Battery pack and powered device

Abstract

The application provides a battery pack and a power utilization equipment, and relates to the technical field of batteries. The battery pack comprises: a battery pack; and a shell comprising: a bottom frame, the bottom frame having a containing cavity, the containing cavity having a bottom opening, a support flange being arranged at the bottom opening of the bottom frame, and the battery pack being arranged in the containing cavity and supported on the support flange; wherein a bearing safety factor S of the support flange satisfies: S <= 1. The battery pack provided by the application has the advantages of light weight, improved structural strength and stability, improved load dispersion capacity, and avoidance of structural deformation caused by stress concentration.

Description

Technical Field

[0001] This application relates to the field of battery technology, and more particularly to a battery pack and an electrical device. Background Technology

[0002] With the development of new energy vehicles, the demand for battery pack reliability is also increasing.

[0003] Traditional battery packs typically use an aluminum extrusion profile frame combined with a lower cooling plate base. Multiple frames are welded together to form a frame assembly. The lower cooling plate base is connected to the frame assembly by means of adhesive bonding, friction stir welding, etc., to form a cavity to accommodate the battery cells.

[0004] However, the connection of multiple frames of traditional battery trays usually relies on welding, which is complicated to assemble and has poor integration. It cannot effectively distribute the load of the cells, causing the weight of the battery pack to be directly transferred to the bottom plate of the lower cooling plate, resulting in local stress concentration on the bottom plate of the lower cooling plate. Long-term use can easily lead to problems such as cracking and deformation. Summary of the Invention

[0005] In view of the above problems, this application provides a casing and battery pack that improve structural strength and stability, have high integration, enhance load distribution capability, and avoid structural deformation caused by stress concentration.

[0006] In a first aspect, this application provides a battery pack, comprising: a battery assembly and a housing; the housing includes: a bottom frame, the bottom frame having a receiving cavity, the receiving cavity having a bottom opening, and a supporting flange provided at the bottom opening of the bottom frame; the battery assembly is disposed within the receiving cavity and supported by the supporting flange; wherein the load-bearing safety factor S of the supporting flange satisfies:

[0007] S≤1,

[0008] ,

[0009] Wherein, L is the overlap length of the battery pack and the supporting flange, in mm; L0 is the length of the supporting flange along the second direction, in mm; W is the total width of the battery pack along the first direction, in mm; and h is the thickness of the supporting flange, in mm. The allowable stress of the material of the supporting flange is in MPa; m is the mass of a single cell in the battery pack in kg; n is the number of single cells in the battery pack; the end of the battery pack along the second direction is supported by the supporting flange, and the first direction and the second direction form a preset angle.

[0010] In one possible implementation, the bottom frame includes an outer frame and a support beam, the support beam being connected to at least two first side frames of the outer frame opposite each other along the first direction to divide the inner cavity of the outer frame into at least two receiving cavities distributed along the second direction, and the support flanges are provided at the bottom openings of both the outer frame and the support beam.

[0011] In one possible implementation, each of the receiving cavities includes a first flange disposed on the support beam and a second flange disposed on the outer frame, wherein L is the overlap length between the battery pack and the first flange; L0 is the length of the first flange along the second direction; and h is the thickness of the first flange. The allowable stress of the material of the first flange.

[0012] In one possible implementation, the thickness h of the first flange satisfies: 2mm ≤ h ≤ 10mm; and / or, the overlap length L between the battery pack and the supporting flange satisfies: 10mm ≤ L ≤ 100mm; and / or, the total width W of the battery pack along the first direction satisfies: 250mm ≤ W ≤ 1800mm.

[0013] In one possible implementation, the housing further includes: a liner disposed within the receiving cavity and adapted to close the bottom opening; and / or a top cover, the receiving cavity having a top opening, the top cover sealing the top opening.

[0014] In one possible implementation, the liner includes a substrate portion and a retaining portion, the substrate portion being supported by the supporting flange, and the battery pack being disposed on the substrate portion; the retaining portion is disposed around the substrate portion, and the retaining portion is fitted to the peripheral wall of the receiving cavity.

[0015] In one possible implementation, there are two liner plates, each disposed within one of the two receiving cavities, and the top ends of the enclosure portions of the two liner plates facing each other are connected.

[0016] In one possible implementation, the liner is glued to the bottom frame.

[0017] In one possible implementation, the support flange extends circumferentially along the receiving cavity, and a sealing groove is formed on one side surface of the support flange facing the battery pack. The battery pack further includes a first sealant, which is disposed in the sealing groove, and the substrate and the support flange are connected through the first sealant.

[0018] In one possible implementation, the sealing groove is disposed around the receiving cavity, and the first sealant is adapted to the sealing groove.

[0019] In one possible implementation, the sealing groove surrounds the receiving cavity, and the first sealant is formed into an annular shape adapted to the sealing groove.

[0020] In one possible implementation, the sealing groove includes a first groove and a second groove arranged sequentially from the center to the edge of the receiving cavity, wherein the first groove and the second groove are both provided with the first sealant.

[0021] In one possible implementation, the width d1 of the first groove and the width d2 of the second groove satisfy: 5mm≤d2≤d1≤10mm; and / or, the depth h1 of the first groove and the depth h2 of the second groove satisfy: 0.5mm≤h2≤h1≤1.0mm.

[0022] In one possible implementation, the substrate is flat, and the support flange includes a first support segment and a second support segment connected sequentially from the center to the edge of the receiving cavity. The upper surface of the first support segment is lower than the upper surface of the second support segment, so that the first support segment and the second support segment form a stepped structure, and the substrate is supported on the first support segment.

[0023] In one possible implementation, the sealing groove is formed in the first support section.

[0024] In one possible implementation, the upper surface of the substrate is flush with the upper surface of the second support segment.

[0025] In one possible implementation, the liner further includes a baffle portion surrounding the substrate portion, the baffle portion being fitted against the peripheral wall of the receiving cavity.

[0026] In one possible implementation, the top ends of the enclosure portions on the sides of the two liner plates facing each other are connected.

[0027] In one possible implementation, the height h3 of the battery pack, the height h4 of the liner, and the depth h5 of the receiving cavity satisfy: h3≤h4≤h5; and / or, the thickness t1 of the substrate and the thickness t2 of the enclosure satisfy: t2≤t1; and / or, the enclosure is spaced apart from the inner wall of the receiving cavity, and the distance S1 between the enclosure and the inner wall of the receiving cavity satisfies: 1mm≤S1≤2mm.

[0028] In one possible implementation, the enclosure is tilted outward from the receiving cavity relative to the vertical direction.

[0029] In one possible implementation, the angle α between the enclosure and the vertical direction satisfies α≤1.5°.

[0030] In one possible implementation, the top edge of the enclosure is provided with a mounting flange, which is sandwiched between the outer frame and the top cover.

[0031] In one possible implementation, the top cover has a first connecting hole, the mounting flange has a second connecting hole, and the outer frame has a third connecting hole. The first connecting hole, the second connecting hole, and the third connecting hole are opposite to and communicate with each other. The top cover, the mounting flange, and the outer frame are connected by fasteners passing through the first connecting hole, the second connecting hole, and the third connecting hole.

[0032] In one possible implementation, the upper surface of the outer frame is provided with at least one first adhesive groove, the battery pack further includes a first connecting adhesive disposed in the first adhesive groove, and the outer frame is connected to the mounting flange through the first connecting adhesive; and / or, the upper surface of the mounting flange is provided with at least one second adhesive groove, the battery pack further includes a second connecting adhesive disposed in the second adhesive groove, and the top cover is connected to the mounting flange through the second connecting adhesive.

[0033] In one possible implementation, the housing further includes a bottom protective plate disposed at the bottom of the bottom frame, the bottom protective plate being fixedly connected to the bottom frame.

[0034] In one possible implementation, the bottom guard plate is connected to at least one of the frame body and the support flange.

[0035] In one possible implementation, the outer casing further includes: a thermal insulation element disposed at the bottom opening, the thermal insulation element being disposed between the bottom protective plate and the liner.

[0036] In one possible implementation, the density ρ1 of the insulation component satisfies: ρ1 ≥ 0.12 g / cm³ 3 ; and / or, the thermal conductivity λ of the insulation component satisfies: λ≤0.026W / (m·k).

[0037] In one possible implementation, the bottom frame is an aluminum die-cast part; and / or, the liner is a composite material part; and / or, the bottom frame is a one-piece molded part.

[0038] In one possible implementation, the battery pack includes a plurality of individual cells arranged side by side, wherein the total thickness W of the plurality of individual cells satisfies: 250mm ≤ W ≤ 1800mm.

[0039] In one possible implementation, the top cover is provided with cooling channels for the flow of coolant.

[0040] In one possible implementation, the top cover includes a flow channel plate and a heat spreader plate, the flow channel plate and the heat spreader plate being stacked, the heat spreader plate being located on the side of the flow channel plate facing the battery pack, and the cooling flow channel being formed between the flow channel plate and the heat spreader plate.

[0041] In one possible implementation, the flow channel plate is connected to the battery pack via structural adhesive.

[0042] Secondly, this application also provides an electrical device including the aforementioned battery pack.

[0043] This application provides a battery pack and an electrical device. A bottom opening is provided on the bottom frame of the battery pack casing, and the battery pack is placed on the support flange of the bottom opening. This helps to reduce the overall weight of the battery pack and allows the weight load of the battery pack to be evenly transmitted axially through the support flange, avoiding stress concentration. Moreover, by designing the structure of the support flange to meet the load-bearing safety factor, the structural strength is improved, thereby improving the stability and safety of the battery pack. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 This is a schematic diagram of the battery pack structure according to an embodiment of this application. Figure 1 ;

[0046] Figure 2 This is an exploded view of the battery pack according to an embodiment of this application;

[0047] Figure 3 for Figure 2 A schematic diagram of the structure of part A;

[0048] Figure 4 for Figure 2 Structural diagram of the bottom frame and liner Figure 1 ;

[0049] Figure 5 This is a schematic diagram of the battery pack structure according to an embodiment of this application. Figure 2 ;

[0050] Figure 6 for Figure 5 A structural diagram of section B;

[0051] Figure 7 This is a schematic diagram of the battery pack structure according to an embodiment of this application. Figure 3 ;

[0052] Figure 8 for Figure 2 Structural diagram of the bottom frame and liner Figure 2 ;

[0053] Figure 9 for Figure 8 A structural diagram of section C;

[0054] Figure 10 for Figure 8 A structural diagram of section D;

[0055] Figure 11 This is a schematic diagram of the structure supporting the flange in some embodiments of this application. Figure 1 ;

[0056] Figure 12 This is a schematic diagram of the structure supporting the flange in some embodiments of this application. Figure 2 ;

[0057] Figure 13 This is a schematic diagram of the battery pack structure according to an embodiment of this application. Figure 4 ;

[0058] Figure 14 This is a schematic diagram showing the mounting state of the substrate and the top cover in some embodiments of this application;

[0059] Figure 15 This is a schematic diagram illustrating the mounting state of the substrate and top cover in some embodiments of this application. Figure 1 ;

[0060] Figure 16 This is a schematic diagram illustrating the mounting state of the substrate and top cover in some embodiments of this application. Figure 2 ;

[0061] Figure 17 This is a schematic diagram showing the mounting state of the substrate and the top cover in some other embodiments of this application.

[0062] Explanation of reference numerals in the attached figures:

[0063] 10 - Casing; 20 - Battery pack; 21 - Battery array; 22 - Individual cell;

[0064] 100 - Base frame; 101 - Receiving cavity; 110 - Frame body; 111 - Outer frame; 1111 - First side frame; 112 - Support beam; 120 - Support flange; 121 - First flange; 122 - Second flange; 123 - Sealing groove; 1231 - First groove; 1232 - Second groove; 124 - First support section; 125 - Second support section;

[0065] 200 - Liner plate; 210 - Substrate portion; 220 - Enclosure portion; 230 - Mounting flange;

[0066] 300 - Top cover; 310 - Cooling channel; 320 - Flow channel plate; 330 - Heat spreader plate;

[0067] 400 - Bottom guard plate;

[0068] 500 - Insulation components;

[0069] 600 - First sealant;

[0070] 710 - First adhesive; 720 - Second adhesive;

[0071] 800 - Fasteners. Detailed Implementation

[0072] To make the above-mentioned objectives, features, and advantages of the embodiments of this application more apparent and understandable, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0073] Traditional battery trays typically employ a structure combining aluminum extruded profile frames and a lower cold plate base. Multiple frames are connected by arc welding to form a frame assembly, while the lower cold plate base is connected to the frame assembly via adhesive bonding, friction stir welding, or other methods to form a cavity for accommodating the battery.

[0074] Specifically, the frame consists of a front beam, a rear beam, two side beams, a middle crossbeam, and a lower support beam. The side beams and the front beam, as well as the rear beam, the middle beam and the side beams, the lower support beam and the front beam, and the rear beam are all connected by arc welding to form the frame assembly.

[0075] The lower cooling plate base plate is glued to the middle beam and connected to the frame assembly via friction stir welding to form a sealed battery cavity. The front and rear beams can be die-cast aluminum, while the side beams, middle beam, and lower support beam can be extruded aluminum. In this design, the battery cell's load-bearing capacity primarily relies on the lower cooling plate base plate, while the lower support beam reinforces and supports it.

[0076] However, this existing solution has several drawbacks: First, the entire pallet body is made of metal, resulting in a large overall weight and high cost. In addition, the connection of each frame requires a variety of complex processes, such as stamping, welding, and assembly, which leads to low production efficiency, difficulty in quality control, and complicated and cumbersome assembly work. Furthermore, the material utilization rate is low and there is a lot of waste during this process, which increases production costs. Moreover, the sealing performance of the pallet depends entirely on the welding connection between the frame and the base plate, and the sealing effect is unstable, making it prone to leakage problems after long-term use.

[0077] Furthermore, existing battery trays are made entirely of metal and lack insulation properties, requiring additional insulation layers. This increases manufacturing complexity, costs, and vehicle weight, negatively impacting driving range and energy efficiency. Additionally, the insufficient integration of existing battery trays fails to effectively distribute the cell load, causing the weight of the cell assembly to be directly transferred to the base plate. This results in localized stress concentration on the base plate, making it prone to cracking or deformation over long-term use, severely affecting the overall reliability of the battery pack.

[0078] In view of this, the present application provides a battery pack and an electrical device. A bottom opening is provided on the bottom frame of the battery pack shell, and the battery pack is placed on the support flange of the bottom opening. This helps to reduce the overall weight of the battery pack and allows the weight load of the battery pack to be evenly transmitted axially through the support flange, avoiding stress concentration. Moreover, by designing the structure of the support flange to meet the load-bearing safety factor, the structural strength is improved, thereby improving the stability and safety of the battery pack.

[0079] The embodiments of this application will now be described in detail with reference to the accompanying drawings. Optionally, x represents a first direction and y represents a second direction.

[0080] This application provides a battery pack 20, which can be a hybrid electric vehicle battery pack 20, a plug-in hybrid electric vehicle battery pack 20, a pure electric vehicle battery pack 20, etc.

[0081] Combination Figures 1 to 5 The battery pack 20 may include a battery pack 21 and a housing 10. The housing 10 includes a bottom frame 100, which is an integrally formed part. The bottom frame 100 has a receiving cavity 101 with a top opening and a bottom opening. A supporting flange 120 is provided at the bottom opening of the bottom frame 100. The battery pack 21 is disposed in the receiving cavity 101 and supported by the supporting flange 120.

[0082] The battery pack 21 can be a storage unit composed of multiple individual batteries 22, which can be implemented by stacking them side by side.

[0083] Optionally, the base frame 100 can be integrally formed using an aluminum die-casting process, forming a complete frame structure in a single process, avoiding reliance on separate connection processes (such as welding), and also improving structural strength.

[0084] The support flange 120 serves as a load-bearing structure and can extend circumferentially along the bottom of the receiving cavity 101. It can distribute the load of the battery pack 21 to the entire bottom frame 100, avoiding local stress concentration. In some examples, the support flange 120 can form a U-shaped horizontal flange at the bottom of the receiving cavity 101.

[0085] Specifically, the bottom frame 100 can be formed by an integral molding process to form a receiving cavity 101. The supporting flange 120 can extend along the circumference of the receiving cavity 101 as a bottom load-bearing structure. When the battery pack 21 is installed, it can be placed directly on the supporting flange 120, and its load can be transferred to the whole bottom frame 100 through the supporting flange 120.

[0086] By using a one-piece molded base frame 100 design, compared to the traditional multiple connecting welds, the frame structure of the outer shell 10 is integrated, reducing assembly processes and the number of welding points, and improving the overall structural strength.

[0087] As can be seen, the outer shell 10 of this application replaces the multi-part welding connection of the traditional solution with the design of the one-piece molded bottom frame 100, which simplifies the assembly process, improves the structural strength and stability, and has a high degree of integration. In addition, the design of the support flange 120 makes the weight load of the battery pack 21 evenly distributed through the surrounding frame, avoiding stress concentration. The support flange 120 also provides a positioning reference for the installation of the battery pack 21, improving assembly accuracy and production efficiency.

[0088] Furthermore, in some embodiments, combined with Figures 1 to 5 The outer casing 10 may include a bottom frame 100, a liner 200, and a top cover 300. The bottom frame 100 is an integrally formed part. The bottom frame 100 includes a frame body 110 and a support flange 120. The frame body 110 includes an outer frame 111 and a support beam 112. The support beam 112 is connected to at least two first side frames 1111 opposite to the outer frame 111 along a first direction (such as the x direction) to divide the inner cavity of the outer frame 111 into at least two receiving cavities 101 distributed along a second direction (such as the y direction). The first direction is perpendicular to the second direction.

[0089] The receiving cavity 101 has a top opening and a bottom opening. The bottom openings of the outer frame 111 and the support beam 112 are both provided with support flanges 120, and the battery pack 21 is supported on the support flanges 120. The liner 200 is disposed in the receiving cavity 101 and is adapted to close the bottom opening; the top cover 300 covers the top opening.

[0090] The bottom of the battery pack 21 can be directly supported by the support flange 120, so that the load of the battery pack 21 can be distributed to the outer frame 111 and support beam 112 of the bottom frame 100 of the outer casing 10 through the support flange 120, thus avoiding local stress concentration.

[0091] Optionally, the liner 200 can be made of composite materials, such as glass fiber reinforced plastic, which can provide sealing support, reduce the overall weight of the housing 10, and achieve insulation. The insulation design of the liner 200 eliminates the need for additional insulation layers due to its excellent insulation properties, simplifying the structure, avoiding the risks of misalignment, wrinkles, or damage that may occur due to multi-layer assembly, and improving the reliability of the insulation system.

[0092] Optionally, the top cover 300 can be made of sheet metal by stamping. Optionally, the top cover 300 can be integrated with a cooling channel 310 to realize thermal management function.

[0093] Specifically, the liner 200 can be fitted onto the inner side of the supporting flange 120 to close the bottom opening. Optionally, the liner 200 can also be glued to the bottom frame 100 to form a double-sealed structure. The glue can also distribute local shear stress, achieving reasonable load path distribution and stress control. Optionally, the top cover 300 can be fixed to the top of the frame body 110 by bolts, welding, or other means, forming a complete outer shell 10 together with the bottom frame 10.

[0094] The outer frame 111 may be a frame structure that forms the outer contour of the receiving cavity 101, and may be integrally formed with the support beam 112 by die casting. The support beam 112 may be a transverse connecting member disposed on the inner side of the outer frame 111, and may be integrally formed with the outer frame 111, used to divide the inner cavity of the outer frame 111 into two or more receiving cavities 101 to distribute the load.

[0095] Specifically, the two first side frames 1111 of the outer frame 111 can extend horizontally to form a support base, and the support beam 112 is connected to the inner side of the outer frame 111 to divide the single cavity into two or more independent receiving cavities 101. Optionally, the outer frame 111 and the support beam 112 can both be provided with support flanges 120 to provide a support surface for the battery pack 21.

[0096] The integrated frame structure 110, compared to traditional multiple connecting welds, achieves the integration of the frame structure of the outer shell 10, reducing assembly processes and the number of welding points, and improving the overall structural strength. Furthermore, the division of multiple receiving cavities 101 allows for a more even distribution of the battery cell load on the support beam 112 and the outer frame 111. Additionally, the integrated support flange 120 design, formed integrally with the frame structure 110, enhances the continuity of the bottom support surface, improving sealing reliability and support strength.

[0097] It is evident that the combined design of the supporting flange 120 and the liner 200 improves the sealing effect of the receiving cavity 101, and can also distribute the load of the battery pack 21 to the entire bottom frame 100, thereby improving the load distribution capability, avoiding structural deformation caused by stress concentration, and enhancing the reliability of the outer casing 10.

[0098] In another embodiment disclosed in this application, the bottom frame may also be a non-integral structure, i.e., a split structure. Specifically, the support beam 112 may be directly connected to the outer frame 111, and the frame body provided on the outer frame 111 has multiple side beams. The multiple side beams may be connected by welding or other connection methods to form the frame body, so as to facilitate the production and manufacturing of the bottom frame.

[0099] See also Figure 7 , Figure 7 This is a schematic diagram of the battery pack structure according to an embodiment of this application. Figure 3 The diagram illustrates the position of the battery pack 21 when it is supported by the flange 120.

[0100] The load-bearing safety factor S supporting the 120mm flange satisfies: S≤1, Where L is the overlap length of the battery pack 21 and the support flange 120, in mm, optionally 10mm≤L≤100mm; L0 is the length of the support flange 120 along the second direction, in mm; W is the total width of the battery pack 21 along the first direction, in mm; h is the thickness of the support flange 120, in mm, 2mm≤h≤10mm; The allowable stress of the material supporting the flange 120 is in MPa; m is the mass of the single cell 22 in kg. The end of the battery pack 21 along the second direction is supported on the supporting flange 120, and the first direction and the second direction form a preset angle.

[0101] Specifically, the inventors of this application have discovered that when the supporting flange 120 of the battery pack satisfies S≤1, it can be ensured that when the battery pack 21 is attached to the supporting flange 120, the supporting flange 120 can provide sufficient support force, that is, the maximum bending stress of the supporting flange 120 is less than the allowable stress of the material, so as to ensure that the supporting flange 120 supports the battery pack 21 normally and without the risk of stress concentration failure, thereby improving the safety of the battery pack.

[0102] Understandably, in the above embodiments, S > 0.

[0103] In some embodiments, the supporting flange 120 also satisfies: W=nt, where n is the number of individual cells 22 in a single battery pack 21; t is the thickness of the individual cell 22 in mm.

[0104] The battery pack 21 may include a plurality of individual cells 22 arranged side by side. The total width W of the battery pack 21 along the first direction is W=nt, where n is the number of individual cells 22 in a single battery pack 21 and t is the thickness of the individual cell 22.

[0105] In some embodiments, the multiple individual cells 22 have the same specifications and the thickness of each individual cell 22 is equal (t). Thus, the total width W of the battery pack 21 along the first direction can be the product of the number n of individual cells 22 in a single battery pack 21 and the thickness t of the individual cell 22.

[0106] In other embodiments, the plurality of individual cells 22 within the battery pack 21 may have at least two different specifications, and the individual cells 22 of different specifications may have different thicknesses. In this case, the total width W of the battery pack 21 along the first direction is the sum of the thicknesses of the plurality of individual cells 22.

[0107] In some embodiments, combined with Figure 2 and Figure 4 Each receiving cavity 101 includes a support flange 120 comprising a first flange 121 disposed on the support beam 112 and a second flange 122 disposed on the outer frame 111; wherein, L is the overlap length between the battery pack 21 and the first flange 121; L0 is the length of the first flange 121 along the second direction; and h is the thickness of the first flange 121. The allowable stress of the material of the first flange 121.

[0108] The first flange 121 can be a structural component that is integrally formed with the support beam 112 and located at the bottom edge of the support beam 112. The second flange 122 can be a structural component that is integrally formed with the outer frame 111 and located at the bottom edge of the outer frame 111. The first flange 121 and the second flange 122 together constitute the continuous bearing surface of the support flange 120.

[0109] L, L0, h and Further detailed design clarifies that the calculation of the load-bearing safety factor S is based on the mechanical performance evaluation of the first flange 121 of the support flange 120. The first flange 121 is the main load-bearing flange. By ensuring that the first flange 121 meets the safety requirements, the battery pack 21 as a whole can be reliably supported. Thus, when the battery pack 21 is placed on the support surface composed of the first flange 121 and the second flange 122, the weight can be transferred to the entire bottom frame 100 through the main load-bearing of the first flange 121, i.e. the support beam 112, and the auxiliary load-bearing of the second flange 122, i.e. the outer frame 111, avoiding the load being concentrated on a single component and ensuring the reliability of the outer shell 10.

[0110] In some embodiments, the thickness h of the first flange 121 satisfies: 2mm ≤ h ≤ 10mm. Optionally, the thickness h of the first flange 121 can be 2mm, 3mm, 4mm, 6mm, 8mm, 9mm, 10mm, etc.

[0111] Understandably, in some cases, insufficient support strength may occur when the thickness is less than 2mm, while exceeding 10mm may lead to material waste and excessive weight. By limiting the thickness range of the first flange 121 within the above-mentioned range, the structural strength can be guaranteed while avoiding the increase in weight due to material accumulation, thereby improving the overall structural reliability of the outer shell 10.

[0112] In some embodiments, combined with Figure 2 and Figure 4 The liner 200 includes a substrate 210 and a baffle 220. The substrate 210 is supported on the support flange 120. The battery pack 21 is disposed on the substrate 210. The baffle 220 surrounds the substrate 210 and fits against the peripheral wall of the receiving cavity 101.

[0113] The substrate 210 can be a flat plate covering the surface of the supporting flange 120, and can be made of injection-molded composite material, which can be used to directly support the bottom load of the battery pack 21. The enclosure 220 can be an enclosure structure extending perpendicular to the edge of the substrate 210, and can be integrally formed with the substrate 210. Its outer surface can form a clearance fit or an interference fit with the inner wall of the receiving cavity 101. In addition, the enclosure 220 can also be separately formed from the substrate 210 for easy manufacturing.

[0114] Specifically, the substrate 210 covers the upper surface of the support flange 120, so that the weight of the battery pack 21 is transferred to the frame body 110 of the bottom frame 100 through the support flange 120, avoiding the load from acting directly on the bottom opening area. The enclosure 220 extends circumferentially along the substrate 210 and fits the inner wall of the receiving cavity 101, forming a closed structure for the bottom opening to prevent foreign objects from entering the receiving cavity 101.

[0115] Optionally, the liner 200 can be adhesively bonded to the base frame 100, specifically using epoxy resin or polyurethane adhesive. After the adhesive cures, a continuous sealed interface is formed between the liner 200 and the base frame 100. Adhesive bonding allows for a flexible connection between the contact area of ​​the liner 200 and the base frame 100, blocking liquid penetration paths and allowing for minor deformation of the material due to temperature changes.

[0116] Thus, a mechanical seal is formed by the fit between the enclosure 220 and the periphery of the receiving cavity 101, and a double seal is achieved by the adhesive connection between the liner 200 and the bottom frame 100. The synergistic effect of the enclosure 220 and the adhesive layer improves the sealing reliability of the bottom opening and prevents coolant or external contaminants from seeping into the battery pack 21 area.

[0117] Furthermore, the planar support structure of the substrate 210 and its adhesive connection with the base frame 100 further distribute the local shear stress, thereby achieving reasonable distribution of the load path and stress control, reducing the risk of local stress concentration on the base plate and extending the service life of the component.

[0118] In some embodiments, combined with Figure 2 and Figure 4 There are two liner plates 200, which are respectively disposed in two receiving cavities 101, and the top ends of the enclosure portions 220 of the two liner plates 200 facing each other are connected.

[0119] Understandably, the design of multiple receiving cavities 101 can improve the bending stiffness of the base frame 100. The number of liner plates 200 can correspond to the number of receiving cavities 101; when there are two receiving cavities 101, there will also be two liner plates 200. The two liner plates 200 are respectively installed in the two receiving cavities 101 separated by the support beam 112, and the enclosure portion 220 of the liner plate 200 fits against the peripheral wall of the receiving cavity 101.

[0120] The top of the enclosure portion 220 of the adjacent liner 200 can form a continuous interface through a connecting structure or an integral molding design. In this way, the two liners 200 can independently support their respective battery packs 21 while forming an integral structure through the connection between the adjacent enclosure portions 220, which further improves the support strength and avoids interface gaps or misalignment problems caused by the split design.

[0121] In some embodiments, combined with Figure 4 , Figures 8 to 10 ,as well as Figures 14 to 17 The supporting flange 120 extends circumferentially along the receiving cavity 101. A sealing groove 123 is provided on the side surface of the supporting flange 120 facing the battery pack 21. The sealing groove 123 extends circumferentially along the receiving cavity 101. The battery pack 20 also includes a first sealant 600, which is disposed in the sealing groove 123. The substrate 210 and the supporting flange 120 are connected by the first sealant 600.

[0122] Optionally, the sealing groove 123 is disposed around the receiving cavity 101, and the first sealant 600 is adapted to the structure of the sealing groove 123. For example, the sealing groove 123 surrounds the receiving cavity 101, and the first sealant 600 is formed in an annular shape adapted to the sealing groove 123. Thus, the annular first sealant 600 forms a complete and reliable sealing barrier between the substrate portion 210 and the support flange 120.

[0123] Optionally, the first sealant 600 can be made of a material with high adhesion, aging resistance, high and low temperature resistance, and elasticity, such as silicone sealant, polyurethane sealant, modified epoxy resin, etc. During assembly, it is filled into the sealing groove 123 by means of dispensing, scraping, etc., and then the liner 200 is pressed together to fill and cure the first sealant 600 to form a continuous and uniform sealant layer.

[0124] Thus, the first sealant 600 forms a reliable sealing barrier between the substrate 210 and the support flange 120, preventing external moisture, dust and other contaminants from entering the cavity 101 from the bottom opening, protecting the battery pack 21 from environmental corrosion and improving the reliability of the battery pack 20.

[0125] Furthermore, the elastic bonding properties of the first sealant 600 allow for slight differences in thermal expansion and contraction between the substrate 210 and the support flange 120, avoiding stress concentration that may occur with rigid connections and improving the structure's adaptability to temperature-changing conditions.

[0126] In addition, the filling of the first sealant 600 enhances the connection stiffness between the substrate 210 and the support flange 120, which helps to disperse local stress and provides a certain buffering effect against vibration and impact.

[0127] In some embodiments, combined with Figure 8 , Figure 9 , Figure 11 and Figure 12 ,as well as Figure 13 , Figure 14 , Figure 15 , Figure 16 and Figure 17 The sealing groove 123 includes a first groove 1231 and a second groove 1232 arranged sequentially from the center to the edge of the receiving cavity 101. The first groove 1231 and the second groove 1232 are each provided with a first sealant 600.

[0128] Optionally, the cross-sections of the first slot 1231 and the second slot 1232 can be polygonal, such as rectangular.

[0129] Thus, both the first groove 1231 and the second groove 1232 are filled with the first sealant 600, forming a double sealing structure. When the substrate portion 210 of the liner 200 is pressed against the support flange 120, the first sealant 600 forms two independent sealing barriers in the first groove 1231 and the second groove 1232, enhancing the reliability of the seal.

[0130] If the sealing performance of the second groove 1232 on the outer side decreases due to long-term aging, mechanical damage, or other reasons, the first groove 1231 on the inner side can still effectively block the intrusion of contaminants, thus improving the sealing effectiveness.

[0131] In addition, this dual-seal design increases the sealing contact area between the substrate 210 and the support flange 120, improving the connection stability between the two.

[0132] In some embodiments, combined with Figure 11 and Figure 12 Optionally, the width d1 of the first slot 1231 and the width d2 of the second slot 1232 satisfy: 5mm≤d2≤d1≤10mm.

[0133] For example, the width combinations of d2 and d1 can be: d2=d1=5mm; d2=5mm,d1=6mm; d2=6mm,d1=7mm; d2=7mm,d1=8mm; d2=9mm,d1=10mm; d2=d1=10mm.

[0134] By limiting d1 and d2 to no more than 10mm, it can be ensured that the first groove 1231 and the second groove 1232 will not excessively weaken the load-bearing cross section of the support flange 120, thus ensuring the structural strength and rigidity of the support flange 120 supporting the battery pack 21.

[0135] Furthermore, by limiting d2 to not less than 5mm and d2≤d1, the first groove 1231, located on the inner side, is closer to the center of the receiving cavity 101 and bears higher and more direct medium pressure. The width d1 of the first groove 1231 is designed to be wider to accommodate more first sealant 600, forming a thicker and more reliable main sealing barrier to withstand internal pressure. The second groove 1232, located on the inner side, can serve as an auxiliary seal, blocking external contaminants and acting as a secondary line of defense. The pre-designed width d2 of the second groove 1232 ensures effective sealing while saving space and materials.

[0136] It can be seen that by controlling the width relationship between the first groove 1231 and the second groove 1232, the balance between sealing performance and structural strength can be ensured, thereby improving sealing reliability.

[0137] In some embodiments, combined with Figure 11 and Figure 12Optionally, the depth h1 of the first groove 1231 and the depth h2 of the second groove 1232 satisfy: 0.5mm≤h2≤h1≤1.0mm.

[0138] For example, the combinations of h2 and h1 can be: h2=h1=0.5mm; h2=0.5mm, h1=0.6mm; h2=0.7mm, h1=0.8mm; h2=0.8mm, h1=0.9mm; h2=0.9mm, h1=1.0mm; h2=h1=1.0mm.

[0139] By limiting h1 to no more than 1.0 mm, it can be ensured that the depth of the first groove 1231 and the second groove 1232 will not excessively weaken the effective load-bearing thickness of the support flange 120, thus ensuring the structural strength and rigidity of the support flange 120 supporting the battery pack 21.

[0140] Furthermore, by requiring h2 to be no less than 0.5mm and h2≤h1, the first groove 1231 on the inner side serves as the main sealing barrier. The depth h1 of the first groove 1231 is designed to be deeper to accommodate a larger volume of the first sealant 600 to form a thick and reliable seal. The second groove 1232 on the outer side serves as an auxiliary seal. The small amount and moderate depth h2 ensures effective filling and also helps to control the amount of adhesive used, thus saving costs.

[0141] In this way, by limiting the depth relationship between the first groove 1231 and the second groove 1232, a balance between sealing reliability and structural integrity can be ensured, and the filling effect can be guaranteed.

[0142] In other embodiments of this application, the support flange 120 may also be provided with multiple sealing grooves 123 to further improve the connection reliability between the liner 200 and the bottom frame 100.

[0143] In some embodiments, combined with Figure 11 , Figure 12 and Figure 14 The substrate 210 is flat, and the support flange 120 includes a first support section 124 and a second support section 125 connected sequentially from the center to the edge of the receiving cavity 101. The upper surface of the first support section 124 is lower than the upper surface of the second support section 125 so that the first support section 124 and the second support section 125 form a stepped structure. The substrate 210 is supported on the first support section 124.

[0144] The stepped structure design of the first support section 124 and the second support section 125 provides an accurate positioning reference for the substrate 210, enabling the substrate 210 to be installed quickly and accurately, thus improving assembly efficiency. Furthermore, this stepped structure also forms a mechanical limit, effectively preventing horizontal displacement of the substrate 210 when subjected to vibration or impact, thereby enhancing structural stability.

[0145] Optionally, the sealing groove 123 is formed in the first support section 124. The first sealant 600 filled in the sealing groove 123 forms a sealant limit after curing, which further enhances the constraint of the substrate 210 in the plane. In this way, the synergistic effect of the stepped limit and the sealant limit is realized, forming a stable constraint on the substrate 210.

[0146] In some embodiments, combined with Figure 14 The upper surface of the substrate 210 is flush with the upper surface of the second support section 125.

[0147] This design enables the substrate 210 and the second support section 125 to form a complete and continuous support plane, providing a uniform and stable support foundation for the battery pack 21 above them. This avoids uneven stress on the battery pack 21 caused by height differences and ensures the rationality of load distribution.

[0148] Furthermore, the flat upper surface design of the substrate 210 and the second support section 125 makes it difficult to directly observe the joint between the edge of the substrate 210 and the second support section 125, thus improving the visual integrity and aesthetics of the battery pack 20. In addition, this flush joint surface design also reduces dust accumulation dead corners, making cleaning and maintenance easier.

[0149] In some embodiments, combined with Figures 8 to 10 , Figures 15 to 17 The liner 200 also includes a baffle 220, which surrounds the substrate 210 and fits against the peripheral wall of the receiving cavity 101.

[0150] Optionally, the enclosure portion 220 and the substrate portion 210 are integrally formed.

[0151] The design of the enclosure 220 forms a physical barrier between the substrate 210 and the peripheral wall of the receiving cavity 101. Even if a small amount of impurities from below break through the seal between the substrate 210 and the support flange 120, they will be blocked by the enclosure 220, which enhances the protection capability of the battery pack 20 and forms a double-sealed defense.

[0152] In addition, the fit between the enclosure 220 and the perimeter wall of the receiving cavity 101 provides radial support and positioning for the liner 200, enhancing the overall rigidity and stability of the liner 200 when subjected to internal pressure or external impact, and preventing the liner 200 from shifting or deforming laterally.

[0153] In some embodiments, not shown in the figures, the top ends of the enclosure portions 220 of the two liner plates 200 facing each other are connected.

[0154] The enclosure portion 220 of the two liner plates 200 is connected at the top, so that the two originally independent liner plates 200 are connected at the top, which enhances the overall rigidity of the liner plates 200 in the second direction of the battery pack 20, suppresses the relative displacement or deformation of the liner plates 200 caused by vibration or internal pressure fluctuation, and improves the stability of the structure.

[0155] In addition, the connected enclosure 220 forms a continuous reinforcing rib between two adjacent receiving cavities 101, which helps to distribute local loads (such as thermal runaway impacts of a single battery pack 21) more evenly to a larger structural area, thereby improving the overall impact resistance and reliability of the battery pack 20.

[0156] In some embodiments, combined with Figure 15 and Figure 16 The height h3 of the battery pack 21, the height h4 of the liner 200, and the depth h5 of the receiving cavity 101 satisfy the following condition: h3≤h4≤h5. Here, the height h4 of the liner 200 refers to the sum of the thickness of the substrate 210 and the height of the enclosure 220.

[0157] Optionally, the liner 200 may be made of composite materials, such as glass fiber reinforced plastic, which can provide sealing support, reduce the overall weight of the housing 10, and achieve insulation.

[0158] Wherein, h3≤h4 ensures that the height of the liner 200 is sufficient to fully accommodate the battery pack 21, providing the necessary constraints and protection for the battery pack 21 to prevent it from shifting or colliding during transportation or use. In addition, h4≤h5 ensures that the liner 200 (including the substrate portion 210 and the enclosure portion 220) can be completely accommodated inside the receiving cavity 101, so that the top of the liner 200 will not protrude and interfere with the installation of other components, ensuring the compactness of the battery pack 20 structure and the smoothness of assembly.

[0159] Furthermore, the design of h3≤h4≤h5 ensures a stable and safe insulation distance between the battery pack 21 and the bottom frame 100 through the insulation effect of the insulating plate 200. The h3≤h4 design guarantees that the battery pack 21 is enclosed within the insulating plate 200, while the h4≤h5 design ensures that there is no interference between the insulating plate 200 and the bottom frame 100, preventing the risk of electrical short circuits due to direct contact or insufficient spacing between the battery pack 21 and the bottom frame 100.

[0160] In some embodiments, combined with Figure 15 and Figure 16 The thickness t1 of the substrate 210 and the thickness t2 of the enclosure 220 satisfy: 1mm≤t2≤t1≤2mm.

[0161] For example, t2 can be 1mm, 1.2mm, 1.4mm, 1.5mm, 1.7mm, or 1.9mm; t1 can be 1.2mm, 1.4mm, 1.6mm, 1.8mm, or 2mm, and t2 ≤ t1.

[0162] The substrate 210 serves as the main load-bearing surface, directly supporting the entire weight of the battery pack 21. It forms the main sealing interface with the support flange 120 through the first sealant 600. Therefore, a large thickness t1 (t1≤2mm) is required to ensure that it has sufficient bending stiffness, strength and stability of the sealing surface, and to prevent deformation or sealing failure under long-term load.

[0163] The main function of the enclosure section 220 is lateral insulation and protection. The stress state is mainly in-plane pressure, and the thickness requirement is relatively low. Therefore, a smaller thickness t2 (t2≥1mm) is adopted to reduce the overall weight while meeting the insulation and basic structural strength requirements. In this way, the material is rationally distributed and lightweight.

[0164] In some embodiments, combined with Figures 15 to 17 The enclosure 220 is inclined outward from the receiving cavity 101 relative to the vertical direction.

[0165] The inclined enclosure 220 can form a tapered guide structure that is narrow at the top and wide at the bottom. When the liner 200 is installed into the receiving cavity 101, it can play a role in automatic centering and guidance, making the assembly process smoother and more convenient.

[0166] Furthermore, the outward tilting structural design makes the enclosure 220 more prone to pressure rather than bending when subjected to pressure from inside the housing cavity 101, such as gas pressure generated by battery thermal runaway. This allows the load to be transferred more effectively to the substrate 210 and the bottom frame 100, improving the internal pressure resistance and overall stability of the liner 200.

[0167] In some embodiments, combined with Figure 15 and Figure 16 The angle α between the enclosure part 220 and the vertical direction satisfies α≤1.5°.

[0168] Optionally, the enclosure 220 can also be fitted to the support beam 112. In this design, the angle α between the enclosure 220 and the vertical direction is 0°.

[0169] For example, α can be selected as 0°, 0.3°, 0.8°, 1°, 1.3°, 1.5°, etc.

[0170] The small tilt angle design of α≤1.5° is sufficient to provide effective guidance and centering during the installation of the liner 200, and also ensures adequate connection and fixation between the enclosure 220 and the support beam 112, achieving good lateral sealing and support.

[0171] In addition, the small tilt angle design reduces the significant bending stress generated by the large angle when the enclosure part 220 is subjected to internal pressure, thereby improving the compressive stability while minimizing the material thickness and weight.

[0172] In some embodiments, combined with Figure 15 and Figure 16 The enclosure portion 220 is spaced apart from the inner wall of the receiving cavity 101, and the distance S1 between the enclosure portion 220 and the inner wall of the receiving cavity 101 satisfies the range of 1mm ≤ S1 ≤ 2mm. For example, the selectable values ​​of S1 are 1mm, 1.2mm, 1.4mm, 1.5mm, 1.8mm, 2mm, etc.

[0173] By controlling the distance S1 between the enclosure 220 and the inner wall of the receiving cavity 101 within a reasonable range, a reasonable tolerance space is provided for the manufacturing tolerance and thermal expansion of the liner 200, avoiding installation interference caused by processing or assembly errors, and ensuring that the structure can freely expand and contract without generating excessive thermal stress when the temperature changes.

[0174] In addition, this gap also forms a buffer zone, which can mitigate and dissipate instantaneous impact energy when the battery pack experiences extreme situations such as thermal runaway.

[0175] In some embodiments, combined with Figure 17 The top edge of the enclosure 220 is provided with a mounting flange 230, which is sandwiched between the outer frame 111 and the top cover 300.

[0176] Optionally, the mounting flange 230, the enclosure portion 220, and the substrate portion 210 are integrally formed.

[0177] Optionally, the mounting flange 230 can also be clamped between the support beam 112 and the top cover 300.

[0178] The flange 230 serves as the top fixing point of the enclosure 220. By being clamped between the outer frame 111 and the top cover 300, it provides reliable top fixing for the entire liner 200, enhances the installation stability of the liner 200, and effectively prevents it from shifting under vibration or impact.

[0179] In addition, the clamping of the mounting flange 230 by the outer frame 111 and the top cover 300 creates a sealing line between the top cover 300 and the outer frame 111, which helps to prevent external contaminants from entering from the top and further ensures the overall sealing of the battery pack 20.

[0180] In actual installation, the liner 200 can be pre-positioned on the outer frame 111 through its mounting flange 230, and then the top cover 300 is installed for final clamping and fixing, which improves the convenience of assembly and simplifies the assembly process.

[0181] In some embodiments, combined with Figure 17 The top cover 300 is provided with a first connecting hole, the mounting flange 230 is provided with a second connecting hole, and the outer frame 111 is provided with a third connecting hole. The first connecting hole, the second connecting hole, and the third connecting hole are opposite to each other and are connected. The top cover 300, the mounting flange 230, and the outer frame 111 are connected by fasteners 800 passing through the first connecting hole, the second connecting hole, and the third connecting hole.

[0182] Optionally, fastener 800 can be selected as rivets, bolts and nuts, rivet bolts and nuts, press-fit bolts and nuts, etc.

[0183] Optionally, the support beam 112 may also have a third connecting hole, and the top cover 300, the mounting flange 230 and the support beam 112 may also be connected by fasteners 800 passing through the first connecting hole, the second connecting hole and the third connecting hole.

[0184] Fastener 800 passes through the first connecting hole, the second connecting hole and the third connecting hole to achieve a rigid connection between the top cover 300, the mounting flange 230 and the outer frame 111. This multi-point fastening method achieves a firm fixation of the top cover 300, the liner 200 and the outer frame 111, enhancing the overall structural rigidity and stability of the battery pack 20.

[0185] In addition, the fastening connection of fastener 800 provides uniform clamping force, ensuring a reliable sealing contact between mounting flange 230 and top cover 300 and outer frame 111, thus improving the sealing performance of the top.

[0186] In some embodiments, combined with Figures 14 to 17 The upper surface of the outer frame 111 is provided with at least one first adhesive groove, and the battery pack 20 also includes a first connecting adhesive 710 disposed in the first adhesive groove. The outer frame 111 and the mounting flange 230 are connected by the first connecting adhesive 710.

[0187] Optionally, the first adhesive 710 can be made of a material with high adhesion, aging resistance, high and low temperature resistance, and elasticity, such as silicone sealant, polyurethane sealant, or modified epoxy resin. During assembly, it is filled into the first adhesive groove by dispensing, scraping, or other methods. Then, the mounting flange 230 is pressed together to fill and cure the first adhesive 710, forming a continuous and uniform sealant layer.

[0188] Optionally, a first adhesive groove for filling the first connecting adhesive 710 may also be provided on the upper surface of the support beam 112, and the support beam 112 and the mounting flange 230 are connected by the first connecting adhesive 710.

[0189] The first adhesive groove provides a stable space for the first adhesive 710, ensuring uniform distribution of the adhesive and forming a reliable bonding and sealing layer, which enhances the sealing performance of the connection. In addition, the elastic bonding performance of the first adhesive 710 can effectively absorb and buffer the vibration energy between the outer frame 111 and the mounting flange 230, reducing the risk of fatigue damage to the connection structure caused by vibration.

[0190] In some embodiments, combined with Figures 14 to 17 The upper surface of the mounting flange 230 is provided with at least one second adhesive groove, and the battery pack 20 also includes a second connecting adhesive 720 disposed in the second adhesive groove. The top cover 300 and the mounting flange 230 are connected by the second connecting adhesive 720.

[0191] Optionally, the second adhesive 720 can be made of a material with high adhesion, aging resistance, high and low temperature resistance, and elasticity, such as silicone sealant, polyurethane sealant, or modified epoxy resin. During assembly, it is filled into the second adhesive groove by dispensing, scraping, or other methods. Then, the top cover 300 is pressed together to fill and cure the second adhesive 720, forming a continuous and uniform sealant layer.

[0192] The second adhesive groove provides a stable space for the second adhesive 720, ensuring uniform distribution of the adhesive and forming a reliable bonding and sealing layer, thus enhancing the sealing performance of the top connection. Furthermore, the elastic bonding properties of the second adhesive 720 effectively absorb and buffer vibration energy between the top cover 300 and the mounting flange 230, reducing the risk of fatigue damage to the connection structure caused by vibration.

[0193] Secondly, this bonding method avoids creating too many connection holes in the thin-walled structure, which helps maintain the structural integrity of the top cover 300. The application of the second bonding adhesive 720 achieves reliable connection while improving the vibration damping performance and sealing reliability of the battery pack 20.

[0194] In another embodiment disclosed in this application, the liner 200 may only include a substrate portion 210 supported on a support flange 120, and the battery pack 21 is disposed on the substrate portion 210.

[0195] The substrate 210 can be a flat plate structure covering the surface of the supporting flange 120, which can be realized by injection molding of a composite material plate and can be used to directly support the load of the battery pack 21.

[0196] Furthermore, in the above embodiments, the peripheral wall of the receiving cavity 101 may be provided with an insulating layer to achieve insulation between the bottom frame and the battery pack 21.

[0197] In some embodiments, combined with Figure 2 The housing 10 also includes a bottom protective plate 400, which is disposed at the bottom of the bottom frame 100 and fixedly connected to the bottom frame 100. The bottom protective plate 400 may be an external protective structure covering the bottom of the bottom frame 100, which can be used to protect the bottom opening from external impacts.

[0198] Optionally, the bottom cover 400 may be made of insulating material, such as engineering plastics or fiber-reinforced composite materials. Alternatively, the bottom cover 400 may also be made of metal, such as steel, steel alloys, aluminum, or aluminum alloys. Alternatively, the bottom cover 400 may be a composite of insulating material and metal material.

[0199] Optionally, the liner 200 can be formed using high pressure resin transfer molding (HP-RTM), prepreg molding (PCM), and sheet molding compound (STM) processes.

[0200] Optionally, the bottom guard plate 400 is connected to at least one of the frame body 110 and the support flange 120, and the connection method can be bolts, welding or other methods.

[0201] It is evident that the rigid connection between the bottom guard plate 400 and the bottom frame 100 enhances the bottom's impact resistance and further improves the support reliability of the outer shell 10.

[0202] In some embodiments, combined with Figure 2 The outer casing 10 also includes a thermal insulation element 500, which is located at the bottom opening and between the bottom protective plate 400 and the liner 200. The thermal insulation element 500 can be a heat insulation material layer, which can be used to block temperature conduction, maintain the operating temperature of the battery cell, and buffer energy absorption, etc.

[0203] Optionally, the insulation component 500 is at least one of polypropylene or polyurethane. Optionally, the density ρ1 of the insulation component 500 is ≥ 0.12 g / cm³. 3 Optionally, the thermal conductivity λ of the insulation component 500 is ≤0.026W / (m·k).

[0204] Optionally, the insulation component 500 can be filled by pre-cut sheets bonded to the upper surface of the bottom protective plate 400 with structural adhesive.

[0205] Optionally, the insulation component 500 can also be filled by first installing the bottom protective plate 400 at the bottom of the bottom frame 100. At this time, there is a gap between the bottom protective plate 400 and the liner 200. The mixed foam is injected into this gap using an online foaming method. After a period of time, the foam expands and completely fills the gap, forming the insulation component 500. At this time, the insulation component 500 bonds the bottom protective plate 400 and the liner 200 together. This can save the amount of structural adhesive and improve the connection stability of the bottom protective plate 400 and the liner 200.

[0206] Understandably, the insulation component 500 can be sandwiched between the bottom protective plate 400 and the liner 200 to form a thermal barrier layer. Optionally, the bottom protective plate 400 can be made of metal, and the liner 200 can be made of composite material. The insulation component 500 forms a thermal insulation layer between the metal bottom protective plate 400 and the composite material liner 200, which can prevent stress concentration between different materials caused by temperature changes and play a role in thermal insulation and buffering energy absorption.

[0207] In some embodiments, the bottom frame 100 may be a die-cast aluminum part; the liner 200 may be a composite material part.

[0208] Specifically, the aluminum die-casting part can be an integral aluminum alloy frame formed by high-pressure casting process. For example, ADC12 aluminum alloy material can be used. The aluminum die-casting part has high overall strength. The composite material part can be a structural plate made of fiber-reinforced matrix. For example, carbon fiber reinforced epoxy resin matrix can be used. The composite material part has the characteristics of lightweight and high strength.

[0209] The aluminum die-cast base frame 100 can be integrated into a frame body 110 with a supporting flange 120 through an integrated casting process. The composite material liner 200 can be fixed to the supporting flange 120 by adhesive, and its enclosure part 220 is tightly fitted to the inner wall of the base frame 100.

[0210] Thus, by using an integral aluminum die-cast base frame 100, the welding joints of the frame in traditional technology are eliminated, and the use of composite material lining plates 200 reduces the overall weight. The combination of the two achieves lightweighting while ensuring structural strength.

[0211] In addition, the low thermal conductivity of the composite material liner 200 effectively suppresses heat loss from the bottom, and the insulation component 500 between the liner 200 and the bottom cover plate 400 forms a double thermal barrier, further achieving the thermal insulation effect.

[0212] In some embodiments, combined with Figure 2 and Figure 3 The top cover 300 is provided with a cooling channel 310 for the flow of coolant.

[0213] The cooling channel 310 can be a channel designed inside the top cover 300 for the flow of cooling medium. Optionally, the cooling channel 310 can be implemented with a serpentine, spiral, or mesh structure, and the specific layout can be adjusted according to the shape of the top cover 300. The coolant can be used to absorb heat. Optionally, the coolant can be water, ethylene glycol solution, or oily medium, and can flow continuously in the cooling channel 310 driven by a pumping system.

[0214] Understandably, the top cover 300 can directly contact the upper surface of the battery cell, and the cooling channel 310 is directly integrated inside the top cover 300, which can directly and quickly dissipate the heat generated by the battery pack 21 through the top cover 300, thus preventing heat from accumulating inside the battery pack 20.

[0215] Specifically, after the top cover 300 is closed by fitting the top opening of the receiving cavity 101, the coolant enters the cooling channel 310 and circulates. The heat generated by the operation of the battery pack 21 is transferred to the coolant in the cooling channel 310 through the top cover 300. After absorbing the heat, the coolant flows out of the battery pack 20, thus achieving active heat dissipation.

[0216] By integrating the cooling channel 310 into the top cover 300, efficient heat exchange is achieved through circulating coolant, ensuring stable cell operating temperature. Furthermore, the integrated design of the coolant circulation system with the top cover 300 simplifies the battery pack 20 structure, reduces the number of heat dissipation components, and lowers assembly complexity.

[0217] In some embodiments, combined with Figure 2 and Figure 3 , Figures 14 to 17 The top cover 300 includes a flow channel plate 320 and a heat spreader plate 330, which are stacked together. The heat spreader plate 330 is located on the side of the flow channel plate 320 facing the battery pack 21, and a cooling channel 310 is formed between the flow channel plate 320 and the heat spreader plate 330.

[0218] Optionally, the material of the flow channel plate 320 can be aluminum alloy, copper alloy, engineering plastic, etc. Aluminum alloy has good thermal conductivity, strength and ductility, and its surface can form an oxide layer, which can resist the corrosion of various coolants.

[0219] Optionally, the material of the vapor chamber 330 can be a copper vacuum chamber vapor chamber plate, an aluminum vapor chamber plate, a high thermal conductivity metal plate, etc.

[0220] The laminated design of the flow channel plate 320 and the heat spreader plate 330 forms the cooling flow channel 310, enabling the coolant to flow efficiently between the flow channel plate 320 and the heat spreader plate 330. Thus, the heat generated by the battery pack 21 is first transferred to the heat spreader plate 330, which is in direct contact with the battery pack 21. The heat spreader plate 330 has good planar thermal conductivity, which can quickly dissipate heat and prevent localized overheating. Subsequently, the evenly diffused heat is conducted to the cooling flow channel 310 and the flow channel plate 320, where the coolant carries the heat away.

[0221] In this way, the excellent temperature uniformity of the heat spreader 330 is combined with the efficient heat dissipation of the cooling channel 310, which improves the heat dissipation efficiency and temperature uniformity of the top cover 300, effectively controls the operating temperature of the battery pack 21, extends its life and improves safety.

[0222] In some embodiments, the flow channel plate 320 and the battery pack 21 are connected by structural adhesive. Optionally, the structural adhesive may be made of thermally conductive sealant, thermally conductive structural adhesive, etc.

[0223] The structural adhesive provides a continuous bonding interface between the flow channel plate 320 and the battery pack 21, ensuring close contact between the two, reducing contact thermal resistance, and optimizing the heat transfer efficiency from the battery pack 21 to the cooling flow channel 310.

[0224] In addition, the structural adhesive itself has a certain degree of elasticity, which can effectively absorb and buffer the small volume changes or vibrations generated by the battery pack 21 during charging and discharging, avoid stress concentration or damage that may be caused by rigid connection, and improve the overall reliability of the battery pack.

[0225] In some specific examples, please refer to Figures 14 to 17 The top cover 300 includes a flow channel plate 320 and a heat spreader plate 330 connected by brazing, wherein the thickness of the heat spreader plate 330 can be 1mm-1.5mm (for example, the thickness can be 1.2mm).

[0226] The top cover 300 can be connected to the frame body 110 by flange bolts to seal the receiving cavity 101. A flow channel plate 320 can be welded to the side of the heat spreader 330 facing the receiving cavity 101. A serpentine cooling flow channel 310 can be formed between the flow channel plate 320 and the heat spreader 330.

[0227] The top of the battery pack 21 can be bonded to the flow channel plate 320 with a high thermal conductivity structural adhesive, so that the heat of the battery can be conducted to the cooling medium in the cooling flow channel 310, and then the heat can be carried out of the battery pack 20 through the cooling medium.

[0228] As can be seen from the above, the relative positional relationship of the various components of the battery pack 20 can be as follows: the top cover 300 covers the opening end of the entire receiving cavity 101 and is mechanically fastened to the upper surface of the bottom frame 100 by bonding with the first connecting adhesive 710 and the second connecting adhesive 720 (or it can be mechanically fastened by pressing with a sealing ring); the multiple receiving cavities 101 of the bottom frame 100 can be arranged along the second direction, and the support flange 120 provided on the bottom frame 100 constitutes a continuous support platform; the bottom base portion 210 of the liner 200 is embedded in the bottom of the receiving cavity 101 and forms a planar contact with the support flange 120; the bottom surface of the battery pack 21 can be bonded to the inner surface of the liner 200 using structural adhesive; the bottom guard plate 400 is mechanically fastened to the lower surface of the bottom frame 100, and the cavity between the bottom guard plate 400 and the liner 200 is filled with a heat insulation component 500. Optionally, the above-mentioned mechanical fastening connection can be achieved by rivets, bolts and nuts, pull rivet bolts and nuts, press rivet bolts and nuts, etc.

[0229] The load transfer mechanism of the battery pack 21 in the battery pack 20 of this application embodiment is as follows: most of the weight of the battery pack 21 is borne by the supporting flange 120, and then transferred to the frame body 110, and then distributed to the vehicle body structure through the outer shell 10 and the vehicle body mounting point; part of the weight of the battery pack 21 is transferred to the supporting flange 120 through the shear deformation of the liner 200. Overall, the aluminum die-cast bottom frame 100 improves the bending stiffness through the multi-cavity design, and the composite material liner 200 shares the local shear stress by bonding with the supporting flange 120 plane.

[0230] In some embodiments, combined with Figure 2 , Figure 4 , Figure 6 and Figure 7 The frame body 110 includes an outer frame 111 and a support beam 112. The bottom of the support beam 112 is provided with a first flange 121. The battery pack 21 is stacked with the first flange 121, and the length L of the overlapping area of ​​the battery pack 21 and the first flange 121 satisfies 10mm≤L≤100mm.

[0231] Optionally, the length L of the overlapping area between the battery pack 21 and the first flange 121 can be 10mm, 20mm, 40mm, 50mm, 70mm, 90mm, 100mm, etc.

[0232] It is understandable that the first flange 121 is the main load-bearing interface of the battery pack 21. The overlap area length L can be the contact length between the bottom surface of the battery pack 21 and the first flange 121 in the horizontal direction, which can be controlled within the range of 10 mm to 100 mm, and can be used to balance the support area and space utilization.

[0233] Thus, by limiting the contact length between the first flange 121 and the battery pack 21 to a specific range, sufficient support area can be ensured to distribute the load, while also avoiding affecting the compactness of the battery pack 20.

[0234] In some embodiments, combined with Figure 5 and Figure 6 The battery pack 21 includes multiple individual cells 22 arranged side by side, and the total thickness W of the multiple individual cells 22 satisfies 250mm ≤ W ≤ 1800mm. Optionally, the total thickness W of the multiple individual cells 22 can be 250mm, 300mm, 400mm, 500mm, 600mm, 800mm, 1000mm, 1200mm, 1400mm, 1700mm, 1800mm, etc.

[0235] Understandably, the total thickness W of multiple individual cells 22 can be the total size of multiple side-by-side individual cells 22 stacked along the arrangement direction, and can be set to 250mm to 1800mm to accommodate the capacity requirements of different battery packs 20.

[0236] In practical applications, the total thickness W of multiple individual cells 22 can be adjusted according to the number of accommodating cavities 101. By controlling the total thickness of multiple individual cells 22 within a preset range, the layout of accommodating cavities 101 of different sizes can be matched to ensure the compatibility of the battery pack 21 with the housing structure.

[0237] In some examples, assuming the number of individual cells 22 in a single receiving cavity 101 is n, and the mass of each individual cell 22 is m, then the weight of the battery pack 21 in a single receiving cavity 101 is nm kg, and the stacking direction of the multiple individual cells 22 is consistent with the length direction of the tray. Assuming the thickness of a single cell is t, then the total thickness W of the battery pack 21 is W = nt, and the total thickness W satisfies 250 mm ≤ W ≤ 1800 mm.

[0238] Several specific embodiments are listed below.

[0239] In a specific embodiment 1, the number n of individual battery cells 22 within a single receiving cavity 101 is 86, the thickness t of an individual battery cell 22 is 10mm, the weight m of an individual battery cell 22 is 4kg, the total width W of the battery pack 21 is 860mm, the thickness h of the supporting flange 120 is 10mm, the overlap length L between the individual battery cell 22 and the supporting flange 120 is 70mm, the length L0 of the supporting flange 120 is 100mm, and the material of the supporting flange 120 is No. 12 aluminum (ADC12), whose allowable stress... The maximum bending stress is 120 MPa. According to the formula, the safety factor S is 0.13≤1. Experiments show that the maximum bending stress of the support flange 120 is 15.29 MPa, which is far below its allowable stress. Therefore, the support flange 120 has no risk of stress concentration and the structure is safe.

[0240] In a specific embodiment 2, the number n of individual battery cells 22 within a single receiving cavity 101 is 50, the thickness t of an individual battery cell 22 is 10mm, the weight m of an individual battery cell 22 is 3kg, the total width W of the battery pack 21 is 500mm, the thickness h of the supporting flange 120 is 2mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 40mm, the length L0 of the supporting flange 120 is 50mm, and the material of the supporting flange 120 is an aluminum-silicon-manganese-magnesium alloy (AlSi). 10 MnMg), its allowable stress The stress is 150 MPa. According to the formula, the safety factor S is 0.89≤1. Experiments show that the maximum stress of the support flange 120 is 61.74 MPa, which is far below the allowable stress of its material. Therefore, the support flange 120 has no risk of stress concentration and the structure is safe.

[0241] In a specific embodiment 3, the number n of individual battery cells 22 within a single receiving cavity 101 is 32, the thickness t of an individual battery cell 22 is 8mm, the weight m of an individual battery cell 22 is 5kg, the total width W of the battery pack 21 is 256mm, the thickness h of the supporting flange 120 is 6mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 10mm, the length L0 of the supporting flange 120 is 80mm, and the material of the supporting flange 120 is No. 12 aluminum (ADC12), whose allowable stress... The stress is 120 MPa. According to the formula, the safety factor S is 0.64 ≤ 1. Experiments show that the maximum stress of the support flange 120 is 76.56 MPa, which is far below the allowable stress of its material. Therefore, the support flange 120 has no risk of stress concentration and the structure is safe.

[0242] In a specific embodiment 4, the number n of individual battery cells 22 within a single receiving cavity 101 is 64, the thickness t of an individual battery cell 22 is 8 mm, the weight m of an individual battery cell 22 is 3 kg, the total width W of the battery pack 21 is 512 mm, the thickness h of the supporting flange 120 is 3 mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 40 mm, the length L0 of the supporting flange 120 is 70 mm, and the material of the supporting flange 120 is an aluminum-silicon-manganese-magnesium alloy (AlSi). 10 MnMg), its allowable stress The stress is 150 MPa. According to the formula, the safety factor S is 0.82≤1. Experiments show that the maximum stress of the support flange 120 is 135.89 MPa, which is lower than the allowable stress of the material. Therefore, the support flange 120 has no risk of stress concentration and the structure is safe.

[0243] In a specific embodiment 5, the number n of individual battery cells 22 within a single receiving cavity 101 is 72, the thickness t of an individual battery cell 22 is 10mm, the weight m of an individual battery cell 22 is 3kg, the total width W of the battery pack 21 is 720mm, the thickness h of the supporting flange 120 is 4mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 100mm, the length L0 of the supporting flange 120 is 150mm, and the material of the supporting flange 120 is No. 12 aluminum (ADC12), whose allowable stress... The stress is 120 MPa. According to the formula, the safety factor S is 0.93≤1. Experiments show that the maximum stress of the support flange 120 is 110.25 MPa, which is lower than the allowable stress of the material. Therefore, the support flange 120 has no risk of stress concentration and the structure is safe.

[0244] In a specific comparative example 1, the number n of individual battery cells 22 within a single receiving cavity 101 is 86, the thickness t of an individual battery cell 22 is 10mm, the weight m of an individual battery cell 22 is 4kg, the total width W of the battery pack 21 is 860mm, the thickness h of the supporting flange 120 is 1.8mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 70mm, the length L0 of the supporting flange 120 is 100mm, and the material of the supporting flange 120 is No. 12 aluminum (ADC12), whose allowable stress... The stress is 120 MPa. According to the formula, the safety factor S is 3.93 > 1. Experiments show that the maximum stress of the support flange 120 is 495.22 MPa, which is higher than the allowable stress of its material. Therefore, the support flange 120 has a risk of stress concentration.

[0245] In a specific comparative example 2, the number n of individual battery cells 22 within a single receiving cavity 101 is 50, the thickness t of an individual battery cell 22 is 10 mm, the weight m of an individual battery cell 22 is 4 kg, the total width W of the battery pack 21 is 500 mm, the thickness h of the supporting flange 120 is 1.9 mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 30 mm, the length L0 of the supporting flange 120 is 50 mm, and the material of the supporting flange 120 is an aluminum-silicon-manganese-magnesium alloy (AlSi). 10 MnMg), its allowable stress The pressure is 150MPa. According to the formula, the safety factor S is 1.52 > 1. Experiments show that the maximum stress of the support flange 120 is 230.15MPa, which is higher than the allowable stress of its material. Therefore, the support flange 120 has a risk of stress concentration.

[0246] In a specific comparative example 3, the number n of individual battery cells 22 within a single receiving cavity 101 is 72, the thickness t of an individual battery cell 22 is 10mm, the weight m of an individual battery cell 22 is 3kg, the total width W of the battery pack 21 is 720mm, the thickness h of the supporting flange 120 is 3.5mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 9mm, the length L0 of the supporting flange 120 is 90mm, and the material of the supporting flange 120 is No. 12 aluminum (ADC12), whose allowable stress... The pressure is 120 MPa. According to the formula, the safety factor S is 1.026 > 1. Experiments show that the maximum stress of the support flange 120 is 129.61 MPa, which is higher than the allowable stress of its material. Therefore, the support flange 120 has a risk of stress concentration.

[0247] In a specific comparative example 4, the number n of individual cells 22 within a single receiving cavity 101 is 89, the thickness t of an individual cell 22 is 10mm, the weight m of an individual cell 22 is 4kg, the total width W of the battery pack 21 is 890mm, the thickness h of the supporting flange 120 is 2.5mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 60mm, the length L0 of the supporting flange 120 is 90mm, and the material of the supporting flange 120 is an aluminum-silicon-manganese-magnesium alloy (AlSi). 10 MnMg), its allowable stress The pressure is 150MPa. According to the formula, the safety factor S is 1.51 > 1. Experiments show that the maximum stress of the support flange 120 is 221.63MPa, which is higher than the allowable stress of its material. At this time, the support flange 120 has obvious stress concentration. Under extreme working conditions, it is prone to failure such as fracture. The structure is unsafe and needs to be optimized.

[0248] In a specific comparative example 5, the number n of individual battery cells 22 within a single receiving cavity 101 is 42, the thickness t of an individual battery cell 22 is 13mm, the weight m of an individual battery cell 22 is 5.5kg, the total width W of the battery pack 21 is 546mm, the thickness h of the supporting flange 120 is 2mm, the overlap length L between the battery pack 21 and the supporting flange 120 is 10mm, the length L0 of the supporting flange 120 is 45mm, and the material of the supporting flange 120 is aluminum (ADC12), whose allowable stress... The stress is 120 MPa. According to the formula, the safety factor S is 2.07 > 1. Experiments show that the maximum stress of the support flange 120 is 270.1 MPa, which is higher than the allowable stress of its material. At this time, the support flange 120 has obvious stress concentration. Under extreme working conditions, it is prone to failure such as fracture. The structure is unsafe and needs to be optimized.

[0249] Table 1 below shows the data and technical effects of the above specific embodiments and comparative examples.

[0250] Table 1

[0251]

[0252] Note: In Table 1, the total width of the battery pack 21 is preferably 250mm-1800mm, the thickness of the supporting flange 120 is preferably 2mm-10mm, the overlap length between the battery pack 21 and the supporting flange 120 is preferably 10mm-100mm, and the maximum bending stress is... The safety factor is The experimental result is the maximum bending stress measured by simulation. Unit: MPa.

[0253] As can be seen from Examples 1 to 5, the technical effect is that the safety factor S is less than 1, that is, the maximum bending stress of the support flange 120 is less than the allowable stress of the material, the support flange 120 has no risk of stress concentration failure, and the structure is safe.

[0254] Comparative Examples 1 to 6 show that the technical effect is that the safety factor is greater than 1, the maximum bending stress of the support flange 120 is greater than the allowable stress of the material, there is obvious stress concentration, and failures such as fracture are likely to occur under extreme working conditions.

[0255] The testing methods for the values ​​of each variable in the above formula are as follows.

[0256] The number n of individual cells 22 within a single receiving cavity 101 can be directly counted; the mass m of an individual cell 22 can be directly measured using weighing equipment, such as a precision electronic balance, analytical balance, or micro / semi-micro balance; the thickness t of an individual cell 22 can be measured using a digital caliper at the center and four corners of the cell, and the average value is taken; the length L0 of the support flange 120 can be obtained by measuring the distance from the end of the support flange 120 closest to the center of the receiving cavity 101 to the end where the support flange 120 intersects with the support beam 112 using a coordinate measuring machine platform; the thickness h of the support flange 120 can be measured using a digital caliper at different positions on the flange, and the average value is taken to avoid the influence of uneven thickness of the die-casting parts; the overlap length L between the battery pack 21 and the support flange 120 can be accurately measured using an industrial CT scanner; the allowable stress of the material... The tensile test can be performed in accordance with the provisions of standard GB / T 228.1-2010 "Metallic materials - Tensile testing - Part 1: Test method at room temperature". The maximum stress of the support flange 120 can be extracted through static stress simulation. Abaqus simulation software was selected for simulation testing. First, the geometric model was processed, that is, the key features such as the bottom frame 100, the liner 200, the support flange 120, and the battery pack 21 were retained, while the secondary features such as bolt holes and fillets were removed. Then, material properties were assigned (that is, the material properties and structural properties of the above structural components were defined). The battery pack 21 can be equivalent to a homogeneous rigid body (that is, the internal material structure of the battery cell is ignored, and it is regarded as a rigid mass block, only its mass and the space it occupies are considered). Next, the mesh was generated, and the mesh of key areas such as the support flange 120 was refined. That is, the mesh density of the key components support flange 120 and bottom frame 100 is greater than that of liner 200 and battery pack 21. Then, constraints (fixed constraints are applied according to the actual fixing points of the whole pack and the vehicle body) and loads (volume forces are applied to the battery pack 21 as loads to the support flange) were applied. Finally, the model was submitted for running calculation and the maximum stress of the support flange 120 was extracted.

[0257] In one specific embodiment, the single battery cell 22 is a square cell, such as... Figure 2 , Figure 5 and Figure 6 As shown, the square battery cells are placed along the first direction (x-direction). A support beam 112 is provided between adjacent individual battery cells 22. The bottom of the support beam 112 has support flanges 120 extending to both sides to support the battery pack 21. The parameters are defined as follows: the number of individual battery cells 22 in a single receiving cavity 101 is n, the mass of a single battery cell 22 is m, then the weight of the battery pack 21 in one receiving cavity 101 is nmKg. The arrangement direction of the individual battery cells 22 is perpendicular to the length direction of the bottom frame 100. The thickness of a single battery cell 22 is t, then the total width of the battery pack 21 in a single receiving cavity 101 is W=nt. L is the overlap length between the battery pack 21 and the support flange 120. The support flange 120 has a rectangular cross-section with a length of L0 and a thickness of h. A safety factor is defined. According to the stress check formula for support beam 112, in order to ensure that the support flange 120 supports the battery pack 21 normally and that there is no risk of stress concentration failure in the material, the value of L0 should be selected based on satisfying the following formula, that is, S≤1. .

[0258] The electrical equipment according to the third aspect of this application includes the battery pack of the above embodiments.

[0259] The electrical equipment in this embodiment can be a new energy vehicle, an energy storage cabinet, a communication base station, etc., or of course, other equipment.

[0260] The electrical equipment in this embodiment also has the effects of the battery pack described in the above embodiment, and will not be described again here.

[0261] The various embodiments or implementation methods described in this specification are presented in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0262] It should be noted that the embodiments referred to in the specification, such as "one embodiment," "embodiment," "exemplary embodiment," and "some embodiments," may include specific features, structures, or characteristics, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0263] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0264] It should be readily understood that the terms “on,” “above,” and “on top of” in this disclosure should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on top of something” but also “on top of something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0265] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0266] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A battery pack, characterized in that, include: Battery pack; The housing includes: The bottom frame has a receiving cavity with a bottom opening and a supporting flange at the bottom opening. The battery pack is disposed in the receiving cavity and supported by the supporting flange. Wherein, the load-bearing safety factor S of the supporting flange satisfies: S≤1， ， Where L is the overlap length between the battery pack and the supporting flange, in mm; W is the total width of the battery pack along the first direction, in mm; L0 is the length of the supporting flange along the second direction, in mm; h is the thickness of the supporting flange, in mm, and h satisfies: 2mm≤h≤10mm; The allowable stress of the material supporting the flange, in MPa; m is the mass of a single cell in the battery pack, in kg; n is the number of individual cells in the battery pack; The end of the battery pack along the second direction is supported by the supporting flange, and the first direction and the second direction form a preset angle.

2. The battery pack according to claim 1, characterized in that, The bottom frame includes an outer frame and a support beam. The support beam is connected to at least two first side frames of the outer frame that are opposite each other along the first direction, so as to divide the inner cavity of the outer frame into at least two receiving cavities distributed along the second direction. The bottom openings of the outer frame and the support beam are provided with the support flange.

3. The battery pack according to claim 2, characterized in that, Each of the accommodating cavities includes a first flange located on the support beam and a second flange located on the outer frame. Wherein, L is the overlap length between the battery pack and the first flange; L0 is the length of the first flange along the second direction; h is the thickness of the first flange; The allowable stress of the material of the first flange is given.

4. The battery pack according to claim 1, characterized in that, The overlap length L between the battery pack and the supporting flange satisfies: 10mm≤L≤100mm; And / or, the total width W of the battery pack along the first direction satisfies: 250mm ≤ W ≤ 1800mm.

5. The battery pack according to any one of claims 1-4, characterized in that, The outer casing also includes: A liner, wherein the liner is disposed within the receiving cavity and adapted to close the bottom opening; and / or, A top cover, wherein the receiving cavity has a top opening, and the top cover seals the top opening.

6. The battery pack according to claim 5, characterized in that, The liner includes: The substrate is located on the supporting flange, and the battery pack is located on the substrate.

7. The battery pack according to claim 6, characterized in that, The liner is glued to the bottom frame.

8. The battery pack according to claim 7, characterized in that, The supporting flange extends circumferentially along the receiving cavity. A sealing groove is provided on the side surface of the support flange facing the battery pack. The battery pack further includes: a first sealant, which is disposed in the sealing groove, and the substrate and the supporting flange are connected by the first sealant.

9. The battery pack according to claim 8, characterized in that, The sealing groove is arranged around the receiving cavity, and the first sealant is adapted to the sealing groove.

10. The battery pack according to claim 9, characterized in that, The sealing groove surrounds the receiving cavity, and the first sealant is formed into a ring shape adapted to the sealing groove.

11. The battery pack according to claim 8, characterized in that, The sealing groove includes a first groove and a second groove arranged sequentially from the center to the edge of the receiving cavity, and the first sealant is provided in both the first groove and the second groove.

12. The battery pack according to claim 11, characterized in that, The widths d1 of the first groove and d2 of the second groove satisfy: 5mm ≤ d2 ≤ d1 ≤ 10mm; and / or, The depth h1 of the first groove and the depth h2 of the second groove satisfy the following condition: 0.5mm≤h2≤h1≤1.0mm.

13. The battery pack according to claim 8, characterized in that, The substrate portion is flat. The supporting flange includes a first supporting segment and a second supporting segment connected sequentially from the center to the edge of the receiving cavity. The upper surface of the first supporting segment is lower than the upper surface of the second supporting segment, so that the first supporting segment and the second supporting segment form a stepped structure. The substrate is supported by the first support section.

14. The battery pack according to claim 13, characterized in that, The sealing groove is formed in the first support section.

15. The battery pack according to claim 13, characterized in that, The upper surface of the substrate is flush with the upper surface of the second support segment.

16. The battery pack according to claim 6, characterized in that, The liner also includes: A retaining portion is provided around the substrate portion, and the retaining portion is in contact with the peripheral wall of the receiving cavity.

17. The battery pack according to claim 16, characterized in that, The top ends of the enclosures on the sides of the two linings facing each other are connected.

18. The battery pack according to claim 16, characterized in that, The height h3 of the battery pack, the height h4 of the liner, and the depth h5 of the receiving cavity satisfy: h3 ≤ h4 ≤ h5; and / or, The thickness t1 of the substrate and the thickness t2 of the enclosure satisfy: t2 ≤ t1; and / or, The enclosure portion is spaced apart from the inner wall of the receiving cavity, and the distance S1 between the enclosure portion and the inner wall of the receiving cavity satisfies: 1mm≤S1≤2mm.

19. The battery pack according to claim 16, characterized in that, The enclosure is inclined outward from the receiving cavity relative to the vertical direction.

20. The battery pack according to claim 19, characterized in that, The angle α between the enclosure and the vertical direction satisfies α≤1.5°.

21. The battery pack according to claim 16, characterized in that, The top edge of the enclosure is provided with a mounting flange, which is sandwiched between the outer frame and the top cover.

22. The battery pack according to claim 21, characterized in that, The top cover has a first connecting hole, the mounting flange has a second connecting hole, and the outer frame has a third connecting hole. The first connecting hole, the second connecting hole, and the third connecting hole are opposite to each other and are connected. The top cover, the mounting flange, and the outer frame are connected by fasteners passing through the first connecting hole, the second connecting hole, and the third connecting hole.

23. The battery pack according to claim 21, characterized in that, The upper surface of the outer frame is provided with at least one first adhesive groove, and the battery pack further includes a first connecting adhesive disposed in the first adhesive groove. The outer frame and the mounting flange are connected by the first connecting adhesive; and / or, The upper surface of the mounting flange is provided with at least one second adhesive groove, and the battery pack also includes a second connecting adhesive disposed in the second adhesive groove. The top cover and the mounting flange are connected by the second connecting adhesive.

24. The battery pack according to any one of claims 1-4, characterized in that, Also includes: A bottom protective plate is provided at the bottom of the bottom frame, and the bottom protective plate is fixedly connected to the bottom frame.

25. The battery pack according to claim 24, characterized in that, Also includes: An insulation component is provided at the bottom opening, and the insulation component is located between the bottom protective plate and the liner.

26. The battery pack according to claim 25, characterized in that, The density ρ1 of the insulation component satisfies: ρ1≥0.12g / cm³ 3 ; and / or, The thermal conductivity λ of the insulation component satisfies: λ≤0.026W / (m·k).

27. The battery pack according to any one of claims 1-4, characterized in that, The bottom frame is a die-cast part; and / or, the liner is a composite material part; and / or, the bottom frame is an integrally molded part.

28. The battery pack according to any one of claims 1-4, characterized in that, The battery pack includes multiple individual cells arranged side by side, and the total thickness W of the multiple individual cells satisfies: 500mm≤W≤1800mm.

29. The battery pack according to claim 5, characterized in that, The top cover is provided with cooling channels for the flow of coolant.

30. The battery pack according to claim 29, characterized in that, The top cover includes: A flow channel plate and a heat spreader are stacked together, with the heat spreader located on the side of the flow channel plate facing the battery pack, and a cooling channel formed between the flow channel plate and the heat spreader.

31. The battery pack according to claim 30, characterized in that, The flow channel plate is connected to the battery pack by structural adhesive.

32. An electrical appliance, characterized in that, include: The battery pack according to any one of claims 1-31.

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