Shell for battery pack and assembly method thereof

Abstract

The invention relates to the technical field of battery packs, and discloses a shell for a battery pack and an assembly method thereof, the shell for the battery pack comprises: a main shell, which is provided with an accommodating cavity, and one end of which is provided with an opening communicated with the accommodating cavity; the surface cover set is arranged at the opening and comprises a plastic surface cover, a first sheet metal part and a second sheet metal part, and the first sheet metal part and the second sheet metal part are arranged at the two ends of the plastic surface cover respectively and fixedly connected with the plastic surface cover; the first sheet metal part and the second sheet metal part respectively extend to the main shell from the two sides of the main shell, are fixedly connected with the main shell and are respectively provided with a lifting handle, and the lifting handles are close to the opening end of the main shell; and the plastic surface cover covers the opening. The shell for the battery pack has the advantages that the shell for the battery pack is low in cost, simple to assemble and high in attractiveness.

Description

Technical Field

[0001] The present invention relates to the technical field of battery packs, and particularly to a housing for a battery pack and an assembly method thereof. Background Art

[0002] The main function of the battery pack housing is to carry and protect structural components such as battery modules, electrical modules, and cooling systems in the battery pack.

[0003] Existing battery pack housings are generally made of multiple sheet metal parts formed by sheet metal stamping. The multiple sheet metal parts are spliced and fixed by screws to form the overall structure of the battery pack housing. A handle is provided on the front panel of the housing to facilitate lifting the battery pack. Although sheet metal stamping is simple, its material cost is high. Moreover, since various wiring terminals are provided on the front panel, corresponding insulation structures are required to avoid short circuits. That is, the existing battery pack housing has high costs, troublesome assembly, and poor aesthetics. Summary of the Invention

[0004] Aiming at the above deficiencies existing in the prior art, the technical problem to be solved by the present invention is to provide a housing for a battery pack with low cost, simple assembly, and high aesthetics, as well as an assembly method for the housing for a battery pack.

[0005] The technical solution adopted by the present invention to solve its technical problems is to provide a housing for a battery pack, including:

[0006] A main housing having a receiving cavity and an opening at one end communicating with the receiving cavity;

[0007] A face cover group provided at the opening, including a plastic face cover, a first sheet metal part, and a second sheet metal part. The first sheet metal part and the second sheet metal part are respectively provided at both ends of the plastic face cover and fixedly connected thereto. The first sheet metal part and the second sheet metal part respectively extend from both sides of the main housing towards the main housing and are fixedly connected to the main housing. A handle is provided on each of them, and the handle is close to the opening end of the main housing. The plastic face cover covers the opening.

[0008] Further, the main housing has a first side wall and a second side wall arranged oppositely. The first sheet metal part and the second sheet metal part respectively extend into the receiving cavity along the first side wall and the second side wall and respectively abut against the first side wall and the second side wall, and are respectively fixedly connected to the first side wall and the second side wall;

[0009] When the user extends both hands from both sides of the main shell to the handle and lifts the battery pack: the connection between the first sheet metal part and the main shell, and the connection between the second sheet metal part and the main shell bear the gravity load of the battery pack; the plastic cover does not bear the gravity load of the battery pack.

[0010] Furthermore, the first sheet metal component and the first side wall, as well as the second sheet metal component and the second side wall are detachably fixedly connected via a plurality of fixing members.

[0011] Furthermore, both the first sheet metal component and the second sheet metal component are provided with a guiding slope at one end away from the plastic cover, and the guiding slope gradually slopes downward from the end close to the plastic cover to the end away from the plastic cover.

[0012] Furthermore, the first sheet metal part and the second sheet metal part are each provided with a connecting plate at one end close to the plastic cover, and the connecting plate is provided with a plurality of fixing holes;

[0013] The inner wall of the plastic cover is provided with threaded holes corresponding to the fixing holes, and a plurality of screws pass through the plurality of fixing holes and are threadedly connected in the plurality of threaded holes, thereby fixing the first sheet metal component and the second sheet metal component on the plastic cover.

[0014] Furthermore, the plastic cover is plug-fitted into the main shell.

[0015] Further, the plastic cover has an upper convex edge and a lower convex edge protruding toward the opening side, and the plastic cover is provided with a first slot near the lower convex edge; the opening of the main shell has an upper edge and a lower edge corresponding to the upper convex edge and the lower convex edge respectively, and the main shell is provided with a second slot near the upper edge;

[0016] The lower edge is inserted into the first slot, and the upper convex edge is inserted into the second slot.

[0017] Further, the handle on the first sheet metal part is convexly arranged on the inner side wall of the first sheet metal part, the handle on the second sheet metal part is convexly arranged on the inner side wall of the second sheet metal part, and both handles are located in the accommodating cavity;

[0018] A through slot opposite to the handle is respectively provided on both sides of the main shell, and a human hand can be extended into the handle through the through slot.

[0019] Furthermore, the two handles respectively separate the communication channels between the two through grooves and the accommodating cavity.

[0020] Further, a positioning block extends from the handle towards one end close to the plastic face cover, and a fixing flange extends towards one end away from the plastic face cover;

[0021] Positioning grooves are provided on both the first sheet metal part and the second sheet metal part. The positioning block is inserted into the positioning groove, and the fixing flange is detachably fixed to the first sheet metal part or the second sheet metal part.

[0022] Further, a plurality of long slots are provided on the fixing flange, and the setting direction of the long slots is the same as the insertion direction of the positioning block inserted into the positioning groove;

[0023] Through holes corresponding to the long slots are provided on the first sheet metal part and the second sheet metal part. A fastener passes through the through hole and the long slot to detachably fix the fixing flange to the first sheet metal part or the second sheet metal part.

[0024] Further, the handle includes a housing convexly provided in the accommodation cavity. The housing has a cavity into which a human hand can extend, and the cavity communicates with the outside;

[0025] After the battery module in the battery pack is installed in the battery pack: in the direction perpendicular to the plastic face cover, the height of the housing in the main housing is higher than the height of the battery module.

[0026] Further, the distance between the housing and the outer wall of the plastic panel is less than or equal to 18 millimeters.

[0027] Further, the handle is made of plastic;

[0028] A rectangular frame is convexly provided on the handle. Rectangular grooves are provided on the first sheet metal part and the second sheet metal part. The rectangular frame is inserted into the rectangular groove.

[0029] Further, the housing of the battery pack is in a cuboid shape;

[0030] The main housing includes a bottom plate and an upper cover covering the bottom plate. The upper cover is detachably fixed to the bottom plate. Both the bottom plate and the upper cover are made of metal; both the first sheet metal part and the second sheet metal part are detachably fixed to the bottom plate and the upper cover.

[0031] Further, a wiring copper bar for docking an electrical device is installed on the plastic face cover, and the wiring copper bar is in direct contact with the plastic face cover.

[0032] The present invention also proposes an assembly method for a housing of a battery pack. The housing of the battery pack includes: a main housing and a face cover group;

[0033] The main housing has a receiving cavity, and one end thereof has an opening communicating with the receiving cavity; the main housing includes a bottom plate and an upper cover covering the bottom plate and detachably and fixedly connected to the bottom plate;

[0034] The face cover group is disposed at the opening and includes a plastic face cover, a first sheet metal part, and a second sheet metal part. The first sheet metal part and the second sheet metal part are respectively disposed at two ends of the plastic face cover and fixedly connected thereto; the first sheet metal part and the second sheet metal part respectively extend from two sides of the main housing towards the main housing and are fixedly connected to the main housing. A handle is provided on each of them, and the handle is close to the opening end of the main housing; the plastic face cover covers the opening;

[0035] The assembly method includes:

[0036] S1. Fix the first sheet metal part and the second sheet metal part to the plastic face cover respectively;

[0037] S2. Fix and install two handles on the first sheet metal part and the second sheet metal part respectively to form the face cover group;

[0038] S3. Fix and install the first sheet metal part and the second sheet metal part on the bottom plate;

[0039] S4. Cover the upper cover on the bottom plate and the face cover group, and make: the upper cover is in plug-in fit with the plastic face cover, and the upper cover is fixedly connected to the first sheet metal part, the second sheet metal part, and the bottom plate.

[0040] Compared with the prior art, the present invention has at least the following beneficial effects:

[0041] (1). In the present invention, the face cover group includes a plastic face cover, a first sheet metal part and a second sheet metal part which are respectively arranged at both ends of the plastic face cover and fixedly connected to the plastic face cover. The material cost of the plastic face cover itself is lower than that of metal materials, which can reduce the material cost. Moreover, due to the insulating property of the plastic face cover itself, a wiring copper bar can be directly arranged on the plastic panel. The wiring copper bar can be directly in contact with the plastic face cover without specially arranging an insulating structure, and the expensive wiring terminals (the structure is generally a conductive metal wrapped in an insulating shell) on the existing battery pack can be cancelled, which can not only simplify the structure and the assembly process, but also further reduce the cost of the battery pack. The handles are respectively arranged on the first sheet metal part and the second sheet metal part and are close to the open end of the main case, which is convenient for users to apply force to lift the battery pack and also ensures that the main case has sufficient strength. Because when the user lifts the battery pack, the plastic face cover does not bear the gravity load of the battery pack, and the gravity load of the battery pack is borne by the connection between the first sheet metal part and the main case and the connection between the second sheet metal part and the main case, without worrying about the problem of insufficient strength of plastic parts. The plastic face cover is directly inserted into the main case without screwing, and the user cannot see the screws on the front of the battery pack during use, so the overall aesthetics is higher.

[0042] (2). In the present invention, the handles on both the first sheet metal part and the second sheet metal part are close to the open end of the main case and are accommodated in the accommodation cavity, and the structure has no outward protrusion. The handle is assembled with the sheet metal part through a positioning block close to the open end, that is, the fixed flange on this side can be cancelled, ensuring that the handle is as close as possible to the open end (the distance between the cover of the handle and the plastic face cover can be made less than or equal to 18 millimeters), which will not interfere with the assembly of the battery module in the battery pack, and can ensure that the structure of the battery pack is more compact. The cover separates and seals the internal accommodation cavity of the main case from the outside, which can prevent sundries from entering the battery pack and ensure that the normal operation of the electrical module in the battery pack is not affected by the outside.

[0043] (3). During the assembly process of the housing for the battery pack of the present invention, first, the first sheet metal part and the second sheet metal part are respectively fixed on the plastic face cover, and then the two handles are respectively fixed and installed on the first sheet metal part and the second sheet metal part to form a face cover group; then the first sheet metal part and the second sheet metal part are fixed and installed on the bottom plate; thus, modules such as the battery module inside the battery pack can be assembled. Finally, the upper cover is covered on the bottom plate and the face cover group, and the upper cover is in plug-in fit with the plastic face cover and is fixedly connected to the first sheet metal part, the second sheet metal part and the bottom plate. It is convenient for the assembly of the internal structure of the battery pack, simplifies its assembly process, improves the assembly efficiency, and can ensure the structural strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 is a schematic structural diagram of the housing for the battery pack of the present invention;

[0045] Figure 2 is Figure 1 a schematic structural diagram from another perspective;

[0046] Figure 3 It is a structural schematic diagram after the main shell and the face cover group of the housing for the battery pack are disassembled;

[0047] Figure 4 It is a structural schematic diagram of the main shell;

[0048] Figure 5 It is a disassembled schematic diagram of the main shell;

[0049] Figure 6 It is a structural schematic diagram of the face cover group;

[0050] Figure 7 It is Figure 6 A structural schematic diagram from another perspective;

[0051] Figure 8 It is a disassembled schematic diagram of the face cover group;

[0052] Figure 9 It is an assembly drawing of the face cover group and the bottom plate;

[0053] Figure 10 It is an assembly drawing of the face cover group and the upper cover;

[0054] Figure 11 It is a schematic diagram of the assembly process of the face cover group;

[0055] Figure 12 It is a schematic diagram of the assembly process of the face cover group and the main shell.

[0056] In the figure:

[0057] 1. Main shell; 11. Bottom plate; 12. Upper cover; 100. Accommodating cavity; 101. Opening; 111. Lower edge; 120. Through groove; 121. First side wall; 122. Second side wall; 123. Upper edge; 124. Second slot;

[0058] 2. Face cover group; 21. Plastic face cover; 22. First sheet metal part; 23. Second sheet metal part; 24. Handle; 210. Threaded hole; 211. Upper convex edge; 212. Lower convex edge; 213. First slot; 220. Guide inclined plane; 221. Connecting plate; 221A. Fixed hole; 221B. Positioning groove; 222. Rectangular groove; 241. Positioning block; 242. Fixed flange; 242A. Long strip groove; 243. Cover shell; 243A. Cavity; 244. Rectangular frame; 25. Wiring copper bar. Specific embodiments

[0059] The following are specific embodiments of the present invention and in combination with the accompanying drawings, the technical solutions of the present invention are further described, but the present invention is not limited to these embodiments.

[0060] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement conditions between components in a specific posture (as shown in the drawings). If the specific posture changes, the directional indications will also change accordingly.

[0061] In addition, in the present invention, descriptions such as "first", "second", "one", etc. are only for descriptive purposes and should not be construed as indicating or implying their relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, the meaning of "a plurality" is at least two, such as two, three, etc., unless otherwise specifically defined.

[0062] In the present invention, unless otherwise clearly specified and defined, terms such as "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components, unless otherwise clearly defined. 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.

[0063] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0064] As Figures 1-4 shown, the housing for the battery pack of this embodiment mainly includes: a main housing 1 and a face cover group 2. Among them, the main housing 1 has a receiving cavity 100, and the receiving cavity 100 is available for installing the battery module in the battery pack, and one end of the main housing 1 has an opening 101 communicating with the receiving cavity 100. The face cover group 2 is arranged at the opening 101. The face cover group 2 includes a plastic face cover 21, a first sheet metal part 22 and a second sheet metal part 23. The first sheet metal part 22 and the second sheet metal part 23 are respectively arranged at both ends of the plastic face cover 21 and fixedly connected thereto; the first sheet metal part 22 and the second sheet metal part 23 respectively extend from both sides of the main housing 1 towards the main housing 1 and are fixedly connected to the main housing 1. A handle 24 is provided on both of them, and the handle 24 is close to the opening 101 end of the main housing 1; the plastic face cover 21 covers the opening 101.

[0065] Moreover, a wiring copper bar 25 for the docking of electrical equipment is installed on the plastic face cover 21, and the wiring copper bar 25 is in direct contact with the plastic face cover 21. The end of the wiring copper bar 25 in the accommodation cavity 100 can be directly fixedly connected and electrically connected to the circuit board in the battery pack, or directly fixedly connected and electrically connected to the battery module in the battery pack.

[0066] Due to the insulating property of the plastic face cover 21 itself, the wiring copper bar 25 can be directly arranged on the plastic panel, and the wiring copper bar 25 can be in direct contact with the plastic face cover 21 without specially arranging an insulating structure. The expensive wiring terminals (the structure of which is generally a conductive metal wrapped in an insulating shell) on the existing battery pack can be cancelled, which can not only simplify the structure and the assembly process, but also reduce the cost of the battery pack. Moreover, corresponding fixing structures can be designed on the inner wall of the plastic face cover 21 to facilitate fixing the circuit board in the battery pack on the plastic face cover 21.

[0067] Specifically, the material of the plastic face cover 21 in this embodiment is an insulating and flame-retardant plastic, which can not only effectively prevent the passage of current and achieve the purpose of insulation, but also prevent fires. For example, it can adopt plastics of the same type such as polyvinyl chloride (PVC) and polycarbonate (PC).

[0068] During actual use, when the user reaches for the handle 24 with both hands from both sides of the main case 1 to lift the battery pack: at the connection between the first sheet metal part 22 and the main case 1, and at the connection between the second sheet metal part 23 and the main case 1, the gravity load of the battery pack is borne, while the plastic face cover 21 does not bear the gravity load of the battery pack. The main case 1 is made of metal, and the first sheet metal part 22 and the second sheet metal part 23 are also made of metal, which can ensure the reliable connection strength between the main case 1 and the first sheet metal part 22 and between the main case 1 and the second sheet metal part 23. The handles 24 are respectively arranged on the first sheet metal part 22 and the second sheet metal part 23, transferring the gravity load of the battery pack to the connection between the main case 1 and the first sheet metal part 22 and the connection between the main case 1 and the second sheet metal part 23, and the plastic face cover 21 does not need to bear the gravity load of the battery pack, ensuring the structural strength of the battery pack housing without worrying about the problem of relatively poor load-bearing capacity of the plastic face cover 21.

[0069] Such as Figures 3-5As shown in the figure, the outer shape of the housing for the battery pack in this embodiment is rectangular. The main housing 1 includes a bottom plate 11 and an upper cover 12 covering the bottom plate 11. The upper cover 12 is detachably and fixedly connected to the bottom plate 11, and both the bottom plate 11 and the upper cover 12 are made of metal. On the four sides of the bottom plate 11, there are no flanges provided on the edges close to the opening 101, while flanges are provided on the other three edges. Screw holes for screw connection or screw through holes for screws to pass through are provided on these flanges, which facilitates the fixation of the bottom plate 11. Correspondingly, on the upper cover 12, there are side walls fixed to the three flanges on the bottom plate 11, namely the first side wall 121, the second side wall 122, and the third side wall (not marked in the figure) between the first side wall 121 and the second side wall 122 and on the opposite side of the opening 101. The three side walls of the upper cover 12 are respectively arranged on the three flanges of the bottom plate 11 and are all fixed by screws, with reliable fixation, thus ensuring the structural strength and facilitating disassembly and assembly.

[0070] Referring to Figures 3-5 and in combination with Figures 9-10 it can be seen that the first side wall 121 and the second side wall 122 on the main housing 1 are arranged opposite to each other, and the second side wall 122 is on the opposite side of the first side wall 121. It can be understood that the first side wall 121 and the second side wall 122 are respectively on the left and right sides of the battery pack. The first sheet metal part 22 extends into the accommodation cavity 100 along the first side wall 121 and abuts against the first side wall 121; the second sheet metal part 23 extends into the accommodation cavity 100 along the second side wall 122 and abuts against the second side wall 122. Between the first sheet metal part 22 and the first side wall 121, and between the second sheet metal part 23 and the second side wall 122, they are detachably fixed by fixing parts, and the fixing parts can be but are not limited to screws. Specifically, between the first sheet metal part 22 and the first side wall 121, and between the second sheet metal part 23 and the second side wall 122, they are detachably fixed and connected by a plurality of fixing parts. The tops of both the first sheet metal part 22 and the second sheet metal part 23 are fixed to the upper cover 12 by a plurality of screws, and the bottoms of both the first sheet metal part 22 and the second sheet metal part 23 are fixed to the upper cover 12 and the bottom plate 11. Specifically, screw holes are provided on the first sheet metal part 22 and the second sheet metal part 23 or nuts are press riveted. At the bottom of the housing, the screws pass through the flanges on the upper cover 12 and the bottom plate 11 from the outside to the inside and are threadedly connected to the first sheet metal part 22 or the second sheet metal part 23, detachably fixing and connecting the upper cover 12, the bottom plate 11 and the first sheet metal part 22, and detachably fixing and connecting the upper cover 12, the bottom plate 11 and the second sheet metal part 23.

[0071] To facilitate the assembly of the upper cover 12 to the face cover group 2, at one end of both the first sheet metal part 22 and the second sheet metal part 23 of this embodiment away from the plastic face cover 21, a guiding inclined surface 220 is provided. The guiding inclined surface 220 gradually slopes downward from the end close to the plastic face cover 21 to the end away from the plastic face cover 21.

[0072] During the assembly process of the upper cover 12 and the face cover group 2, the face cover gradually approaches the first sheet metal part 22 and the second sheet metal part 23 from a position away from the first sheet metal part 22 and the second sheet metal part 23. The face cover can first contact the guiding inclined surfaces 220 on both the first sheet metal part 22 and the second sheet metal part 23, slide along the guiding inclined surfaces 220, slide to the tops of the first sheet metal part 22 and the second sheet metal part 23, and finally be inserted onto the plastic face cover 21.

[0073] The following further introduces the specific structure of the face cover group 2 of this embodiment:

[0074] As Figures 6-8 shown, at one end of both the first sheet metal part 22 and the second sheet metal part 23 close to the plastic face cover 21, a connecting plate 221 is provided. The connecting plate 221 is formed by bending, and the connecting plate 221 is perpendicular to the main structures of the first sheet metal part 22 and the second sheet metal part 23. A plurality of fixing holes 221A are provided on the connecting plate 221, and the fixing holes 221A can allow screws to pass through. Threaded holes 210 corresponding to the fixing holes 221A are provided on the inner wall of the plastic face cover 21. Specifically, the plastic face cover 21 is provided with studs integrally injection-molded therewith, and the threaded holes 210 are provided on the studs. Compared with a face cover made of metal, the plastic face cover 21 of this embodiment is made of plastic, which can facilitate the design of various structures thereon for convenient assembly, and these structures can be injection-molded, reducing its subsequent processing. A plurality of screws respectively pass through the plurality of fixing holes 221A and are threadedly connected in the plurality of threaded holes 210 to fix the first sheet metal part 22 and the second sheet metal part 23 on the plastic face cover 21. The first sheet metal part 22 and the second sheet metal part 23 are symmetrically fixedly connected to both ends of the plastic panel.

[0075] In this embodiment, the handle 24 on the first sheet metal part 22 can be integrally provided or separately provided with the first sheet metal part 22 itself, and the handle 24 on the second sheet metal part 23 can be integrally provided or separately provided with the second sheet metal part 23 itself.

[0076] Of course, it is preferably that the handle 24 is separately provided from the first sheet metal part 22 and the second sheet metal part 23. In this way, the handle 24 can be made of plastic and injection-molded. The plastic handle 24 can improve the feel of the handle 24 and reduce the material cost. After the docking of the first sheet metal part 22 and the second sheet metal part 23 with the plastic panel is completed, the two handles 24 need to be respectively fixedly installed on the first sheet metal part 22 and the second sheet metal part 23.

[0077] In this embodiment, the handle 24 on the first sheet metal part 22 protrudes from the inner side wall of the first sheet metal part 22, and the handle 24 on the second sheet metal part 23 protrudes from the inner side wall of the second sheet metal part 23. The two handles 24 are symmetrically arranged, which is convenient for the user to apply force when lifting the battery pack, and the two handles 24 are located in the accommodation cavity 100 to ensure that they do not protrude outside the battery pack. On both sides of the main case 1, that is, the first side wall 121 and the second side wall 122, there is respectively a through groove 120 opposite to the handle 24. The through groove 120 is rectangular, and a person's hand can extend from the through groove 120 to the handle 24 to facilitate lifting the battery pack.

[0078] A positioning block 241 extends from one end of the handle 24 close to the plastic face cover 21, and a fixing flange 242 extends from the end of the handle 24 far from the plastic face cover 21. Positioning grooves 221B are provided on the connecting plates 221 of both the first sheet metal part 22 and the second sheet metal part 23. The positioning grooves 221B correspond to the positioning blocks 241 one by one, and the positioning blocks 241 are inserted into the positioning grooves 221B. The fixing flange 242 is detachably fixed to the first sheet metal part 22 or the second sheet metal part 23. One end of the handle 24 close to the plastic face cover 21 is inserted into the positioning grooves 221B on both the first sheet metal part 22 and the second sheet metal part 23 through the positioning blocks 241. Without being fixed by screws, it is equivalent to canceling the fixing flange 242 on the side of the handle 24 close to the plastic face cover 21. In this way, the handle 24 can be as close as possible to the opening 101 end of the battery pack housing, without affecting the installation of the battery module inside the battery pack, making the structure of the battery pack more compact.

[0079] Furthermore, a rectangular frame 244 protrudes from the handle 24. Correspondingly, rectangular grooves 222 corresponding to and adapted to it are provided on the first sheet metal part 22 and the second sheet metal part 23. The rectangular frame 244 is inserted into the rectangular groove 222. Through the cooperation of the rectangular frame 244 and the rectangular groove 222, after the handle 24 is assembled to the first sheet metal part 22 and the second sheet metal part 23, the handle 24 cannot move up, down, left or right. Among them, several long slots 242A are provided on the fixing flange 242 of the handle 24. In the illustration of this embodiment, it is shown that there are three long slots 242A on the fixing flange 242, but it is not limited to three. According to the size of the fixing flange 242, more long slots 242A can be opened to ensure reliable fixation. Among them, the setting direction of the long slots 242A is the same as the insertion direction of the positioning blocks 241 into the positioning grooves 221B. Through holes corresponding to the long slots 242A are provided on the first sheet metal part 22 and the second sheet metal part 23. Fasteners (optional bolts or screws) pass through the through holes and the long slots 242A to detachably fix the fixing flange 242 to the first sheet metal part 22 or the second sheet metal part 23.

[0080] During the actual assembly process, since the structure of the fixing flange 242 is omitted at one end of the handle 24 close to the plastic panel, the handle 24 can be as close as possible to the opening 101 end. This end of the handle 24 is fixed to the first sheet metal part 22 and the second sheet metal part 23 through the positioning block 241. The long slot 242A arranged along the insertion direction facilitates the fastener to pass through without the need to specifically align, thereby reducing the assembly difficulty.

[0081] Furthermore, the handle 24 includes a housing 243 protruding inwardly into the accommodation cavity 100. The housing 243 has a cavity 243A into which a human hand can reach. The cavity 243A communicates with the outside and does not communicate with the accommodation cavity 100. That is, the housings 243 of the two handles 24 respectively cut off the communication channels between the two through slots 120 and the accommodation cavity 100. During use, the housing 243 cuts off and seals the accommodation cavity 100 inside the main housing 1 from the outside, preventing foreign objects from entering the battery pack and ensuring that the normal operation of the electrical modules in the battery pack is not affected by the outside. The housing 243 is upturned toward the opening 101 end side in the accommodation cavity 100 to avoid assembly interference with the battery module in the battery pack. After the battery module in the battery pack is installed in the battery pack: in the direction perpendicular to the plastic face cover 21, the height of the housing 243 in the main housing 1 is higher than the height of the battery module, thus avoiding interference between the handle 24 and the battery pack module during the subsequent assembly of the battery module. The distance between the housing 243 and the outer wall of the plastic panel can be made less than or equal to 18 millimeters.

[0082] In this embodiment, the housing 243 has an upper side wall and a lower side wall arranged oppositely. The upper side wall and the lower side wall are connected by a sealing plate. The sealing plate is on the opposite side of the through slot 120. The sealing plate and the upper side wall are transitioned by a large arc. While facilitating the finger to reach, it can also make the handle 24 as close as possible to the opening 101 end and can also facilitate the handle 24 to have no undercut during injection molding, enabling the injection mold to be opened smoothly. Among them, both the upper side wall and the lower side wall are inclined upward from bottom to top, making the housing 243 closer to the opening 101 end. Moreover, when a human hand reaches into the cavity 243A and lifts the handle 24 upward, the bending direction of the four fingers of the user is the same as the inclination direction of the upper side wall, which can effectively improve the comfort of the user when lifting the handle 24 and make the design of the handle 24 more ergonomic.

[0083] In this embodiment, the handles 24 on both the first sheet metal part 22 and the second sheet metal part 23 are close to the opening 101 end of the main case 1 and are accommodated in the accommodation cavity 100, with no external protrusion in the structure. The handle 24 is assembled with the sheet metal part through the positioning block 241 near the opening 101 end, that is, the fixed flange 242 on this side can be cancelled, ensuring that the handle 24 is as close as possible to the opening 101 end (the distance between the cover 243 of the handle 24 and the plastic face cover 21 can be made less than or equal to 18 mm), which will not interfere with the assembly of the battery module in the battery pack and can ensure that the structure of the battery pack is more compact. At the same time, ensuring that the handle 24 is close to the opening 101 end makes it more convenient to carry and the center of gravity is stable.

[0084] After the face cover group 2 is assembled, it needs to be fixed to the bottom plate 11 and the upper cover 12 of the main case 1 successively. The plastic face cover 21 of this embodiment is in plug-in fit with the main case 1, and the plastic face cover 21 does not need to be fixed to the main case 1 with screws. When the user uses it, no screws can be seen on the front of the battery pack, and the overall aesthetic degree is higher. Its specific plug-in structure is as follows: the plastic face cover 21 protrudes towards the opening 101 side with an upper convex edge 211 and a lower convex edge 212, and a first slot 213 is provided near the lower convex edge 212 of the plastic face cover 21. At the opening 101 of the main case 1, there are an upper edge 123 and a lower edge 111 corresponding to the upper convex edge 211 and the lower convex edge 212 respectively, and a second slot 124 is provided near the upper edge 123 of the main case 1. The lower edge 111 is inserted into the first slot 213, and the upper convex edge 211 is inserted into the second slot 124.

[0085] It can be seen from this that in the housing of the battery pack in this embodiment, the face cover group 2 includes a plastic face cover 21, a first sheet metal part 22 and a second sheet metal part 23 which are respectively arranged at both ends of the plastic face cover 21 and fixedly connected to the plastic face cover 21. The material cost of the plastic face cover 21 itself is lower than that of the metal material, which can reduce the material cost. Moreover, due to the insulating property of the plastic face cover 21 itself, the wiring copper bar 25 can be directly arranged on the plastic panel, and the wiring copper bar 25 can be directly in contact with the plastic face cover 21 without specially setting an insulating structure, and the expensive wiring terminals (the general structure is a conductive metal wrapped in an insulating shell) on the existing battery pack can be cancelled, which can not only simplify the structure and the assembly process, but also further reduce the cost of the battery pack. The handles 24 are respectively arranged on the first sheet metal part 22 and the second sheet metal part 23 and are close to the opening 101 end of the main case 1, which is convenient for the user to apply force to lift the battery pack and also ensures that the main case 1 has sufficient strength. Because when the user lifts the battery pack, the plastic face cover 21 does not bear the gravity load of the battery pack, and the gravity load of the battery pack is borne by the connection between the first sheet metal part 22 and the main case 1 and the connection between the second sheet metal part 23 and the main case 1, without worrying about the problem of insufficient strength of the plastic part. The plastic face cover 21 is directly plugged into the main case 1 without locking screws. When the user uses it, no screws can be seen on the front of the battery pack, and the overall aesthetic degree is higher.

[0086] Such asFigures 11-12 As shown, it schematically shows the assembly process of the face cover group 2 and the assembly process of the face cover group 2 and the main housing 1 respectively. The assembly method of the housing for the battery pack in this embodiment is as follows:

[0087] Step S1: Fix the first sheet metal part 22 and the second sheet metal part 23 to the plastic face cover 21 respectively.

[0088] Specifically, align the fixing hole 221A on the connecting plate 221 of the first sheet metal part 22 with the corresponding threaded hole 210 on the plastic face cover 21, and pass a screw through the fixing hole 221A and thread it into the threaded hole 210 to fix the first sheet metal part 22 on the inner wall of the plastic face cover 21. Similarly, align the fixing hole 221A on the connecting plate 221 of the second sheet metal part 23 with the corresponding threaded hole 210 on the plastic face cover 21, and pass a screw through the fixing hole 221A and thread it into the threaded hole 210 to fix the second sheet metal part 23 on the inner wall of the plastic face cover 21, and it is located at the other end of the plastic face cover 21.

[0089] Step S2: Fix the two handles 24 to the first sheet metal part 22 and the second sheet metal part 23 respectively to form the face cover group 2.

[0090] Specifically, align the positioning block 241 of a handle 24 with the positioning groove 221B on the first sheet metal part 22, and insert the positioning block 241 into the positioning groove 221B. After being inserted in place, align the rectangular frame 244 on the handle 24 with the rectangular groove 222 on the first sheet metal part 22, and the rectangular frame 244 can be inserted into the rectangular groove 222, and the long strip groove 242A corresponds to the through holes on the first sheet metal part 22 one by one. Connect the handle 24 to the first sheet metal part 22 by passing a plurality of bolts through the through holes and the long strip groove 242A and connecting them with nuts. Similarly, align the positioning block 241 of the other handle 24 with the positioning groove 221B on the second sheet metal part 23, and insert the positioning block 241 into the positioning groove 221B. After being inserted in place, align the rectangular frame 244 on the handle 24 with the rectangular groove 222 on the second sheet metal part 23, and the rectangular frame 244 can be inserted into the rectangular groove 222, and the long strip groove 242A corresponds to the through holes on the second sheet metal part 23 one by one. Connect the handle 24 to the second sheet metal part 23 by passing a plurality of bolts through the through holes and the long strip groove 242A and connecting them with nuts. At this time, the face cover group 2 has been assembled.

[0091] Step S3: Fix the first sheet metal part 22 and the second sheet metal part 23 to the bottom plate 11.

[0092] Specifically, align the lower edge 111 of the bottom plate 11 near the opening 101 end, that is, the lower edge, with the first slot 213 on the plastic face cover 21 and insert it into the first slot 213. The lower ends of the first sheet metal part 22 and the second sheet metal part 23 are both placed on the flanges on both sides of the bottom plate 11. There is a step at the lower ends of the first sheet metal part 22 and the second sheet metal part 23, and this step just fits with the flanges on the bottom plate 11. After the steps of the first sheet metal part 22 and the second sheet metal part 23 are respectively placed on the flanges on both sides of the bottom plate 11 and cooperate with the insertion connection between the bottom plate 11 and the plastic face cover 21, the relative positional relationship between the bottom plate 11 and the plastic face cover 21 has been determined.

[0093] Step S4: Cover the upper cover 12 on the bottom plate 11 and the face cover group 2, and make: the upper cover 12 is inserted and cooperated with the plastic face cover 21, and the upper cover 12 is fixedly connected to the first sheet metal part 22, the second sheet metal part 23, and the bottom plate 11.

[0094] Specifically, align the second slot 124 on the upper edge 123 of the upper cover 12 with the upper convex edge 211 on the plastic face cover 21 to form an insertion fit. Make the first side wall 121 of the upper cover 12 abut against the outer wall of the first sheet metal part 22 and the outer wall of a flange on the bottom plate 11. Make the second side wall 122 of the upper cover 12 abut against the outer wall of the second sheet metal part 23 and the flange on the bottom plate 11 on the opposite side of the previous flange. Make the third side wall of the upper cover 12 abut against the last flange of the bottom plate 11. At this time, all the through holes and screw holes are already aligned. At the upper end position on the first side wall 121, the screw passes through the upper cover 12 and is threadedly connected to the first sheet metal part 22; at the lower end position on the first side wall 121, the screw passes through the upper cover 12 and the flange on the bottom plate 11 and is threadedly connected to the first sheet metal part 22 to fixedly connect the upper cover 12, the bottom plate 11, and the first sheet metal part 22; similarly, at the upper end position on the second side wall 122, the screw passes through the upper cover 12 and is threadedly connected to the second sheet metal part 23; at the lower end position on the second side wall 122, the screw passes through the upper cover 12 and the other flange on the bottom plate 11 and is threadedly connected to the second sheet metal part 23 to fixedly connect the upper cover 12, the bottom plate 11, and the second sheet metal part 23; at the lower end position on the third side wall, the screw passes through the upper cover 12 and is threadedly connected to the last flange of the bottom plate 11. That is, on the battery pack housing, except for the side where the plastic panel is located, no screws are locked, and the other three sides are all fixed by screws to ensure reliable fixation.

[0095] Looking at the entire housing for the integrated battery pack: First, fix the first sheet metal part 22 and the second sheet metal part 23 to the plastic face cover 21 respectively, and then fix and install the two handles 24 on the first sheet metal part 22 and the second sheet metal part 23 respectively to form the face cover group 2; then fix and install the first sheet metal part 22 and the second sheet metal part 23 on the bottom plate 11; thus, modules such as the battery module inside the battery pack can be assembled. Finally, cover the upper cover 12 on the bottom plate 11 and the face cover group 2. The upper cover 12 is inserted and matched with the plastic face cover 21, and the upper cover 12 is fixedly connected to the first sheet metal part 22, the second sheet metal part 23, and the bottom plate 11. It can facilitate the assembly of the internal structure of the battery pack, simplify its assembly process, improve the assembly efficiency, and ensure the structural strength.

[0096] The housing for the battery pack in this embodiment mainly includes: the main housing 1 and the face cover group 2. Among them, the main housing 1 mainly includes: the bottom plate 11 and the upper cover 12, and the face cover group 2 mainly includes: the plastic face cover 21, the first sheet metal part 22, and the second sheet metal part 23. The face cover group 2 is fixed to the main housing 1 through the first sheet metal part 22 and the second sheet metal part 23 respectively, and a handle 24 is provided on each of the first sheet metal part 22 and the second sheet metal part 23. When the user reaches for the handles 24 with both hands from both sides of the main housing 1 and lifts the battery pack: the connection between the first sheet metal part 22 and the main housing 1, and the connection between the second sheet metal part 23 and the main housing 1 bear the gravity load of the battery pack; the plastic face cover 21 does not bear the gravity load of the battery pack, concentrating the gravity load of the battery pack at the connection of the sheet metal parts, and avoiding the relatively low-strength plastic face cover 21 from bearing the gravity load. The overall cost of the housing for the battery pack in this embodiment is low, the assembly is simple, and the aesthetics is high.

Claims

1. A battery pack housing, characterized in that: include: A main shell having a receiving cavity and an opening at one end thereof communicating with the receiving cavity; A cover assembly is arranged at the opening, comprising a plastic cover, a first sheet metal component and a second sheet metal component, wherein the first sheet metal component and the second sheet metal component are respectively arranged at two ends of the plastic cover and fixedly connected thereto; the first sheet metal component and the second sheet metal component respectively extend from two sides of the main shell to the main shell and are fixedly connected to the main shell, and both are provided with a handle, and the handle is close to the opening end of the main shell; the plastic cover covers the opening.

2. The battery pack housing according to claim 1, characterized in that: The main shell has a first side wall and a second side wall which are arranged opposite to each other, the first sheet metal component and the second sheet metal component extend into the accommodating cavity along the first side wall and the second side wall respectively, and are respectively abutted against the first side wall and the second side wall, and are respectively fixedly connected to the first side wall and the second side wall; When the user extends both hands from both sides of the main shell to the handle and lifts the battery pack: the connection between the first sheet metal part and the main shell, and the connection between the second sheet metal part and the main shell bear the gravity load of the battery pack; the plastic cover does not bear the gravity load of the battery pack.

3. The battery pack housing according to claim 2, characterized in that: The first sheet metal component and the first side wall, as well as the second sheet metal component and the second side wall, are detachably fixedly connected via a plurality of fixing members.

4. The battery pack casing according to claim 2, characterized in that: A guiding slope is disposed at one end of the first sheet metal component and the second sheet metal component away from the plastic cover. The guiding slope gradually slopes downward from an end close to the plastic cover to an end away from the plastic cover.

5. The battery pack casing according to claim 1, characterized in that: The first sheet metal part and the second sheet metal part are each provided with a connecting plate at one end close to the plastic cover, and the connecting plate is provided with a plurality of fixing holes; The inner wall of the plastic cover is provided with threaded holes corresponding to the fixing holes, and a plurality of screws pass through the plurality of fixing holes and are threadedly connected in the plurality of threaded holes, thereby fixing the first sheet metal component and the second sheet metal component on the plastic cover.

6. The battery pack casing according to claim 1, characterized in that: The plastic cover is plug-fitted with the main shell.

7. The battery pack casing according to claim 6, characterized in that: The plastic cover has an upper convex edge and a lower convex edge protruding toward the opening side, and the plastic cover is provided with a first slot near the lower convex edge; the opening of the main shell has an upper edge and a lower edge corresponding to the upper convex edge and the lower convex edge respectively, and the main shell is provided with a second slot near the upper edge; The lower edge is inserted into the first slot, and the upper convex edge is inserted into the second slot.

8. The battery pack casing according to claim 2, characterized in that: The handle on the first sheet metal part is convexly arranged on the inner side wall of the first sheet metal part, and the handle on the second sheet metal part is convexly arranged on the inner side wall of the second sheet metal part, and both handles are located in the accommodating cavity; A through slot opposite to the handle is respectively provided on both sides of the main shell, and a human hand can be extended into the handle through the through slot.

9. The battery pack casing according to claim 8, characterized in that: The two handles respectively separate the communication passages between the two through grooves and the accommodating cavity.

10. The battery pack casing according to claim 1, characterized in that: A positioning block extends from the handle toward one end close to the plastic cover, and a fixing flange extends from the handle toward one end away from the plastic cover. The first sheet metal part and the second sheet metal part are both provided with positioning grooves, the positioning blocks are inserted into the positioning grooves, and the fixing flange is detachably fixedly connected to the first sheet metal part or the second sheet metal part.

11. The battery pack casing according to claim 10, characterized in that: The fixing flange is provided with a plurality of long grooves, and the arrangement direction of the long grooves is the same as the insertion direction of the positioning block into the positioning grooves; The first sheet metal component and the second sheet metal component are provided with through holes corresponding to the long grooves, and fasteners pass through the through holes and the long grooves to detachably fix the fixing flange to the first sheet metal component or the second sheet metal component.

12. The battery pack casing according to claim 10, characterized in that: The handle comprises a cover shell protruding inwardly in the accommodating cavity, the cover shell has a cavity into which a hand can be inserted, and the cavity is communicated with the outside; When the battery modules in the battery pack are installed in the battery pack: along the direction perpendicular to the plastic cover, the height of the cover shell in the main shell is higher than the height of the battery modules.

13. The battery pack casing according to claim 12, characterized in that: The distance between the cover shell and the outer wall of the plastic panel is less than or equal to 18 mm.

14. The battery pack casing according to claim 10, characterized in that: The handle is made of plastic; A rectangular frame is convexly provided on the handle, and rectangular grooves are provided on the first sheet metal part and the second sheet metal part, and the rectangular frame is inserted into the rectangular grooves.

15. The battery pack casing according to claim 1, characterized in that: The battery pack shell is in the shape of a rectangular parallelepiped; The main shell includes a bottom plate and an upper cover arranged on the bottom plate, the upper cover is detachably fixedly connected to the bottom plate, and the bottom plate and the upper cover are both made of metal; the first sheet metal component and the second sheet metal component are both detachably fixedly connected to the bottom plate and the upper cover.

16. The battery pack casing according to claim 1, characterized in that: A copper busbar for connecting electrical equipment is installed on the plastic cover, and the copper busbar is in direct contact with the plastic cover.

17. A method for assembling a battery pack housing, characterized in that: The battery pack housing comprises: a main housing and a cover assembly; The main shell has a receiving cavity, and one end of the main shell has an opening communicating with the receiving cavity; the main shell includes a bottom plate and an upper cover disposed on the bottom plate and detachably fixedly connected to the bottom plate; The cover assembly is arranged at the opening, and includes a plastic cover, a first sheet metal part and a second sheet metal part. The first sheet metal part and the second sheet metal part are respectively arranged at two ends of the plastic cover and fixedly connected thereto; the first sheet metal part and the second sheet metal part respectively extend from two sides of the main shell to the main shell and are fixedly connected to the main shell, and both are provided with a handle, and the handle is close to the opening end of the main shell; the plastic cover covers the opening; The assembly method comprises: S1. Fixing the first sheet metal part and the second sheet metal part to the plastic cover respectively; S2, fixing two handles on the first sheet metal part and the second sheet metal part respectively to form the cover assembly; S3, fixing the first sheet metal component and the second sheet metal component on the bottom plate; S4, installing the upper cover on the bottom plate and the surface cover assembly, and making the upper cover plug-fit with the plastic surface cover, and the upper cover fixedly connected with the first sheet metal part, the second sheet metal part, and the bottom plate.

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