Integrated battery pack shell

Abstract

The invention discloses an integrated battery pack shell. The integrated battery pack shell comprises an upper cover assembly, a tray assembly and a bottom protection plate assembly, the tray assembly comprises a tray front cross beam, a tray rear cross beam and a tray side edge beam; supporting cross beams and supporting longitudinal beams are arranged in the frame structure; the main body parts of the upper cover assembly and the bottom protection plate assembly are respectively and detachably connected with the supporting cross beam; the peripheral edges of the upper cover assembly and the bottom protection plate assembly are respectively and detachably connected and sealed with the tray front cross beam, the tray rear cross beam and the tray side edge beams; a front cross beam mounting frame, a water nozzle bracket and a wiring harness bracket are integrated on the front side of the tray front cross beam; a battery disconnection unit mounting bracket is integrated on the rear side of the tray front cross beam; the front collision support is connected between the tray front cross beam and the supporting cross beam at the foremost end, installation supports of some parts are integrated on the tray front cross beam, the integration degree of products is improved, the battery cell at the foremost end can be separated from the tray front cross beam by a certain distance, the front collision support is arranged, and the safety performance during collision is improved.

Description

Technical Field

[0001] This invention relates to the field of battery pack technology, and more particularly to an integrated battery pack housing. Background Technology

[0002] The battery pack casing houses the power cells, making its technology crucial for electric vehicles. Due to the operational requirements of the cells, the battery pack casing must possess high levels of sealing performance, flame retardancy, strength, rigidity, impact resistance, vibration resistance, compression resistance, thermal conductivity, and puncture resistance, among other properties. The battery pack casing must withstand the loads of the cell modules and battery drain units (BDUs) as well as external impacts; therefore, its integration performance and collision resistance are critical performance parameters. Simultaneously, to improve the overall energy density of the battery pack, it is desirable to keep the casing lightweight, resulting in a highly complex structure and design.

[0003] In the existing technology, the integration of the mounting brackets of many components with the front crossbeam of the battery pack is low, and they are scattered on the top cover and bottom plate of the battery pack. The front crossbeam of the battery pack is directly used to install the front end of the battery cells, and the impact crush performance still needs to be improved. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated battery pack housing that integrates the mounting brackets of some components onto the front crossbeam of the tray, thereby improving the integration of the product. It also allows the frontmost battery cell to be a certain distance away from the front crossbeam of the tray and is equipped with a front collision bracket, thereby improving the safety performance in the event of a collision.

[0005] The present invention provides an integrated battery pack housing, comprising an upper cover assembly, a tray assembly, and a bottom protective plate assembly connected sequentially from top to bottom; The pallet assembly includes a front crossbeam, a rear crossbeam, and two side beams connected in a frame structure. The frame structure contains multiple support crossbeams and at least one support longitudinal beam. The two ends of the support crossbeams are connected to the two side beams of the pallet, respectively. The support longitudinal beam is arranged perpendicularly to the support crossbeams and is connected to each of the support crossbeams. The front end of the support longitudinal beam is connected to the foremost support crossbeam, and the rear end of the support longitudinal beam is connected to the rear crossbeam of the pallet. The main bodies of the upper cover assembly and the bottom guard plate assembly are detachably connected to the support beam, and the four edges of the upper cover assembly and the bottom guard plate assembly are detachably connected to and sealed to the front crossbeam, the rear crossbeam, and the side beam of the pallet, respectively. The front side of the front crossbeam of the tray integrates a front crossbeam mounting bracket, a water nozzle bracket, and a wire harness bracket. The rear side of the front crossbeam of the tray is integrated with a battery disconnect unit mounting bracket. A front bumper bracket connects the front crossbeam of the pallet to the foremost support crossbeam.

[0006] In one of the alternative technical solutions, CIPG sealant is applied between the four edges of the top cover assembly and the bottom guard plate assembly and the front crossbeam, the rear crossbeam, and the side beam of the pallet, respectively. An adhesive is applied to the outside of the CIPG sealant, and the adhesive seals the four edges of the top cover assembly and the bottom guard plate assembly and the outer surfaces of the front crossbeam, the rear crossbeam, and the side beam of the pallet.

[0007] In one of the alternative technical solutions, the front crossbeam of the tray is a cast aluminum part with a cavity.

[0008] In one alternative technical solution, the supporting longitudinal beam is connected to the bottom of the plurality of supporting transverse beams.

[0009] In one of the alternative technical solutions, the front crossbeam of the pallet includes a middle crossbeam and two end crossbeams arranged at both ends of the middle crossbeam. The middle crossbeam is arranged ahead of the end crossbeams. Each end crossbeam is connected to the middle crossbeam through a transition beam. The end crossbeams are connected to the side beams of the pallet. Each of the end crossbeams integrates a front crossbeam mounting bracket and a water nozzle bracket on its front side; The wire harness bracket is integrated on the front side of one of the transition beams; Two battery disconnect unit mounting brackets are integrated on the rear side of the intermediate crossbeam; Each of the end beams is connected to a front bumper bracket by the foremost support beam.

[0010] In one of the alternative technical solutions, the pallet side beam includes a side beam body and a side beam boss connected to the outside of the side beam body, wherein the top surface of the side beam body is higher than the top surface of the side beam boss. The side beam body has multiple main body cavities arranged at intervals along the vertical direction, and the side beam boss has multiple boss cavities arranged at intervals along the horizontal direction. The side edge of the upper cover assembly is connected to the top surface of the side beam body by a first bolt, the lower end of the first bolt extending into a cavity in the top of the body; The top surface of the main body of the bottom guard plate assembly is provided with a water-cooled plate, and the edge of the water-cooled plate is detachably installed on the bottom surface of the side beam body. The side edge of the bottom guard plate assembly is connected to the bottom surface of the side beam boss by a second bolt, the upper end of the second bolt extending into a cavity of the boss.

[0011] In one of the alternative technical solutions, the side edge of the water-cooled plate is connected to the bottom surface of the side beam body by a first screw, the tail end of the first screw extending into a cavity in the bottom of the body.

[0012] In one of the alternative technical solutions, the pallet rear crossbeam includes a front cavity and a rear cavity arranged front to back, and the front cavity is divided into a front upper cavity and a front lower cavity by a transverse rib; The rear edge of the upper cover assembly is connected to the top surface of the rear crossbeam of the tray by a third bolt, the lower end of the third bolt extending into the rear cavity; the rear edge of the bottom guard plate assembly is connected to the bottom surface of the rear crossbeam of the tray by a fourth bolt, the upper end of the fourth bolt extending into the rear cavity. The rear edge of the water-cooled plate is connected to the bottom surface of the rear crossbeam of the tray by a second screw, and the tail end of the second screw extends into the lower front cavity. The top surface of the rear crossbeam of the tray is provided with a fifth bolt for connecting to the battery module, and the lower end of the fifth bolt extends into the upper cavity on the front side.

[0013] In one of the alternative technical solutions, the supporting beam includes a plurality of beam cavities arranged at vertical intervals; The water-cooled plate is connected to the bottom of the supporting crossbeam by a sixth bolt, which extends into one of the crossbeam cavities at the bottom. The main body of the upper cover assembly is connected to the upper part of the support beam via a bolt and nut assembly; The bolt and nut assembly includes a fixing nut fixedly disposed in a cavity of the top beam, a double-ended stud connecting the supporting beam and the main body of the upper cover assembly, and a seventh bolt fixing the main body of the upper cover assembly to the double-ended stud. The lower end of the double-ended stud has an external thread end, and the upper end of the double-ended stud has an internal thread hole. The external threaded end is connected to the fixing nut, and the seventh bolt passes through the main body of the upper cover assembly and is connected to the internal threaded hole.

[0014] In one of the alternative technical solutions, the double-ended stud has a stepped portion, and a gasket is provided between the stepped portion and the top surface of the supporting crossbeam.

[0015] The above technical solution has the following beneficial effects: The integrated battery pack housing provided by the present invention includes a top cover assembly, a tray assembly, and a bottom protective plate assembly. The top cover assembly is detachably connected to the top of the tray assembly, and the bottom protective plate assembly is detachably connected to the bottom of the tray assembly.

[0016] The pallet assembly is roughly a frame structure, including a front crossbeam, a rear crossbeam, and two side beams. Within the frame structure are multiple support beams and at least one support longitudinal beam, used for mounting the battery cells. The two ends of the support beams connect to the side beams on both sides of the pallet. The support longitudinal beam is arranged perpendicularly to the support beams and connects to each support beam. The front end of the support longitudinal beam connects to the foremost support beam, and its rear end connects to the rear crossbeam. A predetermined distance is maintained between the foremost support beam and the front crossbeam, thus the front end of the support longitudinal beam is a certain distance away from the front crossbeam.

[0017] The main body of the top cover assembly and the bottom guard plate assembly are detachably connected to the support beam. The four edges of the top cover assembly and the bottom guard plate assembly are detachably connected to and sealed to the front crossbeam, the rear crossbeam, and the side beam of the tray, respectively, so that the integrated battery pack housing can be disassembled and repaired.

[0018] The front side of the tray front crossbeam integrates a front crossbeam mounting bracket, a water nozzle bracket, and a wiring harness bracket, while the rear side of the tray front crossbeam integrates a battery disconnect unit mounting bracket, improving the product's integration. These brackets are integrated and installed on the tray front crossbeam, which helps to optimize the structure of the top cover assembly and the bottom guard plate assembly, reducing the burden on the top cover assembly and the bottom guard plate assembly.

[0019] A front-collision bracket connects the front crossbeam of the tray to the foremost support crossbeam to enhance front-collision protection. Because the front edge of the foremost battery cell is mounted on the foremost support crossbeam, it is a certain distance from the front crossbeam. Therefore, even if the front crossbeam of the tray undergoes some collapse and deformation during a collision, it will not immediately crush the battery cells behind it, thus improving the product's safety performance.

[0020] In summary, the integrated battery pack housing provided by this invention not only integrates the mounting brackets of some components onto the front crossbeam of the tray, improving the integration of the product, but also allows the frontmost battery cell to be a certain distance away from the front crossbeam of the tray, and is equipped with a front collision bracket, improving safety performance in the event of a collision. Attached Figure Description

[0021] The disclosure of this invention will become more readily understood by referring to the accompanying drawings. It should be understood that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings: Figure 1 This is an exploded view of an integrated battery pack housing provided in an embodiment of the present invention; Figure 2 An exploded view of the top cover assembly and CIPG sealant; Figure 3 This is a top view of the underbody protection assembly; Figure 4 This is a top view of the tray assembly; Figure 5 For the integrated battery pack housing along Figure 4 A sectional view along the AA direction; Figure 6 For the integrated battery pack housing along Figure 4 A sectional view along the BB direction; Figure 7 For the integrated battery pack housing along Figure 4 A cross-sectional view along the CC direction. Detailed Implementation

[0022] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0023] like Figure 1-4 As shown, an integrated battery pack housing provided in one embodiment of the present invention includes an upper cover assembly 1, a tray assembly 2, and a bottom protective plate assembly 3 connected sequentially from top to bottom.

[0024] The pallet assembly 2 includes a front crossbeam 21, a rear crossbeam 22, and two side beams 23 connected in a frame structure. The frame structure contains multiple support crossbeams 24 and at least one support longitudinal beam 25. The two ends of each support crossbeam 24 are connected to the two side beams 23. The support longitudinal beam 25 is arranged perpendicularly to the support crossbeams 24 and is connected to each support crossbeam 24. The front end of the support longitudinal beam 25 is connected to the foremost support crossbeam 24, and the rear end of the support longitudinal beam 25 is connected to the rear crossbeam 22.

[0025] The main bodies of the top cover assembly 1 and the bottom guard plate assembly 3 are detachably connected to the support beam 24, and the four edges of the top cover assembly 1 and the bottom guard plate assembly 3 are detachably connected to and sealed to the front crossbeam 21, the rear crossbeam 22 and the side beam 23 of the pallet.

[0026] The front side of the front crossbeam 21 of the tray integrates a front crossbeam mounting bracket 214, a water nozzle bracket 215, and a wire harness bracket 216.

[0027] The rear side of the front crossbeam 21 of the tray has an integrated battery disconnect unit mounting bracket 217.

[0028] A front bumper bracket 218 is connected between the front crossbeam 21 of the pallet and the foremost support crossbeam 24.

[0029] The integrated battery pack housing provided by the present invention includes a top cover assembly 1, a tray assembly 2, and a bottom protective plate assembly 3. The top cover assembly 1 is detachably connected to the top of the tray assembly 2, and the bottom protective plate assembly 3 is detachably connected to the bottom of the tray assembly 2, facilitating disassembly and maintenance.

[0030] The top cover assembly 1 includes a generally rectangular main body 11, with its perimeter bent downwards and outwards to form lower peripheral edges 12. The peripheral edges 12 are divided into a front edge, side edges 121, and a rear edge 122. The peripheral edges 12 are sealed to the perimeter frame of the tray assembly 2.

[0031] The bottom guard plate assembly 3 includes a generally rectangular main body 31, with its perimeter bent upwards and outwards to form high peripheral edges 32. The peripheral edges 32 are divided into a front edge, side edges 321, and a rear edge 322. The peripheral edges 32 are sealed to the perimeter frame of the tray assembly 2.

[0032] The pallet assembly 2 is generally a frame structure, including a front crossbeam 21, a rear crossbeam 22, and two side beams 23. Within the frame structure, multiple support beams 24 and at least one support longitudinal beam 25 are provided for mounting battery cells. The two ends of the support beams 24 are connected to the side beams 23 on both sides of the pallet. The support longitudinal beam 25 is arranged perpendicularly to the support beams 24 and is interconnected with each support beam 24. The front end of the support longitudinal beam 25 is connected to the foremost support beam 24, and its rear end is connected to the rear crossbeam 22. A predetermined distance is maintained between the foremost support beam 24 and the front crossbeam 21, thus the front end of the support longitudinal beam 25 is a certain distance away from the front crossbeam 21.

[0033] During assembly, the main body 11 of the upper cover assembly 1 is detachably connected to the support beam 24 via a connecting component, and the main body 31 of the bottom guard plate assembly 3 is detachably connected to the support beam 24 via a connector.

[0034] The four edges 11 of the top cover assembly 1 are detachably connected to the front crossbeam 21, the rear crossbeam 22, and the side beams 23 of the tray via connectors and are sealed. The four edges 31 of the bottom cover assembly 3 are detachably connected to the front crossbeam 21, the rear crossbeam 22, and the side beams 23 of the tray via connectors and are sealed. This configuration allows the integrated battery pack housing to be disassembled for maintenance.

[0035] The top cover assembly 1 and the bottom guard plate assembly 3 can be made of galvanized steel sheet, which has good corrosion resistance, electromagnetic shielding performance and fire resistance.

[0036] The front side of the front crossbeam 21 of the tray integrates a front crossbeam mounting bracket 214, a water nozzle bracket 215, and a wiring harness bracket 216. The rear side of the front crossbeam 21 of the tray integrates a battery disconnect unit mounting bracket 217, which improves the integration of the product. These brackets are integrated and installed on the front crossbeam 21 of the tray, which helps to optimize the structure of the top cover assembly 1 and the bottom guard plate assembly 3 and reduce the burden on the top cover assembly 1 and the bottom guard plate assembly 3.

[0037] A front collision bracket 218 connects the front crossbeam 21 of the tray to the foremost support crossbeam 24 to improve front collision protection performance. Since the front edge of the foremost battery cell is mounted on the foremost support crossbeam 24, it is a certain distance away from the front crossbeam 21 of the tray. Even if the front crossbeam 21 of the tray undergoes some collapse deformation during a collision, it will not immediately squeeze the battery cell on the rear side, thus improving the safety performance of the product.

[0038] In this invention, the integrated front crossbeam 21 integrates the battery and vehicle lifting point brackets (front crossbeam mounting bracket 214), inlet / outlet water nozzle protection brackets (water nozzle bracket 215), wiring harness bracket 216, BDU mounting bracket (battery disconnect unit mounting bracket 217), and front collision bracket 218. This integrated design and manufacturing increases structural strength, making the design of inlet / outlet water nozzle protection and battery pack front collision protection more refined, while also achieving a lighter weight while meeting the installation requirements of the BDU and connectors. The BDU (Battery Disconnect Unit / Battery Distribution Unit) is a core power distribution and safety component of the high-voltage battery system in new energy vehicles, undertaking three major functions: high-voltage distribution, emergency power cut-off, and status monitoring. During assembly, the front side of the BDU is mounted on the battery disconnect unit mounting bracket 217, and the rear side of the BDU is mounted on the foremost support crossbeam 24.

[0039] In summary, the integrated battery pack housing provided by this invention not only integrates the mounting brackets of some components onto the front crossbeam 21 of the tray, improving the integration of the product, but also allows the frontmost battery cell to be a certain distance away from the front crossbeam 21 of the tray, and is equipped with a front collision bracket 218, improving the safety performance in the event of a collision.

[0040] In one embodiment, such as Figure 2 and Figure 5-6 As shown, CIPG sealant 4 is applied between the four edges of the upper cover assembly 1 and the bottom guard plate assembly 3 and the front crossbeam 21, the rear crossbeam 22 and the side beam 23 of the pallet. Adhesive is applied to the outside of the CIPG sealant 4, and the adhesive sealant is applied to the outer surfaces of the four edges of the upper cover assembly 1 and the bottom guard plate assembly 3 and the front crossbeam 21, the rear crossbeam 22 and the side beam 23 of the pallet.

[0041] CIPG sealant 4 (Cured-In-Place Gasket) is a curing sealing ring applied to the flat surfaces of the four edges 11 of the top cover assembly 1 and the four edges 21 of the bottom guard plate assembly 3. It then bonds to the top and bottom surfaces of the front crossbeam 21, rear crossbeam 22, and side beams 23 of the pallet. After CIPG sealant 4 cures, it bonds with the electrophoretic coating to form a sealing surface, achieving a seal through compression. Simultaneously, it allows for multiple disassemblies of the top cover assembly 1 and the bottom guard plate assembly 3, providing convenience for after-sales maintenance and battery replacement, and exhibits excellent disassembly performance. To improve the sealing performance of CIPG sealant 4, a ring of self-adhesive is applied to the outside of CIPG sealant 4. The self-adhesive seals the gaps between the four edges 11 of the top cover assembly 1, the four edges 31 of the bottom guard plate assembly 3, the outer surface of the front crossbeam 21 of the tray, the outer surface of the rear crossbeam 22 of the tray, and the outer surface of the side beam 23 of the tray, which can prevent gap corrosion and give the integrated battery pack housing good corrosion resistance and sealing performance.

[0042] In one embodiment, the front crossbeam 21 of the pallet is a cast aluminum component with cavities. Under the same strength requirements, cast aluminum components can reduce weight by 30-60% compared to steel sheet metal components in a single step, while achieving near-net-shape forming, eliminating the need for machining, corrosion resistance, 100% recyclability, and significantly reducing overall manufacturing costs. By incorporating multiple cavities within the cast aluminum component while meeting structural strength requirements, material savings, cost reduction, and weight reduction can be achieved.

[0043] In one embodiment, such as Figure 1 and Figure 4 As shown, the support longitudinal beam 25 is connected to the bottom of multiple support crossbeams 24, reinforcing the structure at the bottom and making the top open for easy access to the battery cell. The bottom side of the battery cell can be positioned and installed by the support longitudinal beam 25.

[0044] In one embodiment, such as Figure 4 As shown, the front crossbeam 21 of the pallet includes a middle crossbeam 212 and two end crossbeams 211 arranged at both ends of the middle crossbeam 212. The middle crossbeam 212 is arranged ahead of the end crossbeams 211. Each end crossbeam 211 is connected to the middle crossbeam 212 through a transition beam 213. The end crossbeams 211 are connected to the side beams 23 of the pallet.

[0045] Each end crossbeam 211 integrates a front crossbeam mounting bracket 214 and a faucet bracket 215 on its front side.

[0046] The wire harness bracket 216 is integrated on the front side of a transition beam 213.

[0047] Two battery disconnect unit mounting brackets 217 are integrated on the rear side of the middle crossbeam 212.

[0048] Each end crossbeam 211 is connected to a front bumper bracket 218 between itself and the foremost support crossbeam 24.

[0049] In this embodiment, the middle part of the front crossbeam 21 of the pallet has a forward-protruding structure to facilitate the assembly of the BDU at the rear. Correspondingly, the front edges of the upper cover assembly 1 and the bottom guard plate assembly 3 also have forward-protruding structures to be adapted for installation with the front crossbeam 21 of the pallet.

[0050] Specifically, the front crossbeam 21 of the pallet includes two end crossbeams 211, two arc-shaped transition beams 213, and one intermediate crossbeam 212. The intermediate crossbeam 212 is arranged ahead of the end crossbeams 211, and the two transition beams 213 connect the two end crossbeams 211 to the intermediate crossbeam 212. The end crossbeams 211, transition beams 213, and intermediate crossbeam 212 are integrally cast, which is convenient for processing and forming, and has high structural strength.

[0051] The front crossbeam mounting bracket 214 and the water nozzle bracket 215 are integrally mounted on the front side of each end crossbeam 211. The wire harness bracket 216 is integrally mounted on the front side of a transition beam 213.

[0052] Two battery disconnection unit mounting brackets 217 are integrally set on the rear side of the middle crossbeam 212 and are arranged at intervals.

[0053] Each end crossbeam 211 has an integrally provided front collision bracket 218 on its rear side, which is connected to the foremost support crossbeam 24 to ensure that the collision performance of the left and right sides is consistent.

[0054] In one embodiment, such as Figure 5 As shown, the pallet side beam 23 includes a side beam body 231 and a side beam boss 232 connected to the outside of the side beam body 231. The top surface of the side beam body 231 is higher than the top surface of the side beam boss 232.

[0055] The side beam body 231 has multiple main body cavities 233 arranged at intervals along the vertical direction, and the side beam boss 232 has multiple boss cavities 234 arranged at intervals along the horizontal direction.

[0056] The side edge 121 of the top cover assembly 1 is connected to the top surface of the side beam body 231 by a first bolt 13, and the lower end of the first bolt 13 extends into a main body cavity 233 at the top.

[0057] The top surface of the main body 31 of the bottom guard plate assembly 3 is provided with a water-cooled plate 33, and the edge of the water-cooled plate 33 is detachably installed on the bottom surface of the side beam main body 231.

[0058] The side edge 321 of the bottom guard plate assembly 3 is connected to the bottom surface of the side beam boss 232 by a second bolt 34, and the upper end of the second bolt 34 extends into a boss cavity 234.

[0059] In this embodiment, the pallet side beam 23 is made of aluminum alloy and is formed by extrusion molding, and has multiple cavities inside.

[0060] The top surface of the pallet side beam 23 is stepped, with the top surface of the inner part being higher than the top surface of the outer part. The inner part is referred to as the side beam body 231, and the outer part is referred to as the side beam boss 232.

[0061] The side beam body 231 has multiple main body cavities 233 arranged at intervals along the vertical direction, for example, four main body cavities 233, which serve to reduce weight. The side beam boss 232 has multiple boss cavities 234 arranged at intervals along the horizontal direction, for example, two boss cavities 234, which also serve to reduce weight.

[0062] The top surface of the side beam body 231 provides a sealing surface and tightening point for the side edge 121 of the upper cover assembly 1. Three layers of transverse ribs are arranged inside the side beam body 231 to divide the interior of the side beam body 231 into four vertically arranged main cavities 233. The bottom surface of the side beam body 231 provides FDS tightening points and double-layer sealant 36 for the water-cooled plate 33.

[0063] The bottom surface of the boss 232 of the side beam adjacent to the boss cavity 234 of the side beam body 231 provides connection and sealing for the side edge 321 of the bottom guard plate assembly 3. The top and bottom surfaces of the outermost boss cavity 234 provide mounting points and support points for the entire package.

[0064] Specifically, the top surface of the side beam body 231 is provided with an internal threaded hole, and the side edge 121 of the upper cover assembly 1 is correspondingly provided with a through hole. The first bolt 13 passes through the through hole of the side edge 121 and is connected to the internal threaded hole of the side beam body 231. The lower end of the first bolt 13 extends into a main body cavity 233 at the top. CIPG sealant 4 is pressed between the side edge 121 and the top surface of the side beam body 231 to achieve a sealing effect. Adhesive sealant is applied to the outer surface of the top surface of the side beam body 231, the outer surface of the CIPG sealant 4, and the outer surface of the side edge 121.

[0065] The bottom plate assembly 3 has a cavity between its main body 31 and the bottom surface of the water-cooled plate 33. The side edge of the water-cooled plate 33 is mounted to the bottom surface of the side beam body 231 via a connecting structure. The cavity facilitates the user's assembly of the mounting structure.

[0066] The bottom surface of the side beam boss 232 is provided with an internal threaded hole, and the corresponding side edge 321 of the bottom guard plate assembly 3 is provided with a through hole. The second bolt 34 passes through the through hole of the side edge 321 and is connected to the internal threaded hole of the side beam boss 232. The upper end of the second bolt 34 extends into a boss cavity 234. The CIPG sealant 4 is pressed between the side edge 321 and the bottom surface of the side beam main body 231 to play a sealing role. The adhesive tape is sealed on the bottom surface of the side beam boss 232, the outer surface of the CIPG sealant 4 and the outer surface of the side edge 321.

[0067] In one embodiment, as Figure 5 shown, the side edge of the water-cooling plate 33 is connected to the bottom surface of the side beam main body 231 by the first screw 35, and the tail end of the first screw 35 extends into a main body cavity 233 at the bottom.

[0068] In this embodiment, the connection structure for connecting the water-cooling plate 33 and the side beam main body 231 is the first screw 35. The first screw 35 is a self-tapping screw, and the corresponding internal threaded hole is provided on the bottom surface of the side beam main body 231 to fasten the first screw 35. The head end of the first screw 35 is in the concave cavity at the bottom of the water-cooling plate 33, and the tail end of the first screw 35 extends into a main body cavity 233 at the bottom.

[0069] In one embodiment, as Figure 6 shown, the tray rear cross beam 22 includes a front side cavity 223 and a rear side cavity 224 arranged front and back. The front side cavity 223 is divided into a front side upper cavity 2231 and a front side lower cavity 2232 by a transverse partition rib 222.

[0070] The rear end edge of the upper cover assembly 1 is connected to the top surface of the tray rear cross beam 22 by the third bolt 14, and the lower end of the third bolt 14 extends into the rear side cavity 224. The rear end edge of the bottom guard plate assembly 3 is connected to the bottom surface of the tray rear cross beam 22 by the fourth bolt 37, and the upper end of the fourth bolt 37 extends into the rear side cavity 224.

[0071] The rear end edge of the water-cooling plate 33 is connected to the bottom surface of the tray rear cross beam 22 by the second screw 38, and the tail end of the second screw 38 extends into the front side lower cavity 2232.

[0072] The top surface of the tray rear cross beam 22 is provided with a fifth bolt 15 for connecting with the battery module, and the lower end of the fifth bolt 15 extends into the front side upper cavity 2231.

[0073] In this embodiment, the tray rear cross beam 22 is an extruded aluminum part combined with a "mouth" shape and a "day" shape. The upper end of the "day" shape cavity provides an installation point for the module, and the lower end is used to install the water-cooling plate 33. The upper and lower surfaces of the "mouth" shape cavity provide installation points for the rear end edges of the upper cover assembly 1 and the bottom guard plate assembly.

[0074] Specifically, the cavity of the rear crossbeam 22 of the tray is provided with a vertical partition 221 to divide the cavity into a front cavity 223 and a rear cavity 224. The front cavity 223 is further divided into a front upper cavity 2231 and a front lower cavity 2232 by a horizontal partition 222.

[0075] The top surface of the rear crossbeam 22 of the tray is provided with a fifth bolt 15 for installing and positioning the battery module. The top surface of the rear crossbeam 22 of the tray is provided with an internal threaded hole, through which the fifth bolt 15 passes and extends into the front upper cavity 2231.

[0076] During assembly, the top surface of the front upper cavity 2231 is provided with an internally threaded hole, and the rear end edge 122 of the upper cover assembly 1 is correspondingly provided with a through hole. The third bolt 14 passes through the through hole of the rear end edge 122 and connects to the internally threaded hole on the top surface of the front upper cavity 2231. The lower end of the third bolt 14 extends into the rear cavity 224. CIPG sealant 4 is pressed between the rear end edge 122 and the top surface of the front upper cavity 2231 to provide a seal. Adhesive sealant is applied to the top surface of the front upper cavity 2231, the outer surface of the CIPG sealant 4, and the outer surface of the rear end edge 122.

[0077] The rear edge of the water-cooled plate 33 is provided with a through hole, and the bottom surface of the front lower cavity 2232 is provided with an internal threaded hole. The head end of the second screw 38 is located in the recessed cavity on the bottom surface of the water-cooled plate 33. The second screw 38 passes through the through hole of the water-cooled plate 33 and is connected to the internal threaded hole on the bottom surface of the front lower cavity 2232. The tail end of the second screw 38 extends into the front lower cavity 2232.

[0078] The bottom surface of the rear cavity 224 is provided with an internally threaded hole, and the rear end edge 322 of the bottom guard plate assembly 3 is correspondingly provided with a through hole. A fourth bolt 37 passes through the through hole of the rear end edge 322 and connects to the internally threaded hole on the bottom surface of the rear cavity 224. The upper end of the fourth bolt 37 extends into the rear cavity 224. CIPG sealant 4 is pressed between the rear end edge 322 and the bottom surface of the rear cavity 224, providing a seal. Adhesive sealant is applied to the bottom surface of the rear cavity 224, the outer surface of the CIPG sealant 4, and the outer surface of the rear end edge 322.

[0079] In one embodiment, such as Figure 7 As shown, the supporting beam 24 includes multiple beam cavities 241 arranged at intervals.

[0080] The water-cooled plate 33 is connected to the bottom of the supporting beam 24 by a sixth bolt 38, which extends into a beam cavity 241 at the bottom.

[0081] The main body 11 of the upper cover assembly 1 is connected to the upper part of the support beam 24 via bolt and nut assembly 16.

[0082] The bolt - nut assembly 16 includes a fixed nut 161 fixedly arranged in a cross - beam cavity 241 at the top, a stud 162 connected between the support cross - beam 24 and the main body part 11 of the upper cover assembly 1, and a seventh bolt 163 for fixedly connecting the main body part of the upper cover assembly 1 and the stud 162.

[0083] The lower end of the stud 162 has an external - thread end 1621, and the upper end of the stud 162 is provided with an internal - thread hole 1622.

[0084] The external - thread end 1621 is connected to the fixed nut 161, and the seventh bolt 163 passes through the main body part of the upper cover assembly 1 and is connected to the internal - thread hole 1622.

[0085] In this embodiment, the support cross - beam 24 is an extruded aluminum part in the shape of "mu", which has good performance in resisting deformation and plays a role in supporting the side beam 23 of the tray. The top of the support cross - beam 24 provides a tightening point from top to bottom for the battery or battery module and the main body part 11 of the upper cover assembly 1, and the bottom of the support cross - beam 24 provides a fastening point for the water - cooling plate 33.

[0086] Specifically, the cross - section of the support cross - beam 24 is in the shape of "mu", and it includes three cross - beam cavities 241 arranged at intervals up and down.

[0087] The bottom surface of the bottom cross - beam cavity 241 is provided with an internal - thread hole, and the water - cooling plate 33 is correspondingly provided with a through - hole. The sixth bolt 38 passes through the through - hole of the water - cooling plate 33 and is connected to the internal - thread hole on the bottom surface of the cross - beam cavity 241. The head end of the sixth bolt 38 is in the concave cavity at the bottom of the water - cooling plate 33, and the tail end of the sixth bolt 38 extends into the bottom cross - beam cavity 241. The sixth bolt 38 uses a large - flange blind rivet nut 39 to improve the connection reliability.

[0088] According to requirements, a sealing ring can be arranged between the head of the sixth bolt 38 and the water - cooling plate 33.

[0089] The main body part 11 of the upper cover assembly 1 is suspended above the support cross - beam 24 through the bolt - nut assembly 16.

[0090] Specifically, the bolt - nut assembly 16 includes a fixed nut 161, a stud 162 and a seventh bolt 163. The lower end of the stud 162 has an external - thread end 1621, and the upper end of the stud 162 is provided with an internal - thread hole 1622.

[0091] The fixed nut 161 is pre - fixed in the top cross - beam cavity 241, and it is fixed on the bottom surface of the top cross - beam cavity 241. The top surface of the top cross - beam cavity 241 is provided with a through - hole coaxially arranged with the fixed nut 161. The main body part 11 of the upper cover assembly 1 is also correspondingly provided with a through - hole coaxially arranged with the fixed nut 161.

[0092] The external threaded end 1621 passes downward through the through hole on the top surface of the top crossbeam cavity 241 and connects to the fixing nut 161. The top surface of the double-ended stud 162 abuts against the bottom surface of the main body 11 of the upper cover assembly 1. The seventh bolt 163 passes downward through the through hole of the main body 11 and connects to the internal threaded hole 1622 of the double-ended stud 162, thereby fastening the main body of the upper cover assembly 1, the support crossbeam 24, and the water-cooling plate 33 together.

[0093] The battery cell or battery module has mounting holes that fit the double-ended stud 162. When assembling the battery cell or battery module, first pass the mounting holes of the battery cell or battery module through the double-ended stud 162, then place the top cover assembly 1 into place, and then tighten the seventh bolt 163 downwards.

[0094] If necessary, a sealing ring may be provided between the head of the seventh bolt 163 and the main body 11 of the upper cover assembly 1.

[0095] In one embodiment, such as Figure 7 As shown, the double-ended stud 162 has a stepped portion, and a washer 164 is provided between the stepped portion and the top surface of the support beam 24. The washer 164 is an elastic element, which helps to increase the friction between the double-ended stud 162 and the support beam 24 and prevents the double-ended stud 162 from automatically falling off the support beam 24.

[0096] As needed, the above technical solutions can be combined to achieve the best technical effect.

[0097] The above are merely the principles and preferred embodiments of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principles of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. An integrated battery pack housing, characterized in that, This includes the top cover assembly, tray assembly, and bottom guard assembly, which are connected sequentially from top to bottom; The pallet assembly includes a front crossbeam, a rear crossbeam, and two side beams connected in a frame structure. The frame structure contains multiple support crossbeams and at least one support longitudinal beam. The two ends of the support crossbeams are connected to the two side beams of the pallet, respectively. The support longitudinal beam is arranged perpendicularly to the support crossbeams and is connected to each of the support crossbeams. The front end of the support longitudinal beam is connected to the foremost support crossbeam, and the rear end of the support longitudinal beam is connected to the rear crossbeam of the pallet. The main bodies of the upper cover assembly and the bottom guard plate assembly are detachably connected to the support beam, and the four edges of the upper cover assembly and the bottom guard plate assembly are detachably connected to and sealed to the front crossbeam, the rear crossbeam, and the side beam of the pallet, respectively. The front side of the front crossbeam of the tray integrates a front crossbeam mounting bracket, a water nozzle bracket, and a wire harness bracket. The rear side of the front crossbeam of the tray is integrated with a battery disconnect unit mounting bracket. A front bumper bracket connects the front crossbeam of the pallet to the foremost support crossbeam.

2. The integrated battery pack housing according to claim 1, characterized in that, CIPG sealant is applied between the four edges of the top cover assembly and the bottom guard plate assembly and the front crossbeam, the rear crossbeam, and the side beam of the pallet. An adhesive is applied to the outside of the CIPG sealant, and the adhesive seals the four edges of the top cover assembly and the bottom guard plate assembly and the outer surfaces of the front crossbeam, the rear crossbeam, and the side beam of the pallet.

3. The integrated battery pack housing according to claim 1, characterized in that, The front crossbeam of the tray is a cast aluminum part with a cavity.

4. The integrated battery pack housing according to claim 1, characterized in that, The supporting longitudinal beam is connected to the bottom of the multiple supporting transverse beams.

5. The integrated battery pack housing according to claim 1, characterized in that, The front crossbeam of the pallet includes a middle crossbeam and two end crossbeams arranged at both ends of the middle crossbeam. The middle crossbeam is arranged ahead of the end crossbeams. Each end crossbeam is connected to the middle crossbeam through a transition beam. The end crossbeams are connected to the side beams of the pallet. Each of the end crossbeams integrates a front crossbeam mounting bracket and a water nozzle bracket on its front side; The wire harness bracket is integrated on the front side of one of the transition beams; Two battery disconnect unit mounting brackets are integrated on the rear side of the intermediate crossbeam; Each of the end beams is connected to a front bumper bracket by the foremost support beam.

6. The integrated battery pack housing according to claim 1, characterized in that, The pallet side beam includes a side beam body and a side beam boss connected to the outside of the side beam body, wherein the top surface of the side beam body is higher than the top surface of the side beam boss. The side beam body has multiple main body cavities arranged at intervals along the vertical direction, and the side beam boss has multiple boss cavities arranged at intervals along the horizontal direction. The side edge of the upper cover assembly is connected to the top surface of the side beam body by a first bolt, the lower end of the first bolt extending into a cavity in the top of the body; The top surface of the main body of the bottom guard plate assembly is provided with a water-cooled plate, and the edge of the water-cooled plate is detachably installed on the bottom surface of the side beam body. The side edge of the bottom guard plate assembly is connected to the bottom surface of the side beam boss by a second bolt, the upper end of the second bolt extending into a cavity of the boss.

7. The integrated battery pack housing according to claim 6, characterized in that, The side edge of the water-cooled plate is connected to the bottom surface of the side beam body by a first screw, and the tail end of the first screw extends into a cavity in the bottom of the body.

8. The integrated battery pack housing according to claim 6, characterized in that, The pallet rear crossbeam includes a front cavity and a rear cavity arranged front to back. The front cavity is divided into a front upper cavity and a front lower cavity by a transverse rib. The rear edge of the upper cover assembly is connected to the top surface of the rear crossbeam of the tray by a third bolt, the lower end of the third bolt extending into the rear cavity; the rear edge of the bottom guard plate assembly is connected to the bottom surface of the rear crossbeam of the tray by a fourth bolt, the upper end of the fourth bolt extending into the rear cavity. The rear edge of the water-cooled plate is connected to the bottom surface of the rear crossbeam of the tray by a second screw, and the tail end of the second screw extends into the lower front cavity. The top surface of the rear crossbeam of the tray is provided with a fifth bolt for connecting to the battery module, and the lower end of the fifth bolt extends into the upper cavity on the front side.

9. The integrated battery pack housing according to claim 6, characterized in that, The supporting crossbeam includes multiple crossbeam cavities arranged at intervals. The water-cooled plate is connected to the bottom of the supporting crossbeam by a sixth bolt, which extends into one of the crossbeam cavities at the bottom. The main body of the upper cover assembly is connected to the upper part of the support beam via a bolt and nut assembly; The bolt and nut assembly includes a fixing nut fixedly disposed in a cavity of the top beam, a double-ended stud connecting the supporting beam and the main body of the upper cover assembly, and a seventh bolt fixing the main body of the upper cover assembly to the double-ended stud. The lower end of the double-ended stud has an external thread end, and the upper end of the double-ended stud has an internal thread hole. The external threaded end is connected to the fixing nut, and the seventh bolt passes through the main body of the upper cover assembly and is connected to the internal threaded hole.

10. The integrated battery pack housing according to claim 9, characterized in that, The double-ended stud has a stepped portion, and a gasket is provided between the stepped portion and the top surface of the supporting crossbeam.

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