in any way, but to illustrate the concept of the present invention to those skilled in the art by referring to specific embodiments. Detailed implementation manners

[0071] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention but are not used to limit the scope of the present invention.

[0072] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention.

[0073] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "installation" and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0074] Embodiment 1

[0075] As Figures 1 to 17 shown, an embodiment of the present application provides a battery box assembly, including: a box body, a plurality of battery modules 7, a copper busbar assembly 8, a signal line assembly 9, and a cooling pipeline 10. The box body has a cavity and a side port j communicating with the cavity. Each of the battery modules 7 is disposed in the cavity. The copper busbar assembly 8 is located on one side of the side port j. The copper busbar assembly 8 electrically connects each of the battery modules 7. The signal line assembly 9 is located on the side of the copper busbar assembly 8 facing away from the battery modules 7. The signal line assembly 9 electrically connects each of the battery modules 7. The cooling pipeline 10 is located at the side port j. The cooling pipeline 10 is located on the side of the signal line assembly 9 facing away from the copper busbar assembly 8. At least a part of the structures of any two of the copper busbar assembly 8, the signal line assembly 9, and the cooling pipeline 10 are misaligned.

[0076] The copper busbar assembly 8, the signal line assembly 9, the cooling pipeline 10, etc. in the battery box assembly of the present application are arranged in sequence from inside to outside, and their layouts avoid each other and do not affect each other, making the maintenance of each structural member in the battery box assembly very convenient and the rationality of process disassembly and assembly stronger. When a certain part in the box body needs to be repaired or replaced, for example, when a part of the copper busbar of the copper busbar assembly 8 is damaged and needs to be replaced, there is no need to remove the signal line assembly 9 and the cooling pipeline 10. The copper busbar is directly exposed at the side port j without obstruction, facilitating the operator to directly operate and replace the copper busbar. When the terminal of the signal line assembly 9 is damaged and the wire harness terminal needs to be repaired, there is no need to remove the cooling pipeline 10 or the copper busbar assembly 8. The wire harness is directly exposed at the side port j without obstruction, facilitating the staff to directly operate and replace the wire harness. For another example, when the water pipe of the cooling pipeline 10 is damaged and needs to be replaced, it does not affect the copper busbar assembly 8 and the signal line assembly 9 either, and it can be directly replaced.

[0077] It should be noted that in this application, the at least partial structural misalignment of any two of the copper busbar assembly 8, the signal line assembly 9, and the cooling pipeline 10 should be understood as: at least one of the installation positions and extension directions of any two of the copper busbar assembly 8, the signal line assembly 9, and the cooling pipeline 10 is different, and the projections of any two on the plane where the side port j is located have an interval or an intersection, but the extension directions of the projections are different, and one will not completely cover the top of the other.

[0078] In some possible implementation schemes, as Figure 3 shown, each of the battery modules 7 is arranged in multiple rows. Among two adjacent rows of battery modules 7 up and down, each battery module 7 in one row is a first battery module 7a, and each battery module 7 in the other row is a second battery module 7b. Among the adjacent first battery module 7a and the second battery module 7b up and down, the positive electrode interface of one and the negative electrode interface of the other are located on the same longitudinal line. The copper busbar assembly 8 includes a plurality of longitudinal copper busbars 81 and a plurality of transverse copper busbars 82. The longitudinal copper busbars 81 extend longitudinally, and the positive electrode interfaces and negative electrode interfaces of two adjacent battery modules 7 up and down are electrically connected through the longitudinal copper busbars 81. The transverse copper busbars 82 extend in a direction perpendicular to the longitudinal copper busbars 81, and at least some adjacent two battery modules 7 in the same row of battery modules 7 are connected through the transverse copper busbars 82.

[0079] The longitudinal copper busbars 81 extend in a direction perpendicular to the bottom frame of the box body. Through the reasonable layout of the first battery module 7a and the second battery module 7b, the copper busbar assembly 8 does not need to be provided with inclined copper busbars, that is, the problem of cross-arrangement of copper busbars is avoided, and all the copper busbars extending longitudinally or transversely are adopted, making the layout of the copper busbar assembly 8 regular and orderly, which is convenient for the subsequent orderly layout of the signal line assembly 9 and the cooling pipeline 10. Among them, the MSD100 of the battery box assembly is in an open state during the installation process to ensure connection safety.

[0080] In some possible implementation schemes, as Figure 2 and Figure 4 shown, one BMS slave board a is arranged in each row of battery modules 7, and the BMS slave board a is data-connected to a plurality of battery modules 7. The signal line assembly 9 includes a plurality of low-voltage acquisition harness groups 91. One end of each low-voltage acquisition harness group 91 is connected to a plurality of battery modules 7, and the other end is connected to the corresponding BMS slave board a. As Figure 2 shown, there are three battery modules 7 in each layer, and every three battery modules 7 are connected to the same BMS slave board a through the low-voltage acquisition harness group 91. The broken line or straight line in the figure can be understood as a low-voltage acquisition harness group 91, and the three battery modules 7 passed through by the extension of the broken line are all connected to the same low-voltage acquisition harness group 91.

[0081] Among them, each low-voltage collection harness group 91 and the longitudinal copper bar 81 are staggered, and each low-voltage collection harness group 91 avoids the inner longitudinal copper bar 81 and the transverse copper bar 82, which does not affect the subsequent separate disassembly and assembly of each copper bar.

[0082] In some possible implementations, such as Figure 4 As shown, the signal line assembly 9 also includes a main wire harness 92, which is located in the middle of the side opening j and extends in the longitudinal direction. Each of the low-voltage collection wire harness groups 91 is connected to the main wire harness 92. The main wire harness 92 is located in the middle of the side opening j, which is conducive to avoiding the copper busbar assembly 8. Each low-voltage collection wire harness group 91 is located on both sides of the main wire harness 92, and the signal line assembly 9 is arranged neatly and orderly.

[0083] In some possible implementation schemes, the cooling pipeline 10 includes a water inlet main pipeline 101, a water outlet main pipeline 102, multiple first slave pipelines 103, multiple second slave pipelines 104 and multiple third slave pipelines, each of the first slave pipelines 103 is connected to the corresponding battery module 7 on the first side of each row of battery modules 7 at one end, and the other end of each of the first slave pipelines 103 is connected to the water inlet main pipeline 101, and each of the second slave pipelines 104 is connected to the corresponding battery module 7 on the second side of each row of battery modules 7 at one end, and the other end of each of the second slave pipelines 104 is connected to the water outlet main pipeline 102, and two adjacent battery modules 7 in the same row are connected by a third slave pipeline, wherein each of the water inlet main pipeline 101, the water outlet main pipeline 102, the first slave pipeline 103, the second slave pipeline 104 and the third slave pipeline are staggered with the signal line assembly 9 and the copper busbar assembly 8. It should be noted that the staggered setting here has the same meaning as the misaligned setting mentioned above.

[0084] Among them, Figure 4 and Figure 5 As shown, the water inlet main line 101 and the water outlet main line 102 are both located on one side of the middle of the side port j and extend longitudinally, and the water inlet main line 101 and the water outlet main line 102 are respectively arranged on both sides of the main wiring harness 92. The water inlet main line and the water outlet main line will not block the main wiring harness 92.

[0085] In some possible embodiments, combined with Figure 5 , Figure 6 , Figure 10 and Figure 11As shown in the figure, the box body includes a top frame 13, a bottom frame 11 and a peripheral frame. The peripheral frame is arranged at the edge of the bottom frame 11. The peripheral frame includes a side frame 14 and a rear frame 12. The top frame 13 is connected to the peripheral frame. The top frame 13, the bottom frame 11 and the peripheral frame enclose to form the side opening j. A plurality of aviation plugs are arranged on the bottom frame 11. Each of the aviation plugs is selected from a main positive plug b1, a main negative plug b2, a wire harness plug c and a water nozzle d. Among them, the main positive plug b1 is electrically connected to the copper busbar assembly 8, the wire harness plug c is connected to the signal line assembly 9, and the water nozzle d is connected to the cooling pipeline 10.

[0086] Each aviation plug is arranged at the bottom of the box body assembly, and there is no need to set a maintenance window on the peripheral frame of the box body. The four sides of the battery box assembly can be directly sealed, so that the sealing performance is better guaranteed. For commercial vehicles, especially commercial heavy trucks, the water cooling system of heavy trucks is integrated at the bottom of the battery box assembly. When the aviation plugs are also located at the bottom, the material loss of the external connectors of the aviation plugs is saved, and the layout is more concentrated, improving the safety and aesthetics.

[0087] As Figure 7 As shown in the figure, a support sheet metal assembly 200 is further arranged inside the box body. The support sheet metal assembly 200 includes a plurality of support members. All the support members are installed on the box body. The support members are provided with installation holes, and the copper busbar assembly 8, the signal line assembly 9 and the cooling pipeline 10 can be connected and fixed by mushroom head cable ties to prevent shaking.

[0088] Embodiment 2

[0089] Refer to Figures 10 to 17As shown in the figure, the embodiments of the present application will describe the box in detail. The box includes: an aluminum alloy frame 1, a plurality of high-strength steel laminates 2, a plurality of battery modules, an aluminum alloy sealing plate, and a door cover 4. The aluminum alloy frame 1 encloses to form a cavity and a side port communicating with the cavity. Each of the high-strength steel laminates 2 is located inside the cavity, and each of the high-strength steel laminates 2 is arranged in sequence along the height direction of the aluminum alloy frame 1. Each of the high-strength steel laminates 2 divides the cavity into a plurality of module cavities, and the high-strength steel laminates 2 are detachably connected to the aluminum alloy frame 1 through fasteners 5. The high-strength steel laminate 2 means that the laminate is made of high-strength steel plate. The high-strength steel plate (high-strength plate) has high strength, especially in the normalized or normalized and tempered state, it has high comprehensive mechanical properties. The high-strength steel laminate 2 has significantly enhanced tensile strength compared with the aluminum alloy laminate, can withstand greater pressure, and can maintain good shape stability and deformation ability, increasing the bearing capacity and service life. Each of the battery modules is respectively arranged in a corresponding module cavity. The aluminum alloy sealing plate is connected to the aluminum alloy frame 1. The door cover 4 is detachably connected to the aluminum alloy frame 1 to close the side port, and the door cover 4 and the aluminum alloy sealing plate cooperate to close the cavity. In the multi-layer steel-aluminum hybrid battery box of the present application, a plurality of battery modules are arranged instead of battery packs, which can effectively reduce the height of the entire box and save a lot of space. Moreover, the material is a combination of an aluminum alloy frame and high-strength steel laminates, which has a lower production cost compared with the all-aluminum material, is lighter in weight and more convenient for transportation compared with the all-steel material, and can stably support the battery modules. On the premise of ensuring the structural strength, the cost is reduced and the endurance of the electric vehicle using the box is improved.

[0090] As Figure 10 and Figure 11As shown, the aluminum alloy frame 1 includes a bottom frame 11, a top frame 13 and a peripheral frame. The peripheral frame includes a rear frame 12 and two side frames 14. The rear frame 12 and the two side frames 14 are both connected to the bottom frame 11. The two side frames 14 are located on both sides of the bottom frame 11. The rear frame 12 is located between the two side frames 14 and is respectively connected to the two side frames 14. The top frame 13 is respectively connected to the rear frame 12 and the two side frames 14. The bottom frame 11, the rear frame 12, the top frame 13 and the two side frames 14 enclose to form the cavity and the side opening. A module cavity is formed between adjacent ones of the bottom frame 11, the top frame 13 and each high-strength steel laminate 2, and each battery module is respectively arranged in a corresponding module cavity. Each high-strength steel laminate 2 is located between the two side frames 14, and the high-strength steel laminate 2 is respectively connected to the side frames 14 on both sides through fasteners 5. In the prior art, boxes made of all-aluminum materials or all-steel materials usually adopt welding processes for connection. Welding may cause deformation of the laminate, resulting in poor flatness of the installation surface of the battery module, and greatly reducing the energy density of the battery module. In the multi-layer steel-aluminum hybrid battery box of the present application, the high-strength steel laminates 2 are respectively connected to the side frames 14 on both sides through fasteners 5, reducing the deformation problem caused by welding, ensuring high flatness of the installation surface of the battery module, which is crucial for improving the overall energy density of the battery pack. The high-strength steel laminate 2 has high strength and low cost, not only maintaining the necessary structural strength, but also being relatively low in cost, thus achieving economic optimization without sacrificing performance.

[0091] As Figure 10 and Figure 11 shown, the side frame 14 has a plurality of cross beams 141. Each of the cross beams 141 is sequentially arranged at intervals along the height direction of the aluminum alloy frame 1. Both sides of the high-strength steel laminate 2 are respectively supported on the corresponding cross beams 141, and the fastener 5 passes through the high-strength steel laminate 2 and is connected to the cross beam 141. The plurality of cross beams 141 increase the structural strength of the side frame 14. Adopting the cold connection method of fastening connection reduces the deformation problem caused by welding, ensuring high flatness of the installation surface of the battery module. The cold connection method can not only avoid the degradation of material properties caused by the heat affected zone, but also simplify the production process, improve the assembly accuracy and consistency, which is beneficial to improving the quality and reliability of the multi-layer steel-aluminum hybrid battery box of the present application, and is convenient for disassembly and assembly.

[0092] In a possible implementation, as Figure 15 and Figure 16As shown, a rivet nut 1411 is provided on the crossbeam 141. The fastener 5 includes a stud 51 and a nut 52 connected to the stud 51, the stud 51 passes through the high-strength steel layer plate 2 and is connected to the rivet nut 1411, and the nut 52 is limited to the high-strength steel layer plate 2. The fastener 5 can be a bolt, and the rivet nut 1411 has a thread groove, the stud 51 passes through the high-strength steel layer plate 2 and is threadedly connected to the thread groove, and the nut 52 is limited to the side of the high-strength steel layer plate 2 away from the high-strength steel layer plate 2.

[0093] like Figure 10 , Figure 11 and Figure 12 As shown, the side frame 14 has a plurality of columns 142, each of the cross beams 141 is connected to the column 142, the column 142 is vertically connected to the column 142, and the cross beam 141 and the column 142 are staggered and connected to each other, and the structural strength is high. The edge of the high-strength steel layer plate 2 has a plurality of extension pieces 21, and avoidance gaps 22 are formed between adjacent extension pieces 21, and the column 142 passes through the avoidance gaps 22. The extension piece 21 is supported on the cross beam 141, and the extension piece 21 is connected to the cross beam 141 through a fastener 5. The extension piece 21 has a connecting hole 211, and the stud 51 of the fastener 5 passes through the connecting hole 211 and is threadedly connected to the thread groove of the rivet nut 1411, and the nut 52 is limited to the side of the high-strength steel layer plate 2 away from the high-strength steel layer plate 2.

[0094] In one possible embodiment, Figure 10 and Figure 13 As shown, the aluminum alloy cover plate includes an aluminum alloy skin 31 and an aluminum alloy layer plate 32. The aluminum alloy skin 31 covers the top frame 13, the side frame 14 and the rear frame 12, and the aluminum alloy layer plate 32 covers the side of the bottom frame 11 close to the top frame 13. The battery module on the layer of module cavity closest to the bottom frame 11 is supported by the aluminum alloy layer plate 32. The bottom frame 11 has a high structural strength. The bottom frame 11 can bear the weight of the battery module, thereby increasing the bearing capacity of the aluminum alloy layer plate 32 and making it less likely to deform.

[0095] like Figure 10 As shown, the aluminum alloy layer plate 32 extends out of the rear frame 12 and the side frame 14, so as to be in contact with the aluminum alloy skin 31. The aluminum alloy layer plate 32 is in contact with the aluminum alloy skin 31 and is sealed and welded. The sealing performance of the welded connection is good, and the side frame 14 can be at least supported by the aluminum alloy layer plate 32.

[0096] In one possible embodiment, Figure 12As shown, a plurality of hollow strip grooves 23 are formed on the surface of the high-strength steel laminate 2. The hollow strip grooves 23 serve to reduce weight, not only maintaining the necessary structural strength of the high-strength steel laminate 2, but also making the high-strength steel laminate 2 lighter in weight.

[0097] As Figure 12 and Figure 17 shown, a through hole 24 is provided on one side of the high-strength steel laminate 2 close to the side opening. The through hole 24 can be used to install a wire bundler for fixing cables. The wire bundler can include a wire bundling ring through which the cable passes. The wire bundler is connected to the through hole 24 and the wire bundler can be a cable tie.

[0098] In a possible implementation, as Figure 14 shown, the multi-layer steel-aluminum hybrid battery box body includes a sealing gasket 6. The sealing gasket 6 is located between the door cover 4 and the aluminum alloy frame 1. The sealing gasket 6 closes the gap between the door cover 4 and the aluminum alloy frame 1. The sealing gasket 6 serves to seal the gap between the door cover 4 and the aluminum alloy frame 1, ensuring the sealing performance of the multi-layer steel-aluminum hybrid battery box body of the present application.

[0099] Embodiment III

[0100] As Figures 8 to 9 shown, the battery module 7 of the battery box assembly in the embodiment of the present application is described. The battery module 7 includes a water-cooling plate 71 and a plurality of battery cells, and each battery cell is attached to the water-cooling plate 71. Among them, the water-cooling plate 71 includes: a water-cooling plate main body, a plurality of ribs, a front plug 717 and a rear plug 718. The water-cooling plate main body includes a first main board 711a, a second main board 711b and two side blocking strips 712. The first main board 711a and the second main board 711b are arranged at intervals and in parallel, that is, the first main board 711a and the second main board 711b are arranged in sequence along the thickness direction of the water-cooling plate 71. The two side blocking strips 712 are respectively disposed on both sides of the two first main boards 711a, and the side blocking strips 712 are respectively connected to the first main board 711a and the second main board. The first main board 711a, the second main board 711b and the two side blocking strips enclose an inner cavity 720 and two ports communicating with the inner cavity 720. Each rib is located in the inner cavity 720, and each rib is respectively connected to the first main board 711a and the second main board 711b. The rib extends from one port to the other port. The front plug 717 and the rear plug 718 are respectively disposed at both ends of the water-cooling plate main body and respectively close the two ports of the water-cooling plate main body. Among them, at least part of the endpoints on the same side of adjacent ribs are located on the same locus circle. For example, the endpoints on the same side of four, five or more adjacent ribs are located on the same locus circle.

[0101] It should be noted that in the above text, the first main board 711a and the second main board 711b can both be a single whole board body, or can both be formed by splicing multiple board bodies. For example, the first main board 711a can include two or even more board bodies, each board body is located in the same plane, and two adjacent board bodies are fixed by welding.

[0102] On the water-cooling plate 71 of the present application, the endpoints on the same side of at least some adjacent ribs are located on the same locus circle, so that each rib can be cut by a large-diameter cutter. Compared with the traditional ribs of equal length or arranged in steps, the processing efficiency is significantly improved, and the processing time is shortened to half. And according to the CAE (Computer Aided Engineering) simulation results of the water-cooling plate 71 provided in the embodiment of the present application, compared with the original stepped flow channel, the effect is not much different, that is, compared with the traditional water-cooling plate 71, the heat dissipation efficiency has no obvious difference.

[0103] The structure of the water-cooling plate 71 of the present application supports the processing by a large-diameter cutter. Compared with the traditional milling cutter processing, when using a large-diameter cutter to process the ribs in the flow channel, the single-cutter life is extremely high, and there will be no tool breakage, reducing the tool usage cost.

[0104] In some possible implementation schemes, the front plug 717 has a water inlet and a water outlet communicating with the inner cavity 720. Each of the ribs includes a partition rib 715 and a flow-dividing rib 716. The partition rib 715 and the flow-dividing rib 716 divide the inner cavity 720 to form a flow channel, and the water inlet and the water outlet are respectively communicated with both ends of the flow channel.

[0105] The partition rib 715 contacts the front plug 717. There is a gap between the partition rib 715 and the rear plug 718. Each endpoint of the flow-dividing ribs 716 between the partition rib 715 and the side baffle 712 on one side is located on the first locus circle g near the front plug 717. For example, the number of flow-dividing ribs 716 between the partition rib 715 and the side baffle 712 on one side can be three, four, five, etc. Among them, in each flow-dividing rib, in the direction from the middle to both sides, the extending length of each flow-dividing rib gradually decreases. That is, the endpoints of the flow-dividing ribs closer to the middle are closer to the corresponding ports. The center of the large-diameter cutter is roughly located on the median line of each flow-dividing rib.

[0106] The large-diameter cutter can include a disc body and a transmission shaft. A convex tooth is arranged along the periphery of one side of the disc body, and the transmission shaft is vertically connected to the center of the disc body. The driving mechanism is connected to the transmission shaft and can drive the large-diameter cutter to rotate at a high speed.

[0107] In some possible embodiments, each of the flow-dividing ribs 716 between the isolation rib 715 and the side stop rib 712 on the other side has endpoints on the second locus circle h on the side close to the front plug 717. That is, the large-diameter cutter needs to process the flow-dividing ribs on both sides of the isolation rib 715 separately in two times.

[0108] In some possible embodiments, the endpoints of each of the ribs on the side close to the rear plug 718 are located on the third locus circle i. All the ribs need to have a gap with the rear plug 718. Therefore, one end of each rib close to the rear plug 718 can be machined by the large-diameter cutter at one time, and all the ribs can be machined in place at one time.

[0109] In some possible embodiments, the first locus circle g, the second locus circle h, and the third locus circle i have equal radii. That is, the same large-diameter cutter is used for the three times of rib cutting, and there is no need to replace large-diameter cutters with different outer diameters, which reduces the processes and further improves the processing efficiency.

[0110] In some possible embodiments, on one side of the end of the water-cooling plate body where the inner cavity 720 is located, there is an end insertion cavity 719. The port communicates with the end insertion cavity 719. There is a gap between some ribs and the end insertion cavity 719. Remnant ribs 730 are provided on the inner walls of the first main board 711a and / or the second main board 711b between the ribs and the end insertion cavity 719. Both the front plug 717 and the rear plug 718 have insertion parts, and the insertion parts can be inserted into the corresponding end insertion cavities 719.

[0111] By forming the remnant ribs 730 between the ribs and the end insertion cavity 719, the remnant ribs 730 can act as reinforcing ribs, which is beneficial to improving the strength of the water-cooling plate 71 and reducing the deformation of the first main board 711a and the second main board 711b on the water-cooling plate 71.

[0112] In some possible embodiments, in the direction perpendicular to the first main board 711a, the extension dimension of the remnant rib 730 is smaller than that of the rib. In the direction perpendicular to the first main board 711a, the extension dimension of the remnant rib 730 is 0 to 0.25 mm. The remnant rib 730 is formed by the large-diameter cutter extending into the inner cavity 720 of the water-cooling plate body to cut the rib. After the rib is cut, its size becomes smaller. Since the position where the remnant rib 730 is located does not affect the installation of the plug, the smaller-sized remnant rib 730 will not affect the installation of the plug and will not cause liquid leakage of the water-cooling plate 71.

[0113] Specifically, the thickness of the large-diameter cutter can be about 0.5 to 1 mm smaller than the thickness (or height) of the inner cavity 720. There will be remnant ribs 730 about 0.2 mm on one side of the processed flow channel, which can improve the strength of the flow channel plate and reduce the deformation of the upper and lower surfaces of the flow channel plate.

[0114] In some possible embodiments, in the direction perpendicular to the first main board 711a, the extension dimension of the rib is smaller than the extension dimension of the end insertion cavity 719. In the direction perpendicular to the first main board 711a, the difference between the extension dimension of the end insertion cavity 719 and the extension dimension of the rib is 0.08 mm to 0.12 mm, that is, there is a dimension difference of 0.08 mm to 0.12 mm between the thickness of the end insertion cavity 719 and the middle position of the inner cavity 720. The end insertion cavity 719 can be formed by processing with a small disc cutter. The thickness of the small disc cutter is about 0.1 mm larger than the height (thickness) of the inner cavity 720. The residual rib 730 at the matching part of the runner plate can be completely removed, so that the inner surface of the end insertion cavity 719 is smooth. After the plug is inserted into the end insertion cavity 719, the plug and the inner wall of the end insertion cavity 719 are in close surface-to-surface fit, which can avoid stress concentration caused by the residual rib 730 remaining in the end insertion cavity 719 of the water-cooling plate 71 and cause coolant leakage.

[0115] It should be noted that one of the ports of the water-cooling plate 71 is the front port 713, and the other is the rear port 714. The front plug 717 and the rear plug 718 are respectively arranged at both ends of the water-cooling plate main body and respectively seal the front port 713 and the rear port 714 of the water-cooling plate main body. Among them, at least part of the endpoints on the same side of the adjacent ribs are located on the same locus circle.

[0116] The embodiment of the present application also provides a processing method for the water-cooling plate 71 of the battery box assembly, including: controlling the large disc cutter to extend into the inner cavity 720 to cut each of the ribs so that at least part of the endpoints of the ribs are located on the same locus circle.

[0117] Optionally, the processing method of the water-cooling plate 71 includes:

[0118] The step of controlling the large disc cutter to extend into the inner cavity 720 from the front port 713 to cut each of the ribs so that at least part of the endpoints of the adjacent ribs close to the front port 713 are located on the same locus circle;

[0119] The step of controlling the large disc cutter to extend into the inner cavity 720 from the rear port 714 to cut each of the ribs so that at least part of the endpoints of the adjacent ribs close to the rear port 714 are located on the same locus circle.

[0120] It should be noted that the above two steps are not in a specific order.

[0121] Such as Figure 8As shown, optionally, the step of making the large control cutter extend into the inner cavity 720 from the front port 713 to cut each of the ribs so that the endpoints of at least some adjacent ribs close to the front port 713 are located on the same locus circle includes: first, controlling the large control cutter to extend into the inner cavity 720 from the front port 713 and cutting each of the flow-dividing ribs 716 on one side of the isolation rib 715 so that the corresponding endpoints of each of the flow-dividing ribs 716 on one side of the isolation rib 715 are located on the first locus circle g; then, controlling the large control cutter to extend into the inner cavity 720 from the front port 713 and cutting each of the flow-dividing ribs 716 on the other side of the isolation rib 715 so that the corresponding endpoints of each of the flow-dividing ribs 716 on the other side of the isolation rib 715 are located on the second locus circle h.

[0122] The step of making the large control cutter extend into the inner cavity 720 from the rear port 714 to cut each of the ribs so that the endpoints of at least some adjacent ribs close to the rear port 714 are located on the same locus circle includes: controlling the large control cutter to extend into the inner cavity 720 from the rear port 714 and cutting the isolation rib 715 and each of the flow-dividing ribs 716 so that the endpoints on the corresponding sides of the isolation rib 715 and each of the flow-dividing ribs 716 are located on the third locus circle i. Among them, the length of the isolation rib 715 cut is the largest.

[0123] The above are only the preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Although the present invention has been disclosed above with the preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art of this patent, without departing from the scope of the technical solution of the present invention, can make some changes or modifications using the technical content prompted above into equivalent embodiments of equivalent changes. However, as long as it does not depart from the content of the technical solution of the present invention, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention still fall within the scope of the present invention.

Claims

1. A battery box assembly, characterized in that: include: A box body, the box body having a cavity and a side opening communicating with the cavity; A plurality of battery modules, each of which is disposed in the cavity; A copper busbar assembly, the copper busbar assembly is located at one side of the side opening, and the copper busbar assembly electrically connects the battery modules; A signal line assembly, the signal line assembly is located on a side of the copper busbar assembly away from the battery module, and the signal line assembly is electrically connected to each of the battery modules; A cooling pipeline, the cooling pipeline is located at the side port, and the cooling pipeline is located at a side of the signal line assembly away from the copper busbar assembly; Wherein, at least part of the structures of any two of the copper busbar assembly, the signal line assembly and the cooling pipeline are staggered.

2. The battery box assembly according to claim 1, characterized in that: The battery modules are arranged in multiple rows, and in two upper and lower adjacent rows of battery modules, the battery modules in one row are all first battery modules, and the battery modules in the other row are all second battery modules; In the first battery module and the second battery module that are adjacent to each other vertically, the positive electrode interface of one and the negative electrode interface of the other are located on the same longitudinal line; The copper bar assembly includes a plurality of longitudinal copper bars and a plurality of transverse copper bars; The longitudinal copper bar extends in the longitudinal direction, and the positive electrode interface and the negative electrode interface of two upper and lower adjacent battery modules are electrically connected through the longitudinal copper bar; The transverse copper bar extends in a direction perpendicular to the longitudinal copper bar, and at least two adjacent battery modules in the same row of battery modules are connected via the transverse copper bar.

3. The battery box assembly according to claim 2, characterized in that: A BMS slave board is provided in each row of battery modules, and the BMS slave board data is connected to multiple battery modules; The signal line assembly includes a plurality of low-voltage collection harness groups, one end of each of the low-voltage collection harness groups is connected to a plurality of battery modules, and the other end is connected to a corresponding BMS slave board; Among them, each low-voltage collection harness group and the longitudinal copper busbar are staggered.

4. The battery box assembly according to claim 3, characterized in that: The signal line assembly also includes a main wiring harness; The main wiring harness is located in the middle of the side opening and extends in the longitudinal direction; Each of the low-voltage collection harness groups is connected to the main harness.

5. The battery box assembly according to claim 4, characterized in that: The cooling pipeline includes a water inlet main pipeline, a water outlet main pipeline, a plurality of first slave pipelines, a plurality of second slave pipelines and a plurality of third slave pipelines; One end of each of the first slave pipelines is connected to the corresponding battery module on the first side of each row of battery modules, and the other end of each of the first slave pipelines is connected to the water inlet main pipeline; One end of each of the second slave pipelines is connected to the corresponding battery module on the second side of each row of battery modules, and the other end of each of the second slave pipelines is connected to the water outlet main pipeline; Two adjacent battery modules in the same row are connected via a third slave pipeline; Wherein, each of the water inlet main pipeline, the water outlet main pipeline, the first slave pipeline, the second slave pipeline and the third slave pipeline are staggered with respect to the signal line assembly and the copper busbar assembly.

6. The battery box assembly according to claim 5, characterized in that: The water inlet main channel and the water outlet main channel are both located on one side of the middle portion of the side opening and extend in the longitudinal direction; The water inlet main line and the water outlet main line are arranged on both sides of the main wiring harness.

7. The battery box assembly according to claim 1, characterized in that: The box body comprises a top frame, a bottom frame and surrounding side frames; The peripheral side frames are arranged at the edge of the bottom frame, and the top frame is connected to the peripheral side frames; The top frame, the bottom frame and the surrounding side frames are enclosed to form the side opening; A plurality of aviation plug-ins are arranged on the bottom frame, each of which is selected from a total positive plug-in, a total negative plug-in, a wiring harness plug-in and a water nozzle; Among them, the main positive plug-in is electrically connected to the copper busbar assembly, the wiring harness plug-in is connected to the signal line assembly, and the water nozzle is connected to the cooling pipeline.

8. The battery box assembly according to any one of claims 1 to 7, characterized in that: The battery module includes a water cooling plate and a plurality of battery cells, each battery cell being attached to the water cooling plate; The water cooling plate comprises: A water-cooled plate body, the water-cooled plate body comprising two first main boards, a second main board and two side baffles, the first main board and the second main board are spaced apart and arranged in parallel, the two side baffles are arranged on both sides of the first main board, and the baffles and the side baffles are respectively connected to the first main board and the second main board, the first main board, the second main board and the two side baffles enclose an inner cavity and a front port and a rear port communicating with the inner cavity; A plurality of ribs, each of which is located in the inner cavity, each of which is connected to the first main board and the second main board respectively, and each of which extends from the front port to the rear port; A front plug and a rear plug, the front plug and the rear plug are respectively arranged at two ends of the water-cooling plate body and respectively close the front port and the rear port of the water-cooling plate body; The end points of at least some adjacent ribs on the same side are located on the same trajectory circle.

9. The method for processing a water cooling plate of a battery box assembly according to claim 8, characterized in that: include: The large disc cutter is controlled to extend into the inner cavity to cut the ribs so that the end points of at least some of the ribs are located on the same trajectory circle.

10. The method for processing a water-cooling plate according to claim 9, characterized in that: include: The step of controlling the large disc cutter to extend from the front port into the inner cavity and cut each of the ribs so that the end points of at least some adjacent ribs close to the front port are located on the same trajectory circle; The step of controlling the large disc cutter to extend into the inner cavity from the rear port to cut each of the ribs so that the endpoints of at least some adjacent ribs close to the rear port are located on the same trajectory circle.

11. The method for processing a water-cooling plate according to claim 10, characterized in that: The step of controlling the large disc knife to extend from the front end port into the inner cavity and cut the ribs so that the endpoints of at least some adjacent ribs near the front end port are located on the same trajectory circle comprises: firstly controlling the large disc knife to extend from the front end port into the inner cavity and cut the diverter ribs on one side of the isolation rib so that the corresponding endpoints of the diverter ribs on one side of the isolation rib are located on the first trajectory circle, and then controlling the large disc knife to extend from the front end port into the inner cavity and cut the diverter ribs on the other side of the isolation rib so that the corresponding endpoints of the diverter ribs on the other side of the isolation rib are located on the second trajectory circle; The step of controlling the large disc knife to extend from the rear port into the inner cavity and cut each of the ribs so that the endpoints of at least some adjacent ribs close to the rear port are located on the same trajectory circle includes: controlling the large disc knife to extend from the rear port into the inner cavity and cut the isolation ribs and each diversion rib so that the endpoints on the corresponding sides of the isolation ribs and each diversion rib are located on a third trajectory circle.

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