Battery system and electric vehicle including the same

Abstract

The invention relates to a battery system and an electric vehicle including the same. A battery system includes: a battery case including a frame and a cover plate, and forming an accommodation chamber between the frame and the cover plate; a plurality of battery cells in the accommodating chamber; and an embedded element including a sleeve portion having a through hole extending therethrough and a flange portion at one end of the sleeve portion. A tunnel extends through the frame to receive a fastener that extends to secure the battery system to the vehicle. The sleeve portion extends into the tunnel of the frame, and the flange portion abuts a surface of the cover plate outside of the tunnel. The sleeve portion has a sleeve seal that seals the sleeve portion to an inner surface of the tunnel, and the flange portion has a first flange seal that abuts a surface of the cover plate and seals the flange portion to the cover plate.

Description

Technical Field

[0001] An aspect of the embodiments of this disclosure relates to a battery system having an embedded element that provides multiple seals. Background Technology

[0002] Recently, vehicles using electricity as a power source for transporting goods and people have been developed. Such electric vehicles are automobiles that are propelled, either continuously or temporarily, by an electric motor using energy stored in rechargeable (or secondary) batteries. Electric vehicles can be powered solely by batteries (so-called battery electric vehicles or BEVs), or they can include a combination of an electric motor and, for example, a conventional internal combustion engine (so-called plug-in hybrid electric vehicles or PHEVs). BEVs and PHEVs use high-capacity rechargeable batteries designed to provide power for propulsion over a sustained period of time.

[0003] Generally, a rechargeable (or secondary) battery cell includes an electrode assembly comprising a positive electrode, a negative electrode, and a separator interposed between the electrodes. A solid or liquid electrolyte allows ions to move during the charging and discharging of the battery cell. The electrode assembly is located (or housed) within a housing, and electrode terminals located outside the housing establish electrical connections with the electrodes. The housing may be, for example, cylindrical or rectangular.

[0004] A battery module comprises multiple battery cells connected in series and / or in parallel. That is, a battery module is formed by interconnecting the electrode terminals of multiple battery cells with a number and connection configuration depending on the desired power level, to provide a relatively high-power rechargeable battery.

[0005] Battery modules can have a block design or a modular design. In a block design, each battery cell is integrated into a common current collector structure and a common battery management system, and the unit is housed in a housing. In a modular design, multiple battery cells are connected together to form sub-modules, and several sub-modules are connected together to form a battery module. In automotive applications, a battery system may include multiple battery modules connected in series to provide a desired voltage.

[0006] A battery pack is a group of any number of (typically identical) battery modules or individual battery cells. Battery modules or individual battery cells can be connected in series, parallel, or a series / parallel configuration to provide desired voltage, capacity, and / or power density. The components of a battery pack include individual battery modules and interconnects that provide conductivity between the battery modules.

[0007] The mechanical integration of a battery pack is achieved through appropriate mechanical connections between the various components, such as between battery modules, and between the battery modules and, for example, the vehicle's support structure. These connections should remain functional and safe throughout the entire average lifespan of the battery system. Furthermore, installation space and interchangeability specifications should be met, especially in mobile applications.

[0008] Mechanical integration of the battery module can be achieved by providing a carrier frame and positioning the battery module thereon. Securement of the individual battery cells or the battery module can be achieved through mounting recesses in the frame or through mechanical interconnects such as bolts or screws. In other examples, the battery module is confined by fastening the side panels of the carrier frame to the lateral sides. In some applications, a cover plate can be fixed to the top and bottom of the battery module.

[0009] The battery pack's carrier frame is mounted to, for example, the vehicle's load-bearing structure. When the battery pack is to be secured to the bottom of the vehicle, a mechanical connection can be established from the bottom side via bolts, for example, passing through the carrier frame of the battery pack. The frame is typically made of aluminum or aluminum alloy to reduce the overall weight of the construction.

[0010] Traditional battery systems, despite any modular structure, typically include a battery casing that serves as a protective enclosure to shield the battery system from environmental influences and provide structural protection for the battery system's components. Encased battery systems are usually installed as a whole into their application environment, such as in electric vehicles. Therefore, replacing a defective or damaged system component, such as a defective battery sub-module, requires disassembling the entire battery system and removing its casing. Even defects in small and / or inexpensive system components may necessitate disassembling and repairing the entire battery system individually or replacing the entire battery system. Because high-capacity battery systems are expensive, large, and heavy, the repair process is cumbersome, and storing large battery systems, for example, in a mechanic's workshop is difficult. Summary of the Invention

[0011] Large battery systems often suffer from structural problems due to their length and width. One difficulty in developing such battery systems is ensuring sufficient stability within the battery pack. Therefore, additional fastening devices (e.g., fasteners), such as screw mounts, can be provided, which are located in the middle of the battery pack and extend through it. However, such additional fastening devices can introduce potential locations where water or other contaminants can enter the battery pack from the outside, leading to safety issues. In other words, there may be issues with airtightness or sealing.

[0012] According to embodiments of this disclosure, a battery system is provided that exhibits sufficient stability while protecting the individual battery cells within the battery system from water or other contaminants.

[0013] This disclosure is defined by the appended claims and their equivalents. The following description is subject to this limitation. Any disclosure outside the scope of the claims and their equivalents is intended for illustrative and comparative purposes.

[0014] According to embodiments of this disclosure, a battery system includes: a battery housing including a frame and a cover plate on the frame, forming a receiving chamber defined by the frame and the cover plate; a plurality of battery cells received in the receiving chamber; and an insert element including a sleeve portion and a flange portion at one end of the sleeve portion, and having a through-hole extending through the insert element. A tunnel extends through the frame, is defined from the receiving chamber by its circumferential wall, and is configured to receive a fastener extending through the tunnel to secure the battery system to a load-bearing structure of a vehicle. The sleeve portion extends into the tunnel of the frame, and the flange portion is outside the tunnel and abuts a surface of the cover plate. The sleeve portion includes a sleeve seal extending around the outer surface of the sleeve portion for sealing the sleeve portion to the inner surface of the tunnel, and the flange portion includes a first flange seal extending around the periphery of an opening in the cover plate on one side of the flange portion abutting the surface of the cover plate, and sealing the flange portion to the cover plate.

[0015] The flange portion can be located outside the cover plate, adjacent to the outer surface of the cover plate, such that the first flange seal extends around the periphery of the opening in the cover plate and seals the flange portion to the cover plate from the outer surface of the cover plate. The flange portion can press the cover plate against the frame.

[0016] The sleeve portion can be connected to the tunnel via a threaded connection.

[0017] The flange portion and the frame may have mounting holes that align with each other and with openings in the cover plate. Mounting elements may extend through the openings and mounting holes in the cover plate into the frame, thereby mounting the cover plate and the embedded elements to the frame.

[0018] The flange portion and the frame may each have a first mounting hole aligned with each other and aligned with a first opening in the cover plate. A first mounting element may extend through the first opening and the first mounting hole in the cover plate into the frame. The flange portion and the frame may each have a second mounting hole aligned with each other and aligned with a second opening in the cover plate. A second mounting element may extend through the second opening and the second mounting hole in the cover plate into the frame. The first mounting hole and the first opening are spaced apart from the tunnel by a first distance in a first direction, and the second mounting hole and the second opening are spaced apart from the tunnel by a second distance in a second direction, the second direction being different from the first direction. A first flange seal extends around the periphery of both the first opening and the second opening in the cover plate and seals the flange portion to the cover plate.

[0019] The flange portion may be located between the cover plate and the frame, and the flange portion may abut the inner surface of the cover plate such that the first flange seal extends around the periphery of the opening in the cover plate and seals the flange portion to the cover plate from the inner surface of the cover plate.

[0020] The flange portion may include a second flange seal on one side of the surface of the flange portion adjacent to the frame. The second flange seal may extend around the periphery of the mounting hole and seal the flange portion to the frame.

[0021] The cover can be a top cover or a bottom cover.

[0022] The frame may include crossbeams that include tunnels and / or mounting holes.

[0023] Sleeve seals may include one or more sealing rings.

[0024] The first flange seal may include a sprayed gasket.

[0025] Another embodiment of this disclosure provides an electric vehicle that includes the battery system described above.

[0026] Another embodiment of this disclosure provides an electric vehicle including a load-bearing structure and fasteners that extend through a tunnel through the frame of a battery system to secure the battery system to the load-bearing structure.

[0027] Other aspects and features of this disclosure can be learned from the following description. Attached Figure Description

[0028] The aspects and features of this disclosure will become apparent to those skilled in the art from the detailed description of embodiments thereof with reference to the accompanying drawings, in which:

[0029] Figure 1 This is a schematic perspective view of an embedded element of a battery system according to an embodiment.

[0030] Figure 2 It has Figure 1 A schematic cross-sectional view of the battery system with embedded elements shown.

[0031] Figure 3A and Figure 3B This is a schematic perspective view of an embedded element of a battery system according to another embodiment.

[0032] Figure 4 It has Figure 3A and 3B A schematic perspective view of the battery system with embedded elements shown.

[0033] Figure 5 It has such Figure 4A schematic cross-sectional view of the battery system with embedded elements shown.

[0034] Figure 6 This is a schematic perspective view of the load-bearing structure of an electric vehicle.

[0035] Figure 7 yes Figure 6 The schematic cross-sectional view of the load-bearing structure shown. Detailed Implementation

[0036] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Aspects and features of the embodiments and methods of implementation thereof will be described with reference to the drawings. However, the present disclosure may be implemented in a variety of different forms and should not be construed as limited to the embodiments shown herein. Rather, these embodiments are provided as examples so that this disclosure will be thorough and complete and will fully convey the aspects and features of the present disclosure to those skilled in the art.

[0037] Therefore, processes, components, and techniques that are not considered essential for a person skilled in the art to fully understand the aspects and features of this disclosure may be omitted or only briefly described.

[0038] It will be understood that when an element or layer is referred to as being "on" another element or layer, "connected" to another element or layer, or "bonded" to another element or layer, it can be directly on, directly connected to, or directly bonded to the other element or layer, or there may be one or more intermediate elements or layers. When an element or layer is referred to as being "directly on" another element or layer, "directly connected" to another element or layer, or "directly bonded" to another element or layer, there are no intermediate elements or layers. For example, when a first element is described as being "bonded" or "connected" to a second element, the first element can be directly bonded or connected to the second element, or the first element can be indirectly bonded or connected to the second element via one or more intermediate elements.

[0039] In the accompanying drawings, the dimensions of various elements, layers, etc., may be exaggerated for clarity. The same reference numerals denote the same elements. As used herein, the term “and / or” includes any and all combinations of one or more of the related listed items. Furthermore, the use of “may” when describing embodiments of this disclosure refers to “one or more embodiments of this disclosure.” Expressions such as “at least one of…” and “any one of…” modify the entire column of elements, not individual elements within that column, when following a list of elements. For example, the expression “at least one of a, b, or c” means only a, only b, only c, both a and b, both a and c, both b and c, all a, b, and c, or variations thereof. As used herein, the terms “use,” “using…,” and “being used” may be considered synonymous with the terms “utilize,” “exploiting…,” and “being exploited,” respectively. As used herein, the terms “substantially,” “about,” and similar terms are used as approximate terms, not terms of degree, intended to describe inherent biases in measurements or calculations that would be recognized by one of ordinary skill in the art.

[0040] It will be understood that although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, or portion from another element, component, region, layer, or portion. Therefore, the first element, component, region, layer, or portion discussed below may be referred to as a second element, component, region, layer, or portion without departing from the teachings of the exemplary embodiments.

[0041] For ease of description, spatial relation terms such as “below,” “under,” “down,” “above,” and “above” are used herein to describe the relationship between one element or feature and another element or feature as shown in the figure. It will be understood that, in addition to the orientation depicted in the figure, spatial relation terms are also intended to cover different orientations of the device in use or operation. For example, if the device in the figure is flipped, the element described as “below” or “under” other elements or features will be oriented “above” or “above” other elements or features. Therefore, the term “below” can cover both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relation descriptors used herein should be interpreted accordingly.

[0042] The terminology used herein is for describing embodiments of the present disclosure and is not intended to limit the disclosure. As used herein, the singular form “a” is also intended to include the plural form unless the context clearly indicates otherwise. It will be further understood that the terms “comprising,” “including,” “including,” and / or “containing” as used in this specification indicate the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0043] In view of the overall content of this disclosure, those skilled in the art will understand that suitable features of the various embodiments of this disclosure may be combined in whole or in part, and may be technically associated and operated in a variety of suitable ways, and each embodiment may be implemented independently of each other or in combination with each other in any suitable way, unless otherwise stated or implied.

[0044] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will also be understood that terms (such as those defined in common dictionaries) shall be interpreted as having the meaning consistent with their meaning in the context of the relevant art and / or the context of this specification, and shall not be interpreted in an idealized or overly rigid sense unless expressly defined herein.

[0045] According to one embodiment of this disclosure, a battery system includes a battery housing, which includes a frame and a cover, for example, at least one cover. The cover may be a top cover and / or a bottom cover. In some embodiments, two covers may be provided—a top cover and a bottom cover. The cover may be disposed on the frame. Inside the battery housing, and thus within the internal space formed between the frame and the cover, a receiving chamber is defined, which receives a plurality of battery cells. The receiving chamber is defined by the frame and the cover. The battery system includes a plurality of battery cells, such as prismatic, pouch, or cylindrical battery cells. The battery cells may be arranged to form one or more battery packs.

[0046] The battery system frame forms part of the battery system's carrier frame. The cover plate may also form part of this carrier frame. The carrier frame carries and / or supports the battery cells. The carrier frame provides a structural connection to the vehicle's load-bearing structure, within which the battery system can be mounted / installed. In other words, the frame can be an integral structure of the battery housing, providing structural rigidity to the battery housing. The frame may include beams extending in horizontal and / or vertical planes, and rigidly joined support elements to support the cover plate of the battery housing.

[0047] A tunnel or passageway extends through a frame and through a housing chamber within the frame. The tunnel extends from a first (e.g., lower) end of the housing chamber to a second (e.g., upper) end of the housing chamber. In other words, the tunnel has a first opening at a first end surface of the frame and extends through the frame from the first opening to a second opening at a second end surface of the frame. The tunnel has a circumferential wall that defines the tunnel from the housing chamber. The tunnel thus provides (or forms) a sealed passageway. In other words, the frame includes a (vertical) beam extending through the housing chamber and connecting a first side of the frame to a second side of the frame, and the tunnel is formed within the beam. The tunnel is configured to receive fastening elements (e.g., fasteners) to secure the battery system to the vehicle's load-bearing structure. That is, the tunnel is formed or constructed to accommodate fastening elements, such as screws or bolts, extending through the tunnel. For example, the cross-section or diameter of the tunnel may correspond to the cross-section or diameter of the fastening element. The fastening element secures the frame to the vehicle's load-bearing structure, and thus the battery system to the vehicle's load-bearing structure.

[0048] The battery system further includes an insert element partially disposed within the tunnel. The insert element includes a sleeve portion and a collar portion, the collar portion being disposed at one end of the sleeve portion. The sleeve portion is the part of the insert element disposed within the tunnel. In other words, the insert element is disposed at the frame, its sleeve portion extending into the tunnel of the frame. The collar portion is disposed outside the tunnel and abuts the surface of a cover plate. The collar portion may also abut an outer surface of the frame extending around (or around) the tunnel entrance, or may press the cover plate against the frame, as described below. A through-hole extends through the insert element. That is, the through-hole extends through both the collar portion and the sleeve portion. The through-hole is configured to receive a fastening element to secure the battery system to the vehicle's load-bearing structure. The inner surface of the tunnel may have a recess in which the sleeve portion of the insert element can be received. The cross-section of the through-hole of the insert element may correspond to or be substantially the same as the cross-section of the tunnel. The insert element thus forms a bushing or socket for fastening the element.

[0049] The sleeve portion includes a sleeve seal surrounding (or extending around) the outer surface of the sleeve portion. For example, the sleeve seal may include one or more sealing rings, such as O-rings. When two or more sealing rings are provided, they may be spaced apart (or spaced apart) from each other in the axial direction of the sleeve portion for redundancy. The sleeve seal seals the sleeve portion to the inner surface of the tunnel, and thus seals the embedded element to the inner surface of the tunnel. In other words, the sleeve seal prevents water or other contaminants from entering or seeping between the outer surface of the sleeve portion of the embedded element and the inner surface of the tunnel, thereby preventing water or other contaminants from entering the battery housing and containment chamber.

[0050] The flange portion includes a first flange seal disposed on one side of the flange portion adjacent to the cover plate surface. As described above, the flange portion of the embedded element abuts the cover plate with one side thereon. The first flange seal of the flange portion is disposed on this side of the flange portion. The first flange seal is configured such that it extends around an opening in the cover plate (or around the periphery of an opening in the cover plate) to seal the flange portion to the cover plate. That is, the cover plate has an opening. The opening in the cover plate can be aligned with a tunnel in the frame and can form part of a tunnel through the receiving chamber together with the tunnel and a through-hole in the embedded element. In another embodiment, the opening in the cover plate can be a mounting opening by means of which the cover plate can be fastened to the frame at a location different from the tunnel, as described below. The first flange seal seals the flange portion to the surface of the cover plate, and thus seals the embedded element to the surface of the cover plate. In other words, the first flange seal prevents water or other contaminants from entering between or seeping into the flange portion and the cover plate, thereby preventing water or other contaminants from entering the battery casing and the receiving chamber.

[0051] A battery system according to an embodiment of the present disclosure includes an insert element that provides a dual-sealing structure: a first seal (or first seal) by means of a sleeve seal, which prevents water or other contaminants from entering the receiving chamber via a tunnel; and a second seal (or second seal) by means of a first flange seal, which prevents water or other contaminants from entering the receiving chamber via a cover. Therefore, the battery system can be secured to the vehicle's load-bearing structure by fastening elements extending through the tunnel, while simultaneously protecting the individual battery cells. That is, the battery system according to an embodiment of the present disclosure prevents water or other external or environmental influences from entering the battery pack and causing safety issues through the insert element. Therefore, the battery system according to an embodiment of the present disclosure provides sufficient stability for the battery system due to the tunnel configured to receive the fastening element, while protecting the individual battery cells within the battery system from external or environmental influences through the insert element with its dual-sealing structure. In other words, embodiments of the present disclosure provide an insert element with seals (e.g., a first flange seal and a sleeve seal) without requiring pre-coated fine threads to ensure a sealed battery pack, although screws extending through the battery may be necessary for securely mounting large battery packs.

[0052] Embedded elements can also serve as tolerance compensators. For example, the connection between the cover and the frame, such as the connection between the bottom cover, the frame, and the top cover (when two covers are provided), can easily introduce large tolerances, and therefore, sealing issues can be significant. Embedded elements can overcome this problem because they act as adapters or compensators, widening the surface on which the battery system can be sealed and ensuring a closed containment chamber, despite the presence of tunnels.

[0053] According to one embodiment, a flange portion is disposed on the exterior of a cover plate, abutting the outer surface of the cover plate, such that a first flange seal seals the flange portion to the cover plate around an opening in the cover plate and from the outer surface of the cover plate. The flange portion presses the cover plate against a frame. The flange portion being disposed on the exterior of the cover plate means that a portion of the cover plate extends between the flange portion and the frame. In this embodiment, the surface of the cover plate adjacent to the flange portion of the embedded element is the outer surface of the cover plate, i.e., the surface facing away from the frame. In this embodiment, the opening in the cover plate can be aligned with a tunnel and can form a passage through the receiving chamber together with the tunnel and the through-hole in the embedded element. The embedded element can have rotational symmetry, wherein the axis of symmetry extends centrally through the through-hole. Therefore, in this embodiment, the first flange seal seals the flange portion to the cover plate from the outer surface of the cover plate. The flange portion presses against the cover plate, thus pressing the cover plate disposed between the frame and the flange portion against the frame. Fastening devices (e.g., fasteners) can be provided to achieve this pressing. Thus, the first flange seal prevents water or other contaminants from entering between the outer surface of the cover and the flange portion, and therefore prevents water or other contaminants from entering the housing and reaching the battery cells. Such an embedded element provides a simple and effective seal.

[0054] A simple and effective seal can be achieved when the opening in the cover plate is aligned with the tunnel and the sleeve portion of the insert element is inserted into the tunnel, with the flange portion abutting the outer surface of the cover plate. According to one embodiment, the sleeve portion is connected to the tunnel via a threaded connection. For example, the sleeve portion may have external threads that screw into the internal threads of the frame, such as external threads that screw into the internal threads of the tunnel. That is, the tunnel may have internal threads, and the sleeve portion of the insert element may have external threads. The insert element can be screwed into the tunnel of the frame by means of the sleeve portion, thereby securing the insert element and the cover plate disposed between the frame and the insert element to the frame. This allows for simple and effective installation of the insert element and the cover plate to the frame simultaneously. Therefore, additional fastening devices or screws can be omitted.

[0055] According to one embodiment, the flange portion and the frame have mounting holes that are aligned with each other and with an opening in the cover plate. A mounting element extends through the opening in the cover plate and the mounting hole into the frame, thereby mounting the cover plate and the inserting element to the frame. That is, each of the flange portion and the frame has a mounting hole that aligns with or overlaps with the opening in the cover plate. In other words, the frame may have a first mounting hole, and the flange portion may have a second mounting hole. The first mounting hole, the second mounting hole, and the opening in the cover plate are aligned with each other. The mounting holes and openings are aligned with each other such that a mounting element, such as a screw or bolt, can pass through the opening in the cover plate, through the mounting hole in the flange portion, and into the mounting hole in the frame. Thus, the cover plate and the inserting element are mounted or fastened to the frame. The mounting hole in the frame may have internal threads, and the mounting element (e.g., a screw) may have external threads such that the mounting element can be screwed into the mounting hole in the frame. In one embodiment, the opening in the cover plate is not aligned with the tunnel but forms a mounting opening by means of which the cover plate can be mounted or fastened to the frame at a location different from the tunnel. Such an embodiment can provide an embedded element that is securely fastened to the frame while providing sufficient seal against water and other contaminants. Even if water or contaminants were to enter through an opening in the cover plate along the mounting element, the path into the receiving chamber is blocked between the cover plate and the flange portion.

[0056] The battery system may include multiple such mounting devices, such as two. For example, the frame may have multiple mounting holes, for example, on two opposite sides of the tunnel. The flange portion of the embedded element may have two corresponding mounting holes, each aligned with one of the mounting holes in the frame. Accordingly, the cover may have two openings, each aligned with one of the mounting holes in the frame and the flange portion. That is, according to one embodiment, the flange portion and the frame each have a first mounting hole aligned with each other and aligned with a first opening in the cover. A first mounting element extends through the first opening and the first mounting hole in the cover into the frame. The flange portion and the frame each have a second mounting hole aligned with each other and aligned with a second opening in the cover, and a second mounting element extends through the second opening and the second mounting hole in the cover into the frame. The first mounting hole and the first opening are located at a first distance from the tunnel in a first direction (or spaced apart from the tunnel by a first distance), and the second mounting hole and the second opening are located at a second distance from the tunnel in a second direction. A first flange seal surrounds both the first opening and the second opening in the cover and seals the flange portion to the cover. The first distance may be the same as the second distance. The first direction can be different from the second direction, specifically opposite to it. In other words, the frame can have two mounting holes on its surface on opposite sides of the tunnel. The flange portion can have corresponding mounting holes, and the cover plate can have corresponding openings. Mounting the cover plate to the frame on two opposite sides of the tunnel can provide improved structural stability. In this embodiment, the first flange seal is configured such that it surrounds both openings in the cover plate, namely both the first opening and the second opening in the cover plate. The first flange seal can provide a strong seal, preventing water or other contaminants from entering the receiving chamber from between the flange portion of the cover plate and the embedded element.

[0057] According to one embodiment, a flange portion is disposed inside the cover plate between the cover plate and the frame. The flange portion abuts the inner surface of the cover plate such that a first flange seal seals the flange portion to the cover plate around an opening in the cover plate and from the inner surface of the cover plate. The cover plate and the flange portion (and thus the insert element) are mounted to the frame by one or more mounting elements extending through one or more mounting holes and openings. One or more mounting elements can press the cover plate onto the flange portion and press both the cover plate and the flange portion onto the frame.

[0058] According to one embodiment, the flange portion includes a second flange seal on one side of the surface of the flange portion adjacent to the frame. The second flange seal surrounds the mounting hole and seals the flange portion to the frame. Therefore, in this embodiment, the flange portion of the embedded element includes two flange seals, one on each surface. In other words, the flange portion includes a first flange seal on the surface of the flange portion facing the cover plate and a second flange seal on the surface of the flange portion facing the frame. Here, the flange portion is disposed between the cover plate and the frame. The second flange seal also seals any possible path between the frame and the flange portion. That is, even if water or contaminants were to enter the mounting element through the opening in the cover plate and the mounting hole of the flange portion, the path into the receiving chamber between the flange portion and the frame is blocked by the second flange seal.

[0059] According to one embodiment, the cover is a top cover and / or a bottom cover. As described above, the cover can be either a top cover or a bottom cover. The battery casing may include both a top cover and a bottom cover. If both a top cover and a bottom cover are present, the embodiments disclosed herein apply to both the top cover and the bottom cover.

[0060] According to one embodiment, the frame includes a crossbeam comprising tunnels and / or mounting holes. That is, the tunnel may be formed in / through the crossbeam, and the crossbeam may extend through a receiving chamber. Furthermore, one or more mounting holes for mounting embedded elements into the frame may be provided within the crossbeam. The flange portion of the embedded element may extend above the edge of the crossbeam such that the sealing surface or first flange seal is wider than the crossbeam. Thus, the tunnel openings of the frame, which can be relatively wide compared to the relatively narrow width of the crossbeam, can be sealed without widening the crossbeam, which would reduce the energy density of the battery pack.

[0061] According to one embodiment, the sleeve seal includes one or more sealing rings. As described above, the sleeve seal may include one or more O-rings. When two or more sealing rings are provided, they may be spaced apart (or spaced apart from each other) in the axial direction of the sleeve portion for redundancy. This provides a robust seal between the inner surface of the tunnel and the outer surface of the sleeve portion.

[0062] According to one embodiment, the first flange seal includes a spray-on gasket (or consists of a spray-on gasket). In other words, the first flange seal can be formed by spraying or can be sprayed. Spraying the first flange seal is a simple way to provide the first flange seal. A second flange seal (if present) can be provided in the same manner.

[0063] Embodiments of this disclosure also provide electric vehicles including the battery system described above.

[0064] According to one embodiment, the electric vehicle also includes a load-bearing structure and fastening elements (or fasteners). The fastening elements extend through tunnels in the frame of the battery system to secure the battery system to the load-bearing structure. Fixing elements also extend through through-holes in the embedded elements. Thus, the battery system can be securely fastened to the load-bearing structure while maintaining a robust seal that protects the individual battery cells from water or other contaminants.

[0065] Figure 1 and Figure 2 Aspects of a battery system 100 according to an embodiment of the present disclosure are shown. Figure 1 This is a schematic perspective view of the embedded element 30 of the battery system 100. Figure 2 A portion of a battery system 100, including an embedded element 30, is shown in cross-sectional view. The battery system 100 includes a battery housing 10 that surrounds (or forms) a receiving chamber 11, in which a plurality of battery cells 12 are arranged. The battery housing 10 includes a frame 14 and a cover 16 disposed on the frame 14, the receiving chamber 11 being defined by (or between) the frame 14 and the cover 16. The cover 16 may be a top cover. The frame 14 forms part of a carrier frame of the battery system 100, through which the battery system 100 can be fastened to a carrier structure 200 of an electric vehicle (see, for example...). Figure 7 ).

[0066] Frame 14 includes a tunnel 20 that extends from the upper end of battery system 100 through frame 14 to the lower end of battery system 100. The portion of frame 14 including tunnel 20 may be a (cross)beam that allows adjacent battery cells 12 to be separated. Tunnel 20 extends completely through battery system 100 and therefore also completely through housing 11, i.e., from one end of housing 11 to the other end. Tunnel 20 is defined from housing 11 by its circumferential wall 22.

[0067] Tunnel 20 is configured to receive fastening elements (e.g., fasteners) 210, which can extend through tunnel 20 to fasten battery system 100 to load-bearing structure 200 of electric vehicle (see example). Figure 7 ). Figure 6 A schematic perspective view of the load-bearing structure 200 of the electric vehicle and the battery system 100 disposed therein is shown. Figure 7 Showing through Figure 6The diagram shows a cross-sectional view of the support structure 200 and the battery system 100 disposed therein. In the illustrated embodiment, a fastening element 210 extends through the tunnel 20, with its head 210a abutting against the lower portion of the support structure 200 at the bottom end of the tunnel 20, and its tail 210b fastened to the upper portion of the support structure 200 by a nut 220 at the top end of the tunnel 20. Thus, the battery system 100 is fastened / secured to the support structure 200.

[0068] The battery system 100 further includes an inlay element 30, embodiments of which are described in... Figure 1 The image is shown in perspective. The insert element 30 includes a sleeve portion 32 and a flange portion 34 at the end of the sleeve portion 32. A through-hole 36 extends through the insert element 30, that is, through both the sleeve portion 32 and the flange portion 34, as shown in, for example... Figure 2 As shown. In the assembled state of the battery system 100, the embedded element 30 is disposed at the frame 14, with its sleeve portion 32 extending into the tunnel 20 of the frame 14, and the flange portion 34 outside the tunnel 20 and adjacent to the outer surface of the cover plate 16.

[0069] The sleeve portion 32 includes a sleeve seal 33 that surrounds (or extends around) the outer surface of the sleeve portion 32 for sealing the sleeve portion 32 to the inner surface of the tunnel 20. The sleeve seal 33 may include two sealing rings spaced apart (e.g., spaced apart from each other) in the axial direction of the sleeve portion 32, for example, as... Figure 2 As shown. The flange portion 34 includes a first flange seal 35 on one side of the outer surface of the flange portion 34 adjacent to the cover plate 16. The first flange seal 35 surrounds the opening 18 in the cover plate 16 (e.g., extends around the periphery of the opening 18) and seals the flange portion 34 to the cover plate 16.

[0070] The embedded element 30 can press the cover plate 16 against the frame 14 via the flange portion 34. This can be achieved, for example, through a threaded connection between the sleeve portion 32 and the tunnel 20. For example, the sleeve portion 32 can have external threads that screw into the internal threads of the tunnel 20.

[0071] The embedded element 30 provides a dual-sealing structure for the battery system 100. For example, a first seal (or first seal element) is provided by means of a sleeve seal 33, which prevents water or other contaminants from entering the receiving chamber 11 from the tunnel 20 by flowing between the outer surface of the sleeve portion 32 and the inner surface of the tunnel 20. Furthermore, a second seal (or second seal element) is provided by means of a first flange seal 35, which prevents water or other contaminants from entering the receiving chamber 11 by flowing between the flange portion 34 and the cover plate 16. Thus, the tunnel 20 is provided to receive fastening devices (e.g., fasteners), which are provided by means of a fastening element 210 extending through the tunnel 20, and which are provided to secure the battery system 100 to the vehicle's load-bearing structure 200, while the embedded element 30 ensures protection of the battery cells 12 from water or contaminants.

[0072] Another embodiment of the battery system 100 is in Figures 3A to 5 As shown in the image. Figures 3A to 5 The battery system 100 shown includes an embedded element 130, which is different from the embedded element 30 described above.

[0073] Embedded element 130 in Figure 3A It is shown in perspective top view, and in Figure 3B It is shown in perspective bottom view. Figure 4 An embedded element 130 installed in the battery system 100 is shown, but the cover is not shown (omitted). Figure 5 A portion of the battery system 100 is shown in cross-section, and it has a cover plate.

[0074] The battery system 100 includes a battery casing 110 that surrounds (or forms) a housing 111, in which multiple battery cells 112 are arranged. The battery casing 110 includes a frame 114 and a cover 116 disposed on the frame 114. The cover 116 may be a bottom cover. The frame 114 forms part of a carrier frame of the battery system 100, through which the battery system 100 can be fastened to a load-bearing structure 200 of an electric vehicle, as described above.

[0075] Frame 114 includes a tunnel 120 extending from the upper end of battery system 100 through frame 114 to the lower end of battery system 100. The portion of frame 114 including tunnel 120 may be a crossbeam that separates adjacent battery cells 112. Tunnel 120 extends completely through battery system 100 and therefore also completely through housing 111, i.e., from a first end to a second end of housing 111. Tunnel 120 is defined from housing 111 by its circumferential wall 122. Tunnel 120 is configured to receive fastening elements 210 that may extend through tunnel 120 to fasten battery system 100 to the load-bearing structure 200 of electric vehicle, as described above.

[0076] The insert element 130 includes a sleeve portion 132 and a flange portion 134 at an end of the sleeve portion 132. A through hole 136 extends through the insert element 130, that is, through both the sleeve portion 132 and the flange portion 134, as shown in the example. Figure 3A and 3B As shown. In the assembled state of the battery system 100, the embedded element 130 is disposed at the frame 114, with its sleeve portion 132 extending into the tunnel 120 of the frame 114, and the flange portion 134 outside the tunnel 120 and adjacent to the inner surface of the cover plate 116.

[0077] The sleeve portion 132 includes a sleeve seal 133 that surrounds the outer surface of the sleeve portion 132 (e.g., extends around the outer surface of the sleeve portion 132) for sealing the sleeve portion 132 to the inner surface of the tunnel 120. The sleeve seal 133 may include two sealing rings spaced apart (e.g., spaced apart from each other) in the axial direction of the sleeve portion 132, such as… Figure 3B and Figure 5 As shown.

[0078] The flange portion 134 includes a first flange seal 135 on one side of the inner surface of the adjacent cover plate 16. (Refer to above) Figure 1 and Figure 2 Unlike the described embedded element 30, the flange portion 134 of the embedded element 130 is positioned between the cover plate 116 and the frame 114. (Refer to the above...) Figure 1 and Figure 2 In the described embodiment, the cover plate 16 is positioned between the flange portion 34 and the frame 14. Therefore, a first flange seal 135 of the embedded element 130 is disposed on the upper surface of the embedded element 130. Referring above... Figure 1 and Figure 2In the described embodiment, a first flange seal 35 is disposed on the lower surface of the embedded element 30. The first flange seal 135 surrounds two openings 118a, 118b in the cover plate 116 (e.g., extends around the periphery of the two openings 118a, 118b) and seals the flange portion 134 to the cover plate 116.

[0079] The flange portion 134 and the frame 114 each include first mounting holes (or first mounting openings) 138a and 140a aligned with each other and aligned with a first opening 118a in the cover plate 116. A first mounting element 150a extends through the first opening 118a and the first mounting holes 138a and 140a in the cover plate 116 into the frame 114. The flange portion 134 and the frame 114 each also include second mounting holes (or second mounting openings) 138b and 140b aligned with each other and aligned with a second opening 118b in the cover plate 116. A second mounting element 150b extends through the second opening 118b and the second mounting holes 138b and 140b in the cover plate 116 into the frame 114. The first mounting holes 138a, 140a and the first opening 118a are provided at a first distance d1 from the tunnel 120 in a first direction, and the second mounting holes 138b, 140b and the second opening 118b are provided at a second distance d2 from the tunnel 120 in a second direction opposite to the first direction, for example, Figure 5 As shown. The first flange seal 135 surrounds both the first opening 118a and the second opening 118b in the cover plate 116 (e.g., extends around the periphery of both the first opening 118a and the second opening 118b in the cover plate 116) and seals the flange portion 134 to the cover plate 116.

[0080] The first mounting element 150a and the second mounting element 150b can be connected to their respective first mounting holes 140a and 140b via, for example, a threaded connection. For instance, the first mounting element 150a and the second mounting element 150b can each have external threads and thus can be screwed into the internal threads of the first mounting holes 140a and 140b, respectively. Thus, the first mounting element 150a and the second mounting element 150b can press the cover plate 116 and the flange portion 134 against the frame 114.

[0081] Furthermore, the embedded element 130 includes two second flange seals 139 at the surface of the flange portion 134 adjacent to the surface of the frame 114, specifically at the lower surface of the flange portion 134. The second flange seals 139 surround the first mounting holes 140a and 140b in the frame 114 (and the first mounting holes 138a and 138b in the flange portion 134) (e.g., extending around their periphery) and seal the flange portion 134 to the frame 114.

[0082] Similar to the reference above Figure 1 and Figure 2 The described embedding element 30 and embedding element 130 provide a dual-sealing structure for the battery system 100. For example, a first seal (or first seal) is provided by means of a sleeve seal 133, which prevents water or other contaminants from entering the receiving chamber 111 from the tunnel 120 by flowing between the outer surface of the sleeve portion 132 and the inner surface of the tunnel 120. Furthermore, a second seal (or second seal) is provided by means of a first flange seal 135, which prevents water or other contaminants from entering the receiving chamber 111 by flowing between the flange portion 134 and the cover plate 116. Thus, the tunnel 120 is provided for receiving a fastening device (e.g., a fastener), which is provided by means of a fastening element 210 extending through the tunnel 120, and this fastening device (e.g., a fastener) is provided for securing the battery system to the vehicle's load-bearing structure 200, while the embedding element 130 ensures protection of the battery cells 112 from water or contaminants.

[0083] In addition, the embedded element 130 provides a third seal by means of a second flange seal 139, which prevents water or other contaminants from entering the receiving chamber 111 by flowing from the cover plate 116 through the openings 118a, 118b and the mounting holes 138a, 138b and flowing between the lower surface of the flange portion 134 and the upper surface of the frame 114.

[0084] Therefore, battery systems according to embodiments of this disclosure prevent water or other external or environmental influences from entering the battery system and causing safety issues through their embedded elements. In other words, embodiments of this disclosure provide embedded elements with seals (e.g., first flange seals and sleeve seals) without the need for pre-coated fine threads to ensure a sealed battery pack, although fastening elements extending through the battery system (which may be necessary in large battery packs) are used.

[0085] Some figure labels

[0086] 10 Battery Casing

[0087] 11 Containment Rooms

[0088] 12 battery cells

[0089] 14 frames

[0090] 16 cover plates

[0091] 18 openings in the cover plate

[0092] 20 tunnels

[0093] Circumferential wall of Tunnel 22

[0094] 30 Embedded Components

[0095] 32 sleeve section

[0096] 33 sleeve seal

[0097] 34 flange portion

[0098] 35 First flange seal

[0099] 36 through holes

[0100] 100 battery system

[0101] 110 battery casing

[0102] 111 Accommodation Room

[0103] 112 battery cell

[0104] 114 Frame

[0105] 116 cover plate

[0106] The first opening in the 118a cover plate

[0107] The second opening in the 118b cover plate

[0108] 120 Tunnel

[0109] Circumferential wall of Tunnel 122

[0110] 130 Embedded Components

[0111] 132 sleeve section

[0112] 133 sleeve seal

[0113] 134 flange portion

[0114] 135 First Flange Seal

[0115] 138a First Mounting Hole

[0116] 138b Second Mounting Hole

[0117] 139 Second flange seal (units)

[0118] 136 through hole

[0119] 140a First Mounting Hole

[0120] 140b Second Mounting Hole

[0121] 150a First Mounting Component

[0122] 150b Second Mounting Component

[0123] 200 load-bearing structure

[0124] 210 Fastening Components

[0125] 210a Fastening element head

[0126] 210b Fastening element tail

[0127] 220 nuts

Claims

1. A battery system, comprising: A battery housing includes a frame and a cover plate on the frame, and forms a receiving chamber between the frame and the cover plate, through which a tunnel defined by the receiving chamber extends through the frame via its circumferential wall, the tunnel being configured to receive fasteners extending through the tunnel to secure the battery system to the vehicle's load-bearing structure. Multiple battery cells are housed in the housing chamber; as well as An insert element includes a sleeve portion and a flange portion at one end of the sleeve portion, with a through hole extending through the insert element. The embedded element is located at the frame, with a sleeve portion extending into the tunnel of the frame, and a flange portion located outside the tunnel and adjacent to the surface of the cover plate. The sleeve portion includes a sleeve seal that extends around the outer surface of the sleeve portion and seals the sleeve portion to the inner surface of the tunnel. The flange portion includes a first flange seal on one side of the flange portion adjacent to the surface of the cover plate, the first flange seal extending around the periphery of the opening in the cover plate and sealing the flange portion to the cover plate.

2. The battery system of claim 1, wherein the flange portion is outside the cover plate, abutting the outer surface of the cover plate, such that the first flange seal extends around the periphery of the opening in the cover plate and seals the flange portion to the cover plate from the outer surface of the cover plate, and The flange portion presses the cover plate against the frame.

3. The battery system according to claim 1, wherein, The sleeve portion is connected to the tunnel via a threaded connection.

4. The battery system of claim 1, wherein the flange portion and the frame each have mounting holes that are aligned with each other and with the opening in the cover plate, and The mounting element extends through the opening and mounting hole in the cover plate into the frame, thereby mounting the cover plate and the embedded element to the frame.

5. The battery system of claim 4, wherein the mounting element comprises a first mounting element and a second mounting element, and the opening in the cover comprises a first opening and a second opening. The flange portion and the frame each have a first mounting hole, which are aligned with each other and with the first opening in the cover plate. The first mounting element extends through the first opening and the first mounting hole in the cover plate into the frame. The flange portion and the frame each have a second mounting hole, which are aligned with each other and with the second opening in the cover plate. The second mounting element extends through the second opening and the second mounting hole in the cover plate into the frame. The first mounting hole and the first opening are spaced apart from the tunnel by a first distance in a first direction, and the second mounting hole and the second opening are spaced apart from the tunnel by a second distance in a second direction, the second direction being different from the first direction. The first flange seal extends around the periphery of both the first opening and the second opening in the cover plate and seals the flange portion to the cover plate.

6. The battery system of claim 4, wherein the flange portion is located between the cover plate and the frame, the flange portion abutting the inner surface of the cover plate such that the first flange seal extends around the periphery of the opening in the cover plate and seals the flange portion to the cover plate from the inner surface of the cover plate.

7. The battery system of claim 6, wherein the flange portion includes a second flange seal on one side of the flange portion adjacent to the frame, the second flange seal extending around the periphery of the mounting hole and sealing the flange portion to the frame.

8. The battery system of claim 4, wherein the frame includes a crossbeam and the mounting hole is formed in the crossbeam.

9. The battery system of claim 1, wherein the cover is a top cover or a bottom cover.

10. The battery system of claim 1, wherein the frame includes a crossbeam, and the tunnel is formed in the crossbeam.

11. The battery system of claim 1, wherein the sleeve seal comprises one or more sealing rings.

12. The battery system of claim 1, wherein the first flange seal comprises a sprayed gasket.

13. An electric vehicle comprising a battery system according to any one of claims 1 to 12.

14. The electric vehicle of claim 13, further comprising the load-bearing structure and the fastener, the fastener extending through the tunnel of the frame of the battery system to secure the battery system to the load-bearing structure.

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