Battery pack bottom support
By manufacturing separate sub-trays using an integrated molding process, the problems of heavy weight and high cost of existing battery trays are solved, multi-specification adaptation and structural consistency are improved, and mold opening costs are reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- EVE ENERGY CO LTD
- Filing Date
- 2026-02-06
- Publication Date
- 2026-05-01
AI Technical Summary
The existing commercial vehicle battery pack battery trays are manufactured by cutting square steel and welding accessories, which has problems such as heavy weight, high cost, large size and long production cycle. In addition, the integrated die-casting mold can only produce vehicle beams of one width, resulting in high mold opening costs.
Two separate sub-pallets are manufactured using an integrated molding process, and the connectors can be used to adapt to various vehicle beam specifications, reducing mold opening costs.
It improves the structural consistency and strength of the battery pack base, reduces mold opening costs, adapts to various vehicle beam specifications, reduces deformation and stress concentration at welding points, and enhances the overall connection integrity.
Smart Images
Figure CN121965015A_ABST
Abstract
Description
Battery pack base Technical Field
[0001] This application relates to the field of battery technology, and in particular to a battery pack base. Background Technology
[0002] Currently, most commercial vehicle battery pack trays are manufactured by welding square steel blanks with various components. This type of tray often faces problems such as heavy weight, high cost, large size, and long production cycle. Existing technology uses integrated die casting to manufacture battery trays to solve the above problems. However, each die casting mold can only produce one type of integrated die casting tray, and one integrated die casting tray can only fit one width of vehicle beam. In order to adapt to vehicle beams of different widths, different die casting molds need to be developed to produce integrated die casting trays of different sizes, resulting in high mold opening costs. Summary of the Invention
[0003] This application provides a battery pack base tray, which uses an integrated molding process to obtain two separate sub-trays, allowing the battery pack base tray to be adapted to various vehicle beam specifications. This improves the structural consistency of the battery pack base tray while reducing mold opening costs.
[0004] In a first aspect, embodiments of this application provide a battery pack base for supporting a battery pack, including a tray and a connector. The number of trays is at least two, and there is a separation gap between any two adjacent trays. Each tray includes an integrally formed frame, a reinforcing part, and a connecting part. The frame is used to connect to the vehicle's main beam, the reinforcing part is disposed within the frame, part of the connecting part is disposed within the frame, and another part of the connecting part is disposed within the reinforcing part. The connecting part is used to connect to the battery pack. The connector is located in the separation gap and is connected to any two adjacent frames. The connector is used to connect to the battery pack.
[0005] This application obtains at least two trays through an integral molding process. The at least two trays exist in a split form, and the width of the gap between the splits can be adjusted according to the actual size of the vehicle beam. Connectors are used to integrate multiple trays, so that the battery pack base can be adapted to various vehicle beam specifications. This improves the structural consistency of the battery pack base while reducing mold opening costs.
[0006] There are two trays: a first sub-tray and a second sub-tray. The first sub-tray includes an integrally formed first frame, a first reinforcing part, and a first connecting part. The first reinforcing part is located inside the first frame. The first frame has a first mounting surface, and the first reinforcing part has a second mounting surface. Both the first and second mounting surfaces face the battery pack. A portion of the first connecting part is located on the first mounting surface, and another portion of the first connecting part is located on the second mounting surface. Along the length of the battery pack bottom tray, the separation gap is located between the second sub-tray and the first sub-tray. The second sub-tray includes an integrally formed second frame, a second reinforcing part, and a second connecting part. The second reinforcing part is located inside the second frame. The second frame has a third mounting surface, and the second reinforcing part has a fourth mounting surface. The first, second, third, and fourth mounting surfaces are all located on the same plane. A portion of the second connecting part is located on the third mounting surface, and another portion of the second connecting part is located on the fourth mounting surface. This application embodiment obtains two sub-trays through integrated die casting. The two sub-trays are separate structures. Integrated die casting can integrate the first frame, the first reinforcing part, the first connecting part, the second frame, the second reinforcing part, and the second connecting part into a single structure. This can eliminate the deformation, stress concentration, and potential structural weaknesses of the first and second frames caused by welding points in traditional battery pack base trays, thereby improving the structural strength of the battery pack base tray and the overall connection with other components. The separate trays can be adapted to various beam specifications, reducing mold opening costs.
[0007] In one possible implementation, the first reinforcing part includes intersecting first and second reinforcing ribs, with the sides of both ribs facing the battery pack located on the second mounting surface. The intersecting first and second reinforcing ribs increase the bending and torsional stiffness of the battery pack tray, preventing excessive deformation during bumps or collisions. Since one side of each first and second reinforcing rib is located on the second mounting surface, a portion of the first connecting part can be disposed on the first and second reinforcing ribs, increasing the number of connection points between the first sub-tray and other components, thus improving the connection strength between the battery pack base and other components.
[0008] One possible implementation is that the first and second stiffeners are arranged in a cross shape. This allows the load on the stiffener in one direction to be quickly diverted to the stiffener in the other direction through the intersection, thereby rapidly dispersing the localized concentrated load and reducing the risk of stress concentration.
[0009] In one possible implementation, the first reinforcing part further includes a third reinforcing rib. The side of the third reinforcing rib facing the battery pack is located on the second mounting surface. There are at least two first reinforcing ribs, which are symmetrically distributed about the third reinforcing rib. The width of the third reinforcing rib is greater than the width of the first reinforcing rib. The third reinforcing rib and the at least two first reinforcing ribs can divide the internal space of the first frame into multiple smaller cell units. Some of the first connecting parts can be set on the wider third reinforcing rib, which can ensure the bending and torsional stiffness of the first sub-tray while also improving the connection strength between the first sub-tray and other components.
[0010] In one possible implementation, the first and third reinforcing ribs extend along the direction from the first frame to the second frame. During vehicle operation, the direction from the first frame to the second frame (i.e., the driving direction) is the primary direction in which the battery pack tray bears the load. The third reinforcing rib positioned on the centerline, along with at least two first reinforcing ribs symmetrically distributed about the third reinforcing rib, helps the first sub-tray better resist crushing deformation along the vehicle's driving direction.
[0011] In one possible implementation, the first sub-tray further includes a connecting piece, which is integrally formed with the first frame. The connecting piece is vertically disposed on the side of the first mounting surface adjacent to the split gap, and its length direction is parallel to the length direction of the second reinforcing rib. The connecting piece is used to connect to the vehicle's main beam. When a side impact force acts on the vehicle's main beam, the vertically disposed connecting piece extending along the width direction of the battery pack bottom support can effectively transfer the impact force directly and without attenuation from the vehicle's main beam to the first frame and the internal reinforcing rib network, which helps to ensure the safe use of the battery pack.
[0012] In one possible implementation, the first frame includes a first main body and a first side plate. A portion of the first connecting part is disposed on the first main body, and the first side plate is perpendicularly disposed on the first mounting surface. The first side plate connects the first main body and the connecting piece, and the length direction of the first side plate is parallel to the length direction of the first reinforcing rib. Through the first side plate, the force acting on the connecting piece can be evenly transmitted to the first frame, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the first sub-tray.
[0013] In one possible implementation, the first reinforcing rib includes a first base plate and a second side plate. A portion of the first connecting part is disposed on the first base plate, and the second side plate is vertically disposed on the second mounting surface, connecting the first base plate and the connecting piece. Through the second side plate, the force acting on the connecting piece can be uniformly transmitted to the first reinforcing part, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the first sub-tray.
[0014] In one possible implementation, the second side plate includes a first sub-side plate and a second sub-side plate. The first sub-side plate is rectangular, and the second sub-side plate is triangular, pointing towards the second reinforcing rib along the gap between the two sections. The first and second sub-side plates are arranged sequentially. The rectangular first sub-side plate can both strengthen the structural strength of the first reinforcing rib and optimize the force transmission path of the first reinforcing rib. The triangular second sub-side plate can optimize the force transmission path of the first reinforcing rib, and the weight per unit length of the triangular second sub-side plate is less than the weight per unit length of the rectangular first sub-side plate, which is beneficial for reducing the weight of the battery pack base.
[0015] In one possible implementation, the first connecting portion includes multiple first bushings and multiple second bushings, with the first bushings disposed on a first mounting surface and the second bushings disposed on a second mounting surface. Fastening bolts may be provided inside the bushings to connect the first sub-tray to the battery pack. Distributing the mounting points of the multiple first bushings and multiple second bushings across two different structural levels—the first frame and the internal first reinforcing section—provides a more balanced connection support than concentrating all mounting points on a single structural level (e.g., all on the first frame, or all on the first reinforcing section), which helps avoid localized overload of shear force between the battery pack base and the battery pack.
[0016] In one possible implementation, the second reinforcing portion includes a fourth reinforcing rib and a fifth reinforcing rib. The sides of both the fourth and fifth reinforcing ribs facing the battery pack are located on the fourth mounting surface. There are at least two fourth reinforcing ribs, symmetrically distributed about the fifth reinforcing rib. The width of the fifth reinforcing rib is greater than the width of the fourth reinforcing ribs. The fifth reinforcing rib and the at least two fourth reinforcing ribs can divide the internal space of the second frame into multiple smaller cell sections. Part of the second connecting portion can be located on the wider fifth reinforcing rib, which can ensure the bending and torsional stiffness of the second sub-tray while also improving the connection strength between the second sub-tray and other components.
[0017] In one possible implementation, the fourth and fifth reinforcing ribs extend along the direction from the first frame to the second frame. The fifth reinforcing rib positioned on the centerline, along with at least two fourth reinforcing ribs symmetrically distributed about the fifth reinforcing rib, helps the second sub-pallet better resist crushing deformation along the vehicle's travel direction.
[0018] In one possible implementation, the first frame has multiple first protrusions on one side adjacent to the split gap, and the second frame has multiple second protrusions on one side adjacent to the split gap. The multiple first protrusions and multiple second protrusions are arranged in a one-to-one correspondence. Multiple first grooves are formed between the multiple first protrusions, and multiple second grooves are formed between the multiple second protrusions. Connectors can be provided between the one-to-one corresponding first grooves and second grooves. The inner walls of the first grooves and second grooves can position and fix the connectors, so as to integrate the first sub-tray and the second sub-tray into the battery pack. Attached Figure Description
[0019] Figure 1 is a schematic diagram of the mating structure of the battery pack and the battery pack base provided in an embodiment of this application; Figure 2 is a schematic diagram of the structure of the battery pack base provided in an embodiment of this application; Figure 3 is a schematic diagram of the structure of the battery pack base provided in another embodiment of this application; Figure 4 is a schematic diagram of the structure of the battery pack base provided in another embodiment of this application.
[0020] Reference numerals: 100-Battery pack bottom support; 200-Battery pack housing; 300-Connector; 400-Cell assembly; 10-First sub-tray; 101-First frame; 1011-First mounting surface; 1012-First main body; 1013-First side plate; 1014-First protrusion; 102-First reinforcing part; 1021-Second mounting surface; 1022-First reinforcing rib; 10221-First base plate; 10222-Second side plate; 102221-First sub-side plate; 102222-Second sub-side plate; 102222-Second sub-side plate; 1023-Second reinforcing rib; 1024-Third reinforcing rib; 103-First... 1. Connecting part; 1031-First bushing; 1032-Second bushing; 104-First connecting piece; 20-Second sub-tray; 201-Second frame; 2011-Third mounting surface; 2012-Second main body; 2013-Third side plate; 2014-Second protrusion; 202-Second reinforcing part; 2021-Fourth mounting surface; 2022-Fourth reinforcing rib; 20221-Second base plate; 20222-Fourth side plate; 2023-Fifth reinforcing rib; 203-Second connecting part; 2031-Third bushing; 2032-Fourth bushing; 204-Second connecting piece; 500-Separation gap. Detailed Implementation
[0021] For ease of understanding, the relevant technical terms involved in the embodiments of this application will be explained and described below.
[0022] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the term "connection" should be interpreted broadly. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. The directional terms mentioned in the embodiments of this application, such as "top," "bottom," "inner," "outer," and "side," are only for reference to the directions in the accompanying drawings. Therefore, the directional terms used are for better and clearer explanation and understanding of the embodiments of this application, and are not intended to indicate or imply that the referred device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application. The term "and / or" as used in this application refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations.
[0023] Currently, most commercial vehicle battery pack trays are manufactured by welding square steel blanks with various components. This type of tray often faces problems such as heavy weight, high cost, large size, and long production cycle. Existing technology uses integrated die casting to manufacture battery trays to solve the above problems. However, each die casting mold can only produce one type of integrated die casting tray, and one integrated die casting tray can only fit one width of vehicle beam. In order to adapt to vehicle beams of different widths, different die casting molds need to be developed to produce integrated die casting trays of different sizes, resulting in high mold opening costs.
[0024] This application provides a battery pack base tray, which obtains two separate sub-trays through one-piece die casting, so that the battery pack base tray can be adapted to various vehicle beam specifications, improving the structural consistency of the battery pack base tray while reducing mold opening costs.
[0025] Figure 1 is a schematic diagram of the mating structure of the battery pack and battery pack base 100 provided in an embodiment of this application. Referring to Figure 1, this embodiment of the application provides a battery pack base 100, which can be used to support the battery pack and can also be used to connect to the battery pack. The battery pack base 100 has high strength, rigidity, and impact / compression resistance. The battery pack may include a battery pack housing 200 and a cell assembly 400. The battery pack housing 200 encloses and forms an accommodating space, in which the cell assembly 400 is placed. Specifically, the battery pack housing 200 may integrate structures such as a liquid cooling plate, an explosion-proof valve mounting port, and a bottom anti-corrosion / insulating coating. The battery pack housing 200 has the functions of sealing, insulation, and lightweight protection. The battery pack housing 200 can withstand internal air pressure changes, upper impacts, and hoisting forces. The battery pack enclosure 200 is typically made of lightweight materials (such as aluminum alloy stampings, SMC composite materials, or composite structures of plastic and aluminum) to provide excellent sealing and insulation, as well as electromagnetic shielding. The battery pack enclosure 200 can serve as a mounting carrier for high-voltage electrical interfaces (such as positive and negative terminals), maintenance switches / fuses, and BMS (Battery Management System) controllers.
[0026] Figure 2 is a structural schematic diagram of the battery pack base 100 provided in an embodiment of this application. Referring to Figures 1 and 2, the battery pack base 100 may include a connector 300 and at least two trays, with a separation gap 500 between any two adjacent trays. Exemplarily, the separation gap 500 between two trays is one location. If there are three trays arranged sequentially, there are two separation gaps 500; if the three trays are arranged with two trays side-by-side and the third tray opposite to both of them, there are three separation gaps 500. Each tray includes an integrally formed frame, a reinforcing part, and a connecting part. Schematably, the frame, reinforcing part, and connecting part can be manufactured using an integral die-casting process. The frame can be used to connect to the vehicle's main beam, and the reinforcing part can be disposed within the frame to increase the overall connection strength of the tray. Part of the connecting part can be disposed within the frame, and another part can be disposed within the reinforcing part. The connecting part can be used to connect to the battery pack, so that the frame and the reinforcing part establish a connection relationship with the battery pack housing 200 of the battery pack. The connector 300 is located in the split gap 500. The connector 300 can be connected to any two adjacent frames. The connector 300 can be used to connect the battery pack to further strengthen the connection between the frame and the battery pack. In this embodiment, at least two trays are obtained through one-piece die casting. The at least two trays exist in a split form. The width of the split gap 500 can be adjusted according to the actual size of the vehicle beam. The connector 300 is used to integrate multiple trays, so that the battery pack base can be adapted to various vehicle beam specifications, improving the structural consistency of the battery pack base while reducing mold opening costs.
[0027] It should be noted that any number of trays can be manufactured separately using an integral molding process, and then combined with the vehicle body beam and battery pack into an integral structure through connecting parts and connectors. This application does not limit the number of trays.
[0028] Referring to Figures 1 and 2, in one possible implementation, the battery pack base 100 may include a first sub-tray 10 and a second sub-tray 20, i.e., there can be two trays, one for the first sub-tray 10 and the other for the second sub-tray 20. The first sub-tray 10 includes an integrally formed first frame 101, a first reinforcing portion 102, and a first connecting portion 103. The first frame 101 forms the main outline and boundaries of the first sub-tray 10 and provides lateral stiffness and protection. The first reinforcing portion 102 is disposed inside the first frame 101 and increases the bending and torsional stiffness of the first frame 101, preventing excessive deformation of the first sub-tray 10 during bumps or collisions. The first connecting portion 103 connects the first sub-tray 10 to the battery pack. The first frame 101 has a first mounting surface 1011, and the first reinforcing part 102 has a second mounting surface 1021. Both the first mounting surface 1011 and the second mounting surface 1021 face the battery pack. A portion of the first connecting part 103 is disposed on the first mounting surface 1011, and another portion of the first connecting part 103 is disposed on the second mounting surface 1021. By arranging the connection points at the structural strength points of the first frame 101 and the first reinforcing part 102 respectively, the load path of the first sub-tray 10 can be optimized, which is beneficial to improving the connection stiffness and overall modality of the first sub-tray 10.
[0029] Referring to Figures 1 and 2, the second sub-tray 20 includes an integrally formed second frame 201, a second reinforcing portion 202, and a second connecting portion 203. The second frame 201 forms the main outline and boundaries of the second sub-tray 20 and provides lateral stiffness and protection. The second reinforcing portion 202 is disposed inside the second frame 201, increasing the bending and torsional stiffness of the second frame 201 and preventing excessive deformation of the second sub-tray 20 during bumps or collisions. The second connecting portion 203 connects the second sub-tray 20 to the battery pack. The second frame 201 has a third mounting surface 2011, and the second reinforcing portion 202 has a fourth mounting surface 2021, both facing the battery pack. Part of the second connecting portion 203 is disposed on the third mounting surface 2011, and another part of the second connecting portion 203 is disposed on the fourth mounting surface 2021. By arranging the connection points at the structural strength points of the second frame 201 and the second reinforcement 202 respectively, the load path of the second sub-tray 20 can be optimized, which is beneficial to improving the connection stiffness and overall modal characteristics of the second sub-tray 20. By making both the first sub-tray 10 and the second sub-tray 20 integrally molded structures, the side beam deformation, stress concentration, and potential structural weaknesses caused by welding points in the traditional battery pack base 100 can be eliminated, resulting in better overall mechanical properties of the first sub-tray 10 and the second sub-tray 20. Lightweighting can be achieved while ensuring the structural strength of the first sub-tray 10 and the second sub-tray 20. Furthermore, the height design of the battery pack base 100 is not limited by the dimensions of the fixed square steel used in traditional welding, providing greater design freedom and enriching the application scenarios of the battery pack base 100.
[0030] As shown in Figures 1 and 2, the first mounting surface 1011, the second mounting surface 1021, the third mounting surface 2011, and the fourth mounting surface 2021 are all located on the same plane, which allows the battery pack base 100 to provide a flat mounting platform. For example, components such as battery modules and thermal management systems can be mounted flat on this common reference mounting platform, which helps ensure good contact and fixation.
[0031] Referring to Figures 1 and 2, a separation gap 500 exists between the second sub-tray 20 and the first sub-tray 10 along the length of the battery pack base 100. This allows for flexible combination of modular battery pack bases 100 of different sizes or specifications for different vehicle platforms. For example, the split battery pack base 100 can adapt to various battery pack specifications, avoiding the need to develop different die-casting molds to produce integrated die-cast trays of different sizes, thus reducing mold opening costs.
[0032] Referring to Figures 1 and 2, in one possible embodiment, the first reinforcing part 102 includes intersecting first reinforcing ribs 1022 and second reinforcing ribs 1023. Schematic, the first reinforcing ribs 1022 and second reinforcing ribs 1023 can form right angles, obtuse angles, and acute angles. The intersecting first reinforcing ribs 1022 and second reinforcing ribs 1023 can increase the bending and torsional stiffness of the first sub-tray 10, preventing excessive deformation of the battery pack tray during bumps or collisions. The sides of the first reinforcing ribs 1022 and second reinforcing ribs 1023 facing the battery pack are both located on the second mounting surface 1021, allowing some of the first connecting parts 103 to be disposed on the first reinforcing ribs 1022 and second reinforcing ribs 1023, increasing the number of connection points between the first sub-tray 10 and other components, which is beneficial for improving the connection strength between the battery pack base 100 and other components. In another possible implementation, the second reinforcing portion 202 may include intersecting fourth reinforcing ribs 2022 and fifth reinforcing ribs 2023. Schematic, the fourth reinforcing ribs 2022 and fifth reinforcing ribs 2023 may form right angles, obtuse angles, and acute angles. The intersecting fourth reinforcing ribs 2022 and fifth reinforcing ribs 2023 can increase the bending and torsional stiffness of the second sub-tray 20, preventing excessive deformation of the battery pack tray during bumps or collisions. The sides of the fourth reinforcing ribs 2022 and fifth reinforcing ribs 2023 facing the battery pack are both located on the fourth mounting surface 2021, allowing some of the second connecting portions 203 to be disposed on the fourth reinforcing ribs 2022 and fifth reinforcing ribs 2023, increasing the number of connection points between the second sub-tray 20 and other components, and thus improving the connection strength between the second sub-tray 20 and other components.
[0033] Referring to Figures 1 and 2, in one possible implementation, the first reinforcing rib 1022 and the second reinforcing rib 1023 are arranged in a cross shape, meaning they are perpendicular to each other. This allows the load on the reinforcing rib in one direction to be quickly diverted to the reinforcing rib in the other direction through the intersection node, thereby rapidly dispersing localized concentrated loads and reducing the risk of stress concentration. In another possible implementation, the fourth reinforcing rib 2022 and the fifth reinforcing rib 2023 can also be arranged in a cross shape.
[0034] Referring to Figures 1 and 2, in one possible implementation, the first connecting portion 103 may include a plurality of first bushings 1031 and a plurality of second bushings 1032. The plurality of first bushings 1031 are disposed on the first mounting surface 1011, and the plurality of second bushings 1032 are disposed on the second mounting surface 1021. Illustratively, all of the plurality of second bushings 1032 may be disposed on the first reinforcing rib 1022, or all of the plurality of second bushings 1032 may be disposed on the second reinforcing rib 1023, or some of the second bushings 1032 may be disposed on the first reinforcing rib 1022, and another portion of the second bushings 1032 may be disposed on the second reinforcing rib 1023. Fastening bolts may be provided inside the bushings to connect the first sub-tray 10 to the battery pack. Distributing the mounting points of multiple first bushings 1031 and multiple second bushings 1032 on two different structural levels, the first frame 101 and the internal first reinforcement 102, provides a more balanced connection support than concentrating all mounting points on one structural level (e.g., all on the first frame 101, or all on the first reinforcement 102), which helps to avoid local overload of shear force between the battery pack base support 100 and the battery pack.
[0035] Referring to Figures 1 and 2, in one possible implementation, a portion of the second bushing 1032 can be disposed on the first reinforcing rib 1022, and another portion of the second bushing 1032 can be disposed on the second reinforcing rib 1023. That is, connection points are provided in both the longitudinal and transverse directions of the first reinforcing part 102, further equalizing the connection points of the first sub-pallet 10, which is beneficial for distributing the shear force between the first sub-pallet 10 and the vehicle beam.
[0036] In one possible implementation, the second connecting portion 203 may include a plurality of third bushings 2031 and a plurality of fourth bushings 2032, wherein the plurality of third bushings 2031 are disposed on the third mounting surface 2011, and the plurality of fourth bushings 2032 are disposed on the fourth mounting surface 2021. Illustratively, all of the plurality of fourth bushings 2032 may be disposed on the fourth reinforcing rib 2022, or all of the plurality of fourth bushings 2032 may be disposed on the fifth reinforcing rib 2023, or some of the fourth bushings 2032 may be disposed on the fourth reinforcing rib 2022, and another portion of the fourth bushings 2032 may be disposed on the fifth reinforcing rib 2023. Fastening bolts may be provided inside the bushings to connect the second sub-tray 20 to the battery pack. Distributing the mounting points of multiple third bushings 2031 and multiple fourth bushings 2032 on two different structural levels, the first frame 101 and the internal first reinforcement 102, provides a more balanced connection support than concentrating all mounting points on one structural level (e.g., all on the first frame 101, or all on the first reinforcement 102), which helps to avoid local overload of shear force between the battery pack base support 100 and the battery pack.
[0037] In one possible implementation, a portion of the fourth bushing 2032 can be disposed on the fourth reinforcing rib 2022, and another portion of the fourth bushing 2032 can be disposed on the fifth reinforcing rib 2023. That is, connection points are provided in both the longitudinal and transverse directions of the second reinforcing part 202, further balancing the connection points of the second sub-pallet 20, which is beneficial for distributing the shear force between the second sub-pallet 20 and the vehicle beam.
[0038] Figure 3 is a structural schematic diagram of the battery pack base 100 provided in another embodiment of this application. Referring to Figures 1 and 3, in one possible implementation, the number of first reinforcing ribs 1022 can be at least two, and these at least two first reinforcing ribs 1022 can be sequentially spaced along the length direction of the second reinforcing ribs 1023. Schematic, the number of first reinforcing ribs 1022 is three, and the cooperation structure of the three first reinforcing ribs 1022 and the second reinforcing ribs 1023 can be in a U-shape. This can further optimize the bending and torsional stiffness of the first sub-tray 10. In another possible implementation, the number of fourth reinforcing ribs 2022 can be at least two, and the cooperation structure of the fourth reinforcing ribs 2022 and the fifth reinforcing ribs 2023 can also be in a U-shape.
[0039] Referring to Figures 1 and 3, in one possible implementation, the first sub-tray 10 further includes a first connecting piece 104. The first connecting piece 104 is integrally formed with the first frame 101. The first connecting piece 104 is vertically disposed on one side of the first mounting surface 1011 adjacent to the split gap 500. The length direction of the first connecting piece 104 is parallel to the length direction of the second reinforcing rib 1023. The first connecting piece 104 is used to connect to the vehicle's main beam. When a side impact force acts on the vehicle's main beam, the first connecting piece 104, which is vertically disposed and extends along the width direction of the battery pack base 100, can effectively transfer the impact force directly and without attenuation from the vehicle's main beam to the first frame 101 and the internal reinforcing rib network, which is beneficial to ensuring the safe use of the battery pack.
[0040] Referring to Figures 1 and 3, in one possible embodiment, the second sub-tray 20 further includes a second connecting piece 204, which is integrally formed with the second frame 201. The second connecting piece 204 is vertically disposed on one side of the third mounting surface 2011 adjacent to the split gap 500. The length direction of the second connecting piece 204 is parallel to the length direction of the second reinforcing rib 1023. The second connecting piece 204 is used to connect to the vehicle's main beam. When a side impact force acts on the vehicle's main beam, the vertically disposed second connecting piece 204, which extends along the width direction of the battery pack base support 100, can effectively transfer the impact force directly and without attenuation from the vehicle's main beam to the second frame 201 and the internal reinforcing rib network, which is beneficial to ensuring the safe use of the battery pack.
[0041] Referring to Figures 1 and 3, in one possible implementation, the first frame 101 includes a first main body 1012 and a first side plate 1013. A portion of the first connecting part 103 is disposed on the first main body 1012, and the first side plate 1013 is vertically disposed on the first mounting surface 1011. The first side plate 1013 connects the first main body 1012 and the first connecting piece 104, and the length direction of the first side plate 1013 is parallel to the length direction of the first reinforcing rib 1022. Through the first side plate 1013, the force acting on the first connecting piece 104 can be evenly transmitted to the first frame 101, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the first sub-tray 10.
[0042] Referring to Figures 1 and 3, in one possible embodiment, the first reinforcing rib 1022 includes a first substrate 10221 and a second side plate 10222. A portion of the first connecting portion 103 is disposed on the first substrate 10221, and the second side plate 10222 is vertically disposed on the second mounting surface 1021, connecting the first substrate 10221 and the first connecting piece 104. Through the second side plate 10222, the force acting on the first connecting piece 104 can be uniformly transmitted to the first reinforcing portion 102, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the first sub-tray 10.
[0043] Figure 4 is a structural schematic diagram of the battery pack base 100 provided in another embodiment of this application. Referring to Figures 1 and 4, in one possible implementation, the first reinforcing part 102 may further include a third reinforcing rib 1024. The side of the third reinforcing rib 1024 facing the battery pack is located on the second mounting surface 1021. The number of first reinforcing ribs 1022 is at least two, and the at least two first reinforcing ribs 1022 are symmetrically distributed about the third reinforcing rib 1024. The width of the third reinforcing rib 1024 is greater than the width of the first reinforcing rib 1022. That is, along the length direction of the second reinforcing rib 1023, the size of the third reinforcing rib 1024 is greater than the size of the first reinforcing rib 1022. The third reinforcing rib 1024 and at least two first reinforcing ribs 1022 can divide the internal space of the first frame 101 into multiple smaller cell units. Part of the first connecting part 103 can be disposed on the wider third reinforcing rib 1024, which can ensure the bending and torsional stiffness of the first sub-tray 10 while also improving the connection strength between the first sub-tray 10 and other components.
[0044] Referring to Figures 1 and 4, in one possible implementation, the first reinforcing rib 1022 and the third reinforcing rib 1024 extend in the direction from the first frame 101 to the second frame 201, that is, the length direction of the first reinforcing rib 1022 and the third reinforcing rib 1024 is parallel to the length direction of the battery pack base tray 100. During vehicle operation, the direction from the first frame 101 to the second frame 201 (i.e., the driving direction) is the main direction in which the battery pack tray bears the load. The third reinforcing rib 1024 located on the centerline and at least two first reinforcing ribs 1022 symmetrically distributed about the third reinforcing rib 1024 help the first sub-tray 10 better resist crushing deformation along the vehicle's driving direction.
[0045] Referring to Figures 1, 3, and 4, in one possible embodiment, the second side plate 10222 may include a first sub-side plate 102221 and a second sub-side plate 102222. The first sub-side plate 102221 is rectangular, and the second sub-side plate 102222 is triangular, pointing towards the second reinforcing rib 1023 along the split gap 500. The first sub-side plate 102221 and the second sub-side plate 102222 are arranged sequentially. The rectangular first sub-side plate 102221 can both strengthen the structural strength of the first reinforcing rib 1022 and optimize the force transmission path of the first reinforcing rib 1022. The triangular second sub-side plate 102222 can optimize the force transmission path of the first reinforcing rib 1022, and the weight per unit length of the triangular second sub-side plate 102222 is less than the weight per unit length of the rectangular first sub-side plate 102221, which is beneficial to the weight reduction of the battery pack base 100. In another possible implementation, the second side plate 10222 can be rectangular, which helps to further strengthen the structural strength of the first reinforcing rib 1022. In another possible implementation, the second side plate 10222 can be triangular, which helps to further reduce the weight of the first sub-tray 10 while optimizing the force transmission path of the first reinforcing rib 1022.
[0046] Referring to Figures 1 and 4, in one possible embodiment, the second reinforcing part 202 includes a fourth reinforcing rib 2022 and a fifth reinforcing rib 2023. The sides of the fourth reinforcing rib 2022 and the fifth reinforcing rib 2023 facing the battery pack are both located on the fourth mounting surface 2021. There are at least two fourth reinforcing ribs 2022, symmetrically distributed about the fifth reinforcing rib 2023. The width of the fifth reinforcing rib 2023 is greater than the width of the fourth reinforcing rib 2022. That is, along the length of the second reinforcing rib 2023, the size of the fifth reinforcing rib 2023 is larger than the size of the fourth reinforcing rib 2022. The fifth reinforcing rib 2023 and at least two fourth reinforcing ribs 2022 can divide the internal space of the second frame 201 into multiple smaller cell sections. Part of the second connecting part 203 can be located on the wider fifth reinforcing rib 2023, which can ensure the bending and torsional stiffness of the second sub-tray 20 while also improving the connection strength between the second sub-tray 20 and other components.
[0047] Referring to Figures 1 and 4, in one possible implementation, the fourth reinforcing rib 2022 and the fifth reinforcing rib 2023 extend in the direction from the first frame 101 to the second frame 201, that is, the length direction of the first reinforcing rib 1022 and the third reinforcing rib 1024 is parallel to the length direction of the battery pack base 100. The fifth reinforcing rib 2023 disposed on the center line and at least two fourth reinforcing ribs 2022 symmetrically distributed about the fifth reinforcing rib 2023 help the second sub-tray 20 better resist crushing deformation along the vehicle's driving direction.
[0048] Referring to Figures 1 and 3, in one possible embodiment, the second frame 201 includes a second main body 2012 and a third side plate 2013. A portion of the second connecting part 203 is disposed on the second main body 2012, and the third side plate 2013 is vertically disposed on the third mounting surface 2011. The third side plate 2013 connects the second main body 2012 and the second connecting piece 204, and the length direction of the third side plate 2013 is parallel to the length direction of the fourth reinforcing rib 2022. Through the third side plate 2013, the force acting on the second connecting piece 204 can be evenly transmitted to the second frame 201, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the second sub-tray 20.
[0049] Referring to Figures 1 and 3, in one possible embodiment, the fourth reinforcing rib 2022 includes a second substrate 20221 and a fourth side plate 20222. A portion of the second connecting portion 203 is disposed on the second substrate 20221, and the fourth side plate 20222 is vertically disposed on the fourth mounting surface 2021, connecting the second substrate 20221 and the second connecting piece 204. Through the fourth side plate 20222, the force acting on the second connecting piece 204 can be uniformly transmitted to the second reinforcing portion 202, optimizing the force transmission path and improving the impact resistance and potential energy absorption capacity of the second sub-tray 20.
[0050] Referring to Figures 1 and 4, in one possible embodiment, the first frame 101 has a plurality of first protrusions 1014 on one side adjacent to the split gap 500, and the second frame 201 has a plurality of second protrusions 2014 on one side adjacent to the split gap 500. The plurality of first protrusions 1014 and the plurality of second protrusions 2014 are arranged in a one-to-one correspondence. A plurality of first grooves are formed between the plurality of first protrusions 1014, and a plurality of second grooves are formed between the plurality of second protrusions 2014. A connector 300 can be provided between the one-to-one corresponding first groove and second groove. The inner walls of the first groove and the second groove can position and fix the connector 300, so as to integrate the first sub-tray 10 and the second sub-tray 20 into the battery pack.
[0051] In summary, this application obtains two separate sub-trays through an integrated molding process, which allows the battery pack base tray to be adapted to various vehicle beam specifications, improving the structural consistency of the battery pack base tray while reducing mold opening costs.
[0052] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. 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 of the technical features. 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.
Claims
1. A battery pack base support for supporting a battery pack, characterized in that, include: The pallet, comprising at least two pallets, with a separation gap between any two adjacent pallets, each pallet including an integrally formed frame, a reinforcing portion, and a connecting portion, wherein the frame is used to connect to the vehicle's main beam, the reinforcing portion is disposed within the frame, a portion of the connecting portion is disposed within the frame, and another portion of the connecting portion is disposed within the reinforcing portion, the connecting portion being used to connect to the battery pack; and a connector, located in the separation gap, connecting to any two adjacent frames, the connector being used to connect to the battery pack.
2. The battery pack base according to claim 1, characterized in that, The number of trays is two, one of which is a first sub-tray and the other is a second sub-tray. The first sub-tray includes an integrally formed first frame, a first reinforcing part, and a first connecting part. The first reinforcing part is disposed inside the first frame. The first frame has a first mounting surface, and the first reinforcing part has a second mounting surface. Both the first mounting surface and the second mounting surface face the battery pack. Part of the first connecting part is disposed on the first mounting surface, and another part of the first connecting part is disposed on the second mounting surface. Along the length of the battery pack base, the separation gap is located between the second sub-tray and the first sub-tray. The second sub-tray includes an integrally formed second frame, a second reinforcing part, and a second connecting part. The second reinforcing part is disposed inside the second frame. The second frame has a third mounting surface, and the second reinforcing part has a fourth mounting surface. The first mounting surface, the second mounting surface, the third mounting surface, and the fourth mounting surface are all located on the same plane. Part of the second connecting part is disposed on the third mounting surface, and another part of the second connecting part is disposed on the fourth mounting surface.
3. The battery pack base according to claim 2, characterized in that, The first reinforcing part includes a first reinforcing rib and a second reinforcing rib arranged in a cross manner, and the side of the first reinforcing rib and the second reinforcing rib facing the battery pack is located on the second mounting surface.
4. The battery pack base according to claim 3, characterized in that, The first reinforcing rib and the second reinforcing rib have a cross-shaped structure.
5. The battery pack base according to claim 3, characterized in that, The first reinforcing part further includes a third reinforcing rib, the side of the third reinforcing rib facing the battery pack is located on the second mounting surface, the number of the first reinforcing ribs is at least two, the at least two first reinforcing ribs are symmetrically distributed about the third reinforcing rib, and the width of the third reinforcing rib is greater than the width of the first reinforcing rib.
6. The battery pack base according to claim 5, characterized in that, The first reinforcing rib and the third reinforcing rib extend in the direction from the first frame to the second frame.
7. The battery pack base according to claim 3, characterized in that, The first sub-tray also includes a connecting piece, which is integrally formed with the first frame. The connecting piece is vertically disposed on the side of the first mounting surface adjacent to the split gap. The length direction of the connecting piece is parallel to the length direction of the second reinforcing rib. The connecting piece is used to connect the vehicle's main beam.
8. The battery pack base according to claim 7, characterized in that, The first frame includes a first main body and a first side plate. A portion of the first connecting part is disposed on the first main body. The first side plate is perpendicularly disposed on the first mounting surface. The first side plate is connected between the first main body and the connecting piece. The length direction of the first side plate is parallel to the length direction of the first reinforcing rib.
9. The battery pack base according to claim 7, characterized in that, The first reinforcing rib includes a first base plate and a second side plate. A portion of the first connecting part is disposed on the first base plate, and the second side plate is vertically disposed on the second mounting surface. The second side plate is connected between the first base plate and the connecting piece.
10. The battery pack base according to claim 9, characterized in that, The second side plate includes a first sub-side plate and a second sub-side plate. The first sub-side plate is rectangular and the second sub-side plate is triangular. The first sub-side plate and the second sub-side plate are arranged sequentially along the gap between the two parts, pointing towards the second reinforcing rib.
11. The battery pack base according to claim 2, characterized in that, The first connecting portion includes a plurality of first bushings and a plurality of second bushings, wherein the plurality of first bushings are disposed on the first mounting surface and the plurality of second bushings are disposed on the second mounting surface.
12. The battery pack base according to claim 2, characterized in that, The second reinforcing part includes a fourth reinforcing rib and a fifth reinforcing rib. The side of the fourth reinforcing rib and the side of the fifth reinforcing rib facing the battery pack are both located on the fourth mounting surface. There are at least two fourth reinforcing ribs, and the at least two fourth reinforcing ribs are symmetrically distributed about the fifth reinforcing rib. The width of the fifth reinforcing rib is greater than the width of the fourth reinforcing rib.
13. The battery pack base according to claim 12, characterized in that, The fourth reinforcing rib and the fifth reinforcing rib extend in the direction from the first frame to the second frame.
14. The battery pack base according to claim 2, characterized in that, The first frame has a plurality of first protrusions on one side adjacent to the split gap, and the second frame has a plurality of second protrusions on one side adjacent to the split gap, with the plurality of first protrusions and the plurality of second protrusions being arranged in a one-to-one correspondence.