Battery box and battery system

Abstract

The invention discloses a battery box body and a battery system, the battery box body comprises a box body and a box cover, the box body comprises a box body frame and a bottom protection beam connected with the box body frame, a bottom protection plate is arranged below the bottom protection beam, and the bottom protection beam is detachably connected with the box body frame through a fastener. When the battery system supports the bottom, the bottom protection beam can improve the bottom supporting resistance of the battery system, and the bottom protection plate is mounted on the bottom protection beam, so that the bottom of the battery can be further protected.

Description

Technical Field

[0001] This invention relates to the field of battery housing technology, and in particular to a battery housing and battery system. Background Technology

[0002] Currently, lithium-ion batteries are being used in an increasingly wide range of applications, particularly in the automotive sector, where they are receiving significant market attention. As the market develops, the demand for electric vehicles is increasing. To meet the requirements of high capacity, long range, and high energy density, battery systems need to improve space utilization and achieve lighter weight.

[0003] In a battery system, various components are arranged systematically within the battery casing. New products need to be structurally simple, easy to manufacture and assemble, and the utilization rate of internal space and structural strength of the battery system need further improvement. Simultaneously, to withstand impacts to the bottom of the battery system, the bottom structure of the casing needs to be reinforced to avoid safety risks. Existing battery systems require bottom support and reinforcement of the casing's bottom structure to avoid safety risks. Increasing material thickness, selecting higher-strength materials, or using thermoforming technologies for the bottom structure significantly increases the manufacturing cost of the battery system. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings and defects of the prior art and to provide a battery housing and battery system. The battery housing structure of this invention, when the bottom of the battery system is exposed to the ground, features a bottom protective beam that protects the internal battery cells from intrusion, ensuring vehicle safety. It also fully utilizes the bottom space of the battery system, enhances its resistance to bottoming out, reduces structural complexity, improves space utilization, and lowers manufacturing costs.

[0005] The first objective of this invention is to provide a battery enclosure, including an enclosure and a cover. The enclosure includes an enclosure frame and a bottom protective beam connected to the enclosure frame. A bottom protective plate is provided below the bottom protective beam. The bottom protective beam and the enclosure frame are detachably connected by fasteners.

[0006] Preferably, a liquid cooling plate is arranged above the bottom protective beam, and the battery module is located above the liquid cooling plate.

[0007] Preferably, a leakage sensor is provided between the bottom protective plate and the bottom protective beam, and the leakage sensor is connected to the battery management system.

[0008] Preferably, the bottom protective beam is formed by vertically connecting longitudinal beams and transverse beams to form a rectangular grid structure, and the bottom protective plate is a grid structure.

[0009] Preferably, the longitudinal beams and transverse beams are arranged in upper and lower layers and are fixedly connected by welding.

[0010] Preferably, there is a flat bottom protective plate sealing gasket between the bottom protective plate and the bottom protective beam, and the bottom protective plate, bottom protective plate sealing gasket, and bottom protective beam are adapted to the outer contour and size of the box body.

[0011] Preferably, a sealing gasket is provided between the sealing surfaces of the box lid and the box body.

[0012] Preferably, the bottom protective beam is bolted to the box frame, and the bottom protective plate is bolted to the bottom protective beam and the box frame.

[0013] Preferably, the end of the bottom protective beam is machined with an avoidance groove according to the shape of the bottom protective plate to accommodate the installation of the bottom protective plate.

[0014] A second objective of the present invention is to provide a battery system including the battery housing.

[0015] The battery housing of this invention places the bottom protective beam inside the battery system, between the liquid cooling plate and the bottom protective plate, without occupying external space. It uses a uniform aluminum profile cross-section and the aluminum profiles are welded together. The bottom protective beam designed between the liquid cooling plate and the bottom protective plate has high integration and light weight, which improves the battery system's modal and bottom impact resistance.

[0016] The battery box of the present invention has a bottom protective beam placed at the position corresponding to the battery system and the vehicle mounting hole. It can be adjusted according to the mounting point of different vehicle models, optimizes the transmission path when the structure bears external loads, enables the force to be transmitted axially, and increases the structural rigidity.

[0017] The battery box of the present invention has a bottom protective beam that is bolted to the box frame, and a bottom guard plate that is bolted to the bottom protective beam and the box frame. After the battery system is impacted, the bottom protective beam and the bottom guard plate can be repaired by removing the fastening bolts, thereby reducing the repair cost after a vehicle accident.

[0018] This invention provides a novel battery system housing structure design and installation method. Utilizing the internal space of the battery system housing components, the integrated design of structural components, and the use of standardized aluminum profiles, it saves on mold development costs and manufacturing time. Simultaneously, it optimizes the battery system's bottom impact resistance, proposes a new connection method, simplifies structural complexity, and improves space utilization. Furthermore, to address the high repair costs after bottom impacts on the battery system, the bottom protective beam of the housing is designed to be detachable, reducing repair costs after vehicle accidents and lowering manufacturing costs. Attached Figure Description

[0019] Figure 1This is a schematic diagram of the overall structure of the battery system in this application.

[0020] Figure 2 This is an exploded view of the battery system in this application.

[0021] Figure 3 This is an exploded view of the battery compartment in this application.

[0022] Figure 4 This is a bottom view of the enclosure before the bottom guard plate is installed, as per this application.

[0023] Figure 5 This is a schematic diagram of the bottom protective beam of this application.

[0024] Figure 6 This is a schematic diagram of the end clearance structure of the bottom protective beam below the box frame and liquid cooling plate of this application.

[0025] Figure 7 This is a top view of the battery box of this application after the welded box frame is formed into a box frame and the liquid cooling plate, bottom protective beam and bottom protective plate are assembled in sequence. Detailed Implementation

[0026] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0027] In an exemplary embodiment of this application, a battery housing is provided, including a housing 1 and a housing cover 4. The housing includes a housing frame 1-5 and a bottom protective beam 1-3 connected to the housing frame. A bottom protective plate 1-1 is provided below the bottom protective beam. The bottom protective beam and the housing frame are detachably connected by fasteners. When the battery system is bottomed out, the bottom protective beam can increase the battery system's resistance to bottoming out. The bottom protective plate installed on the bottom protective beam is beneficial for further strengthening the protection of the bottom of the battery.

[0028] In a preferred embodiment, the bottom protective beam is formed by vertically connecting longitudinal and transverse beams to create a rectangular grid structure. In this application, adding a bottom protective beam inside the housing increases the housing's resistance to bottoming out, and allows for adjustment of the width and wall thickness of the bottom protective beam according to battery system requirements, thereby adjusting the mode frequency of the battery system. In a more preferred embodiment, the longitudinal and transverse beams of the bottom protective beam are arranged in upper and lower layers and fixedly connected by welding.

[0029] In some embodiments, a liquid cooling plate 1-4 is arranged above the bottom protective beam 1-3, and the battery module or module assembly 2 is located above the liquid cooling plate. In an exemplary embodiment, a leakage sensor (not shown) is located between the bottom protective plate and the bottom protective beam. The leakage sensor is connected to the battery management system (BMS). When the leakage sensor detects leakage, it transmits a signal to the BMS for alarm, thereby monitoring the status of the battery system and ensuring that an alarm is triggered immediately upon failure.

[0030] In some embodiments, the bottom protective plate is a grid-like structure. Exemplarily, the bottom protective beam is connected to the beams inside the box using fasteners including at least bolts. Specifically, the upper surface of the bottom protective beam has bolt mounting holes for bolting the box frame 1-5, specifically for bolting the box perimeter and internal structural beams. The lower surface of the bottom protective beam has rivet nut mounting holes for installing rivet nuts to bolt the bottom protective plate 1-1, thereby achieving the fixation of multi-level structural components and enhancing overall strength.

[0031] In this embodiment, the bottom protective beam of the battery system housing is preferably placed at the position corresponding to the mounting holes of the battery system and the vehicle, i.e., according to the layout of the vehicle mounting points, it can be aligned with the vehicle mounting points to protect the battery pack in the event of a collision. Through tooling adjustments, it can be flexibly adjusted for different mounting points on different vehicle models. When the bottom of the battery system is impacted, it protects the bottom of the battery system. In this application, considering the bottom impact resistance, the beams are evenly distributed and adapted to the vehicle mounting point positions. Extruded profile beams are welded into a frame structure and bolted to the housing frame for the bottom protective plate. In addition to being bolted around the perimeter, the bottom protective plate is also locally and evenly installed on the profile bottom protective beam.

[0032] In practical implementation, the bottom protective beam can use a simple aluminum profile cross-section to further reduce manufacturing costs. The horizontal and vertical profiles can have a unified cross-section, achievable with a single extrusion mold. Then, using existing welding processes, the horizontal and vertical beams are welded together after the welding fixture is positioned, thus manufacturing the bottom protective beam. The technique of bolting the bottom protective beam 1-3 to the housing frame 1-5 facilitates subsequent maintenance and replacement of the battery system, ensuring its maintainability after being supported by the bottom.

[0033] In some embodiments, a flat bottom protective plate sealing gasket 1-2 is provided between the bottom protective plate 1-1 and the bottom protective beam 1-3. Specifically, the bottom protective plate 1-1 is bolted to the bottom protective beam 1-3 and the perimeter of the housing frame 1-5, i.e., connected along the side wall end face of the housing frame 1-5. Before bolting, the bottom protective plate sealing gasket 1-2 is pasted to ensure a seal within the space between the bottom protective plate 1-1 and the liquid cooling plate 1-4. Installing the bottom protective plate 1-1 on the bottom protective beam 1-4 further increases the battery system's resistance to bottoming out.

[0034] In a preferred embodiment, the bottom protective plate, the bottom protective plate sealing gasket, and the bottom protective beam are adapted to the outer contour and size of the box body 4 or the box frame 1-5.

[0035] In this embodiment, preferably, the main structure of the housing frame is made of aluminum extruded profiles as raw material. Aluminum alloy profile side beams are prepared through aluminum extrusion and machining processes, and then welded using welding fixtures. The housing frame, through the aluminum extrusion process, has its own cavity, resulting in a lightweight and high-strength design while meeting the vibration strength requirements of the battery system, and also exhibiting good thermal conductivity. Preferably, the bottom liquid cooling plate is a stamped and brazed cold plate, satisfying temperature control functions and exhibiting high integration. Preferably, the bottom protective plate 1-1 and the bottom protective beam 1-3 enhance the battery system's resistance to bottom ball impacts, meeting the national standard strength requirements for bottom ball impacts.

[0036] In this application, the inlet and outlet ports of the liquid cooling plate 1-4 are machined water nozzles welded to the liquid cooling plate. The housing frame 1-5 and the liquid cooling plate 1-4 are fixed using self-tapping thermal rivets, but can also be adjusted to friction stir welding according to the battery system design to ensure the sealing level requirements of the cell cavity.

[0037] Specifically, before installing module assembly 2 into the enclosure, thermally conductive structural adhesive is applied to the liquid cooling plates 1-4 at the bottom of the enclosure. The module units are then installed into the enclosure as a whole using hoisting tools. Each module is connected to the liquid cooling plates 1-4 at the bottom of the enclosure using thermally conductive structural adhesive and bolts, forming module assembly 2. Module assembly 2 is then bolted and fixed to the enclosure frame 1-5 using bolts passing through the module end plates and mounting holes of liquid cooling plates 1-4.

[0038] In some embodiments, the ends of the profiles of the bottom protective beams 1-3 are machined with clearance grooves or clearance structures 8 according to the shape / design of the bottom protective plate 1-1 to accommodate the installation of the bottom protective plate.

[0039] In some embodiments, a lid sealing gasket 3 is provided between the sealing surfaces of the lid and the box body, and the bottom protective plate 1-1 is connected to the bottom protective beam 1-3 and the box body frame 1-5 by bolts to form a detachable connection structure.

[0040] Figure 7 The diagram shows a top view of the enclosure of this application after the welded enclosure frame is formed by the enclosure frame, and the liquid cooling plate, bottom protective beam, and bottom protective plate are assembled in sequence. Figure 7 The first image on the left is a top view of the welded box frame forming the box body; the second image on the left is a top view of the assembled liquid cooling plate; the third image on the left is a top view of the assembled bottom protective beam; and the fourth image on the left is a top view of the assembled bottom protective plate.

[0041] This application embodiment further provides a battery system, including the battery housing, in which there are module assemblies 2, battery management system (BMS) 5, high voltage box 6, module support foam 7 and other battery system components and parts, wherein the module arrangement order and direction can be adjusted, and the number and size of cells can be increased or decreased according to the battery system requirements, while the overall design remains unchanged.

[0042] The modules of the module assembly 2 are connected by thermally conductive structural adhesive, and the modules form the module assembly 2. The bottom liquid cooling plate 1-4 not only provides liquid cooling function, but also serves as a structural component to ensure the structural strength of the module.

[0043] Furthermore, the module assembly 2 is fixed by bolting, and the module unit is installed into the enclosure as a whole using a hoisting tool. Mounting bolts pass through the mounting holes of the module end plate and liquid cooling plate 1-4 of the module assembly 2 and are fixed to the bolt mounting holes of the enclosure frame 1-5. Then, the battery management system (BMS) and high-voltage box 6 are installed sequentially using bolting, and components such as the busbar are connected. Finally, the enclosure cover sealing gasket 3 and module support foam 7 are pasted on, and the enclosure cover 4 is bolted on, completing the battery packing system.

[0044] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention.

[0045] Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of the equivalents of the claims be included within the invention.

[0046] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A battery case, characterized by, The device includes a box body and a box cover. The box body includes a box body frame and a bottom protective beam connected to the box body frame. A bottom protective plate is provided below the bottom protective beam. The bottom protective beam and the box body frame are connected in a detachable manner by fasteners.

2. The battery case according to claim 1, wherein A liquid cooling plate is arranged above the bottom protective beam, and the battery module is located above the liquid cooling plate.

3. The battery pack of claim 2, wherein, A leakage sensor is located between the bottom protective plate and the bottom protective beam, and the leakage sensor is connected to the battery management system.

4. The battery pack of claim 1, wherein, The bottom protective beam is formed by vertically connecting longitudinal beams and transverse beams to form a rectangular grid structure, and the bottom protective plate is a grid structure.

5. The battery pack of claim 4, wherein, The longitudinal beams and transverse beams are arranged in upper and lower layers and are fixedly connected by welding.

6. The battery housing according to claim 1, characterized in that, There is a flat bottom protective plate sealing gasket between the bottom protective plate and the bottom protective beam. The bottom protective plate, the bottom protective plate sealing gasket, and the bottom protective beam are adapted to the outer contour and size of the box body.

7. The battery housing according to claim 1, characterized in that, There is a sealing gasket between the lid and the sealing surface of the box body.

8. The battery housing according to claim 1, characterized in that, The bottom protective beam is bolted to the box frame, and the bottom protective plate is bolted to the bottom protective beam and the box frame.

9. The battery housing according to claim 1, characterized in that, The end of the bottom protective beam is machined with a clearance groove according to the shape of the bottom protective plate to accommodate the installation of the bottom protective plate.

10. A battery system, characterized in that, Includes the battery housing.

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