Box structure, battery pack and electric equipment

Abstract

The invention discloses a box body structure, a battery pack and electric equipment, and belongs to the technical field of batteries, the box body structure comprises a plurality of box body single bodies which are stacked in the height direction of the box body structure, each box body single body comprises a box body frame and a structural beam which are connected, and the structural beams are installed in the box body frames; the fastener assembly comprises a first fastener and a second fastener, and in every two adjacent box body single bodies, the first fastener is arranged on the structural beam of one box body single body in a penetrating mode and connected with the structural beam of the other box body single body; at least part of the second fastener is installed on the structural beam of the other box body single body. Wherein at least part of the first fasteners and the second fasteners are arranged at intervals in the direction perpendicular to the height direction of the box body structure. By means of the technical scheme, multi-dimensional stress generated by battery thermal expansion and the vehicle running working condition can be well dispersed and borne, a continuous stress concentration path is not likely to be formed, and the overall strength of the box body structure can be improved.

Description

Technical Field

[0001] This application relates to the field of battery technology, and in particular to a housing structure, a battery pack, and an electrical device. Background Technology

[0002] With the development of the times, people's requirements for the driving range of new energy vehicles are increasing. Improving the energy density and space utilization of battery packs has become the key to improving the driving range of new energy vehicles.

[0003] In related technologies, multiple vertically aligned bolts are installed around the perimeter of the enclosure to connect multiple single-layer enclosures. In these solutions, the bolts installed on adjacent single-layer enclosures are aligned or approximately in a straight line along the height of the enclosure. This connection method has weak torsional and shear resistance, and the aligned bolts create continuous stress concentration paths, resulting in weak overall enclosure strength. Summary of the Invention

[0004] This application provides a housing structure, a battery pack, and an electrical device to at least partially solve the above-mentioned technical problems.

[0005] To achieve the above objectives, according to a first aspect of this application, a box structure is provided, comprising: a plurality of box units stacked along the height direction of the box structure, each box unit comprising a connected box frame and a structural beam, the structural beam being installed within the box frame; The fastener assembly includes a first fastener and a second fastener. In two adjacent housing units, the first fastener passes through a structural beam of one housing unit and is connected to a structural beam of the other housing unit; at least a portion of the second fastener is mounted on a structural beam of the other housing unit. In particular, at least some of the first fasteners and second fasteners are spaced apart in the height direction perpendicular to the box structure.

[0006] Compared to related technologies where bolts installed on adjacent single-layer boxes are aligned or approximately on the same straight line along the height direction of the box, or where the projections of bolts on adjacent single-layer boxes onto the base plate are substantially coincident along the height direction of the box, in this embodiment, the structural beams of multiple box units stacked along the height direction of the box structure are connected by first and second fasteners, thereby achieving the connection of multiple box units. Perpendicular to the height direction of the box structure, at least some of the first and second fasteners are spaced apart, which can better disperse and bear the multidimensional stresses generated by battery thermal expansion and vehicle driving conditions, making it less likely to form continuous stress concentration paths, thus improving the overall strength of the box structure.

[0007] Furthermore, when the vehicle is in motion, a large stress along the driving direction is applied to the battery pack, which can easily cause the housing structure to deform. The first fastener passes through the structural beam of one of the housing units and is connected to the structural beam of another housing unit. At least part of the second fastener is installed on the structural beam of the other housing unit, which can strengthen the structural beam of the housing unit, prevent it from deforming, and reduce the probability of its damage.

[0008] Optionally, along the height direction of the box structure, the plurality of box units include a third box unit, a first box unit, and a second box unit stacked sequentially. The box structure also includes a bottom support plate, which is located on the side of the second box unit away from the first box unit and is connected to the structural beam of the second box unit.

[0009] With this configuration, the first housing unit, the second housing unit, and the base plate can be connected by the first fastener and the second fastener. In this way, force can be transmitted from the first fastener to the first housing unit and the second housing unit, and from the second housing unit and the second fastener to the base plate.

[0010] Optionally, the second fastener includes a base plate fastener, which passes through the base plate and is connected to one end of the structural beam of the second housing unit near the base plate.

[0011] The first and second housing units are connected by the first fastener, and the bottom support plate is connected to the structural beam of the second housing unit by the bottom support plate fastener, thereby realizing the connection between the bottom support plate and the second housing unit. Force can be transmitted to the bottom support plate along the structural beam of the first and second housing units, thereby improving the load-bearing capacity of the housing unit.

[0012] Optionally, the first fastener passes through the structural beam of the first housing unit and is connected to the end of the structural beam of the second housing unit away from the bottom support plate; along the height direction of the housing structure, the end of the bottom support plate fastener away from the bottom support plate is spaced apart from the end of the first fastener near the bottom support plate.

[0013] The end of the base plate fastener away from the base plate is spaced apart from the end of the first fastener near the base plate, so that the base plate fastener has a shorter length, which is only long enough to connect the base plate and the second housing unit. On the one hand, it is convenient for installation and operation, and on the other hand, the base plate fastener has a lighter weight, which can achieve a better weight reduction effect.

[0014] Optionally, the second fastener includes a single fastener that passes through the structural beam of the third box unit along the height direction of the box structure and is connected to the end of the structural beam of the first box unit away from the bottom support plate.

[0015] The third housing unit is connected to the first housing unit using individual fasteners. These fasteners also reinforce the structural beams of the third housing unit and the end of the structural beams of the first housing unit that faces away from the bottom support plate, making these areas less prone to deformation or damage.

[0016] Optionally, the shortest distance N1 between the end of the single fastener facing the base plate and the first fastener is in the range of: 18mm ≥ N1 ≥ 0mm.

[0017] This configuration ensures a shorter force transmission path between the individual fastener and the first fastener. It also avoids the formation of continuous stress concentration paths.

[0018] Optionally, an installation gap is formed between the first housing unit and the third housing unit, and the end of the first fastener facing away from the base plate is located in the installation gap.

[0019] The presence of an installation gap can prevent interference between the third housing unit and the first fastener, thus avoiding deformation or loosening of the first fastener, and also facilitates the installation of the first fastener.

[0020] Optionally, the housing unit includes a first boss, at least a portion of which is located in the mounting interval. One end of the first boss is connected to the structural beam of the first housing unit, and the other end of the first boss abuts against the structural beam of the third housing unit. The housing fastener passes through the structural beam of the third housing unit and the first boss, and is connected to the structural beam of the first housing unit.

[0021] This design facilitates a tight connection between the third and first housing units using individual fasteners. It also ensures a shorter force transmission path between the two units. The first boss can bear a portion of the force, preventing the structural beams of the first housing unit from being crushed.

[0022] Optionally, the first housing unit includes a mounting component, which is mounted on the structural beam of the first housing unit. The mounting component includes a first sub-component and a second sub-component connected together. The end of the first sub-component facing away from the bottom support plate is connected to a first boss, and a first through hole penetrates the first boss and the first sub-component. The second sub-component has a second through hole spaced apart from the first through hole. Both the first through hole and the second through hole penetrate the first housing unit along the height direction of the housing structure. A portion of the first fastener is installed in the second through hole, and the end of the housing fastener facing the bottom support plate is installed in the first through hole.

[0023] The first and second sub-components connect the end of the individual fastener facing the base plate to the first fastener, forming a relatively stable force transmission path. The first boss prevents the first housing unit from being deformed during the installation of the individual fasteners, thus improving the load-bearing capacity of the first housing unit.

[0024] Optionally, the box structure includes a second boss, which is connected to the end of the structural beam of the second box unit facing the first box unit. The end face of the second boss away from the bottom support plate abuts against the structural beam of the first box unit. The first fastener passes through the structural beam of the first box unit and the second boss, and is connected to the structural beam of the second box unit.

[0025] During installation, the end of the first fastener facing away from the base plate can be located at the installation interval. The first fastener is partially installed in the first through hole, and simultaneously, the end of the first fastener facing the base plate passes through a second through hole, then through the second boss, and into the structural beam of the second housing unit. In this way, a tight connection between the second housing unit and the first housing unit is achieved through the first fastener. The second boss prevents the second housing unit from being deformed during the installation of the first fastener.

[0026] Optionally, the relationship between the connection length L1 between the single fastener and the structural beam of the first box unit and the height L2 of the first box unit satisfies: .

[0027] This design allows the first fastener to effectively connect the first and second housing units while maintaining a relatively short length. It's easy to understand that if the first fastener is too long, resulting in a large connection length L1 between it and the structural beam of the second housing unit, assembly will be difficult. Conversely, if the first fastener is too short, resulting in a short connection length L1 between it and the structural beam of the second housing unit, the connection between the first and second housing units will be poor.

[0028] Optionally, the structural beam includes stiffeners and sidewalls, the stiffeners being connected to the sidewalls and forming a weight-reducing cavity with the sidewalls.

[0029] Reinforcing ribs can improve the load-bearing capacity of structural beams, and the setting of weight-reducing cavities can make the box structure lighter, thus better balancing load-bearing capacity and weight, so that the box structure can have good load-bearing capacity while having a small weight.

[0030] Optionally, one of the box-shaped units includes a load-bearing member. Along the height direction of the box structure, at least one side of the opposite sides of the box frame is connected to the load-bearing member, and the thickness M1 of the load-bearing member is greater than the thickness M2 of the sidewall of the structural beam.

[0031] This differentiated design of the box frame and structural beam thicknesses of the individual box units allows for high strength in key connection areas while achieving overall structural lightweighting. This helps maintain a low weight and high strength in the box structure, making it less prone to deformation under stress.

[0032] Optionally, the housing unit is a die-cast housing.

[0033] Compared to sheet metal or profile enclosures, die-cast enclosures reduce weight, increase production efficiency, offer better overall integrity, and allow each structural component to withstand external pressure more effectively. Furthermore, the die-casting process allows for the easy casting of individual components, enabling the creation of various shapes. For example, a single-piece enclosure frame and structural beams can be cast simultaneously using die casting. Compared to enclosures formed by splicing or welding sheet metal, die-cast enclosures eliminate splicing processes, resulting in higher production efficiency and lower costs.

[0034] Optionally, the structural beam includes a first beam and a second beam connected together, the first beam extending along a first direction and the second beam extending along a second direction, the first direction and the second direction having an angle, and the connection between the first beam and the second beam being used to pass through the fastener.

[0035] According to a second aspect of this application, a battery pack is provided, including the aforementioned housing structure.

[0036] According to a third aspect of this application, an electrical device is also provided, including the aforementioned housing structure or the aforementioned battery pack.

[0037] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0039] Figure 1 This is a schematic diagram of the box structure provided in an exemplary embodiment of this disclosure; Figure 2 This is a top view of the box structure provided in an exemplary embodiment of this disclosure; Figure 3 This is a cross-sectional view of the box structure provided in an exemplary embodiment of this disclosure; Figure 4 yes Figure 3 An enlarged schematic diagram of part A in the middle; Figure 5 yes Figure 3 Enlarged schematic diagram of part B in the middle; Figure 6 This is a schematic diagram of the structure of the first housing unit provided in an exemplary embodiment of this disclosure; Figure 7 yes Figure 6 An enlarged schematic diagram of section C; Figure 8 This is a cross-sectional view of the first housing unit provided in an exemplary embodiment of this disclosure; Figure 9 yes Figure 8 An enlarged schematic diagram of section D in the middle; Figure 10 This is a block diagram of an electrical device provided in an exemplary embodiment of this disclosure.

[0040] Explanation of reference numerals in the attached figures: x, first direction; y, second direction; z, height direction of the box structure; 1. Box structure; 10. Unit housing; 11. First unit housing; 13. Second unit housing; 15. Third unit housing; 16. First boss; 17. Second boss; 18. Bearing component; 20. Base plate; 30. Box frame; 31. Mounting cavity; 40. Structural beam; 401. First beam; 403. Second beam; 41. Reinforcing rib; 43. Side wall; 45. Weight reduction cavity; 50. Fastener assembly; 51. First fastener; 53. Second fastener; 55. Base plate fastener; 57. Individual fastener; 60. Mounting component; 61. First sub-component; 611. First through hole; 63. Second sub-component; 631. Second through hole; 65. Mounting interval; 2. Battery pack; 3. Electrical equipment. Detailed Implementation

[0041] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0042] With the development of the times, people's requirements for the driving range of new energy vehicles are increasing. Improving the energy density and space utilization of battery packs has become the key to improving the driving range of new energy vehicles.

[0043] Single-layer battery pack enclosures typically occupy a significant portion of the vehicle chassis's surface area, resulting in insufficient utilization of vertical space. Simply stacking multiple single-layer enclosures vertically leads to issues such as insufficient overall structural rigidity, poor interlayer connection reliability, complex thermal management paths, and difficulties in sealing design. In particular, the thermal expansion stress generated during battery charging and discharging, if not effectively transferred and constrained in a multi-layer stacked structure, can easily cause fatigue of mounting components, enclosure deformation, and even seal failure.

[0044] In related technologies, multiple vertically aligned bolts are installed around the perimeter of the enclosure to connect multiple single-layer enclosures. Specifically, multiple single-layer enclosures are stacked along their height, and multiple bolts extend along the height of the enclosures to connect them. Along the height of each single-layer enclosure, multiple aligned bolts are present, and their projections on the ground almost overlap.

[0045] In the above scheme, the bolts installed on adjacent single-layer battery packs are aligned or roughly in a straight line along the height of the pack. This connection method has weak torsional and shear resistance, and the aligned bolts form a continuous stress concentration path, resulting in weak overall strength of the pack. There is an urgent need for a more stable, reliable, and stronger multi-layer stacked battery pack structure.

[0046] To solve at least some of the aforementioned technical problems, this application provides a box structure 1. Please refer to... Figure 1 , Figure 10In a first aspect, embodiments of this application provide a housing structure 1, which includes a plurality of housing units 10 stacked along the height direction z of the housing structure. The number of housing units 10 can specifically be two, three, four, etc., and this application does not limit this. The housing structure 1 can be the housing structure of a battery pack 2, and the housing structure 1 includes a plurality of housing units 10, which are stacked along the height direction z of the housing structure. The battery pack 2 can be applied to a vehicle, which can be a heavy-duty truck. The battery pack 2 is carried in the driver's cab of the vehicle, and when the battery pack 2 is mounted on the vehicle, the housing structure 1 is connected to the vehicle.

[0047] Please combine Figure 6 A single housing unit 10 includes a connected housing frame 30 and a structural beam 40, with the structural beam 40 installed within the housing frame 30. The housing frame 30 may have a mounting cavity 31, within which the structural beam 40 is installed. Multiple housing units 10 may have substantially the same structure; in some examples, each housing unit 10 may include a connected housing frame 30 and a structural beam 40. The housing frame 30 and structural beam 40 may form multiple battery module compartments, dividing the interior of the housing frame 30 into multiple battery module compartments, each housing a battery module. The housing frame 30 may be a rectangular frame formed by a frame profile.

[0048] The structural beam 40 is connected to the box frame 30, which on the one hand strengthens the box frame 30, improves its load-bearing capacity, and makes it less prone to deformation or damage under stress. On the other hand, it absorbs the expansion force of the battery module, thereby increasing the service life of the battery pack 2.

[0049] To facilitate the absorption of the expansion force of the battery module, the structural beam 40 may be provided with multiple weight-reducing cavities 45, which are spaced apart. The structural beam 40 can serve as an expansion beam structure. In some embodiments, the structural beam 40 may include a crossbeam and a longitudinal beam. The crossbeam is disposed within the mounting cavity 31 and extends along the width direction of the housing structure 1. Along the width direction of the housing structure 1, the opposite ends of the crossbeam are connected to the housing frame 30. The crossbeam is provided with weight-reducing cavities 45 to facilitate the absorption of the expansion force of the battery module. In the crossbeam, multiple weight-reducing cavities 45 may be spaced apart along the width direction of the housing structure 1.

[0050] Please combine Figure 6 , Figure 7 The longitudinal beam is installed within the mounting cavity 31 and extends along the length of the housing structure 1. The longitudinal beam has a weight-reducing cavity 45. Along the length of the housing structure 1, the opposite ends of the longitudinal beam are connected to the housing frame 30. The weight-reducing cavity 45 in the longitudinal beam facilitates the absorption of the expansion force of the battery module. Multiple weight-reducing cavities 45 can be spaced apart along the length of the housing structure 1 within the longitudinal beam.

[0051] Please combine Figure 3 The enclosure structure 1 also includes a fastener assembly 50, which includes a first fastener 51 and a second fastener 53. In adjacent enclosure units 10 (which are easily understood to be stacked along the height direction z of the enclosure structure), please refer to... Figure 4 The first fastener 51 passes through the structural beam 40 of one box-type unit 10 and connects to the structural beam 40 of another box-type unit 10. This arrangement connects the structural beams 40 of adjacent box-type units 10 via the first fastener 51, thus achieving the connection between the two adjacent box-type units 10. In some examples, the first fastener 51 can be a bolt. The connection between the first fastener 51 and the structural beam 40 of the box-type unit 10 can be a screw connection.

[0052] At least a portion of the second fastener 53 is mounted to the structural beam 40 of another housing unit 10. The second fastener 53 can be used to connect the other housing unit 10; for example, the second fastener 53 can be used to connect the other housing unit 10 to the base plate 20, or the second fastener 53 can be used to connect the other housing unit 10 to one of the aforementioned housing units 10. In some examples, the second fastener 53 can be a bolt.

[0053] The second fastener 53 is installed on the structural beam 40 of another box unit 10. The second fastener 53 can locally strengthen the structural beam 40 of the box unit 10, making it less prone to deformation or damage.

[0054] In particular, at least some of the first fasteners 51 and the second fasteners 53 are spaced apart in the direction perpendicular to the height of the box structure.

[0055] Compared to related technologies where the bolts installed on adjacent single-layer boxes are aligned or roughly on the same straight line along the height direction of the box, or where the projections of the bolts installed on adjacent single-layer boxes on the bottom support plate 20 are basically coincident along the height direction of the box, in this embodiment, at least some of the first fasteners 51 and the second fasteners 53 are spaced apart along the height direction perpendicular to the box structure. This can better disperse and bear the multidimensional stress generated by battery thermal expansion and vehicle driving conditions, making it less likely to form a continuous stress concentration path, which is beneficial to improving the overall strength of the box structure 1.

[0056] Furthermore, when the vehicle is in motion, a large stress along the driving direction is applied to the battery pack 2, which can easily cause the housing structure 1 to deform. The first fastener 51 passes through the structural beam 40 of one of the housing units 10 and is connected to the structural beam 40 of the other housing unit 10. At least part of the second fastener 53 is installed on the structural beam 40 of the other housing unit 10, which can strengthen the structural beam 40 of the housing unit 10, prevent it from deforming, and reduce the probability of its damage.

[0057] In this embodiment, at least a portion of the first fasteners 51 and second fasteners 53 are spaced apart in the direction perpendicular to the height of the enclosure structure. This achieves a cross-staggered locking of the first fasteners 51 and second fasteners 53, transforming the interlayer connection points into multiple distributed rigid nodes. Through this cross-staggered locking of the first fasteners 51 and second fasteners 53, a spatial truss-like load-bearing structure is formed, improving the overall bending, torsional, and shear resistance of the enclosure structure 1, and effectively constraining battery thermal expansion. The spaced arrangement of the first fasteners 51 and second fasteners 53, with their staggered arrangement, avoids concentrated stress transmission in the vertical direction, distributing the load more evenly across the entire enclosure frame and improving the lifespan of the enclosure structure.

[0058] The fastener assembly 50 includes multiple fasteners (e.g., first fastener 51, second fastener 53) whose extension direction can all be the height direction z of the housing structure. This allows for a vertical connection between upper and lower housing units via the fastener assembly. In some examples, structural adhesive can be applied between the upper and lower housing units to further secure them.

[0059] In some embodiments, the housing structure 1 may further include a base plate 20 located at the bottom of a plurality of housing units 10. The plurality of housing units 10 can be interconnected by fastener assemblies 50, and the base plate 20 is connected to the housing units 10 located thereon via the fastener assemblies 50, thereby connecting the plurality of housing units 10 to the base plate 20. The base plate 20 is used to support the plurality of housing units 10 and to connect to the vehicle's frame beam, thereby mounting the battery pack 2 onto the vehicle.

[0060] Please combine Figure 3 and Figure 4 In some embodiments, along the height direction z of the box structure, the plurality of box units 10 include a third box unit 15, a first box unit 11 and a second box unit 13 stacked in sequence. The box structure 1 also includes a bottom support plate 20, which is located on the side of the second box unit 13 away from the first box unit 11 and is connected to the structural beam 40 of the second box unit 13.

[0061] In some embodiments, along the height direction z of the box structure, from top to bottom, the components may be: a third box unit 15, a first box unit 11, a second box unit 13, and a bottom support plate 20.

[0062] In some embodiments, the first fastener 51 may pass through the structural beam 40 of the first housing unit 11 and connect to the end of the structural beam 40 of the second housing unit 13 away from the bottom support plate 20, thereby connecting the structural beam 40 of the first housing unit 11 and the structural beam 40 of the second housing unit 13. In some examples, the first fastener 51 may be a bolt. The first fastener 51 and the structural beam 40 of the first housing unit 11 may be screwed together.

[0063] With this configuration, the first housing unit 11, the second housing unit 13, and the base plate 20 can be connected by the first fastener 51 and the second fastener 53. In this way, force can be transmitted from the first fastener 51 to the first housing unit 11 and the second housing unit 13, and from the second housing unit 13 and the second fastener 53 to the base plate 20.

[0064] The second fastener 53 includes a bottom plate fastener 55, which passes through the bottom plate 20 and is connected to the end of the structural beam 40 of the second housing unit 13 near the bottom plate 20.

[0065] The first housing unit 11 and the second housing unit 13 are connected by the first fastener 51, and the bottom support plate 20 is connected to the structural beam 40 of the second housing unit 13 by the bottom support plate fastener 55, thereby realizing the connection between the bottom support plate 20 and the second housing unit 13. Force can be transmitted to the bottom support plate 20 along the structural beam 40 of the first housing unit 11 and the structural beam 40 of the second housing unit 13, thereby improving the load-bearing capacity of the housing unit.

[0066] In some examples, the second fastener 53 can be a bolt. The second fastener 53 can be screwed to the end of the structural beam 40 of the second housing unit 13 near the bottom support plate 20.

[0067] Since the base plate 20 is relatively heavy and thick, there can be multiple base plate fasteners 55. These fasteners can be arranged in a direction perpendicular to the height z of the box structure (e.g., along the length or width of the box structure), and the arrangement direction of the multiple fasteners 55 can be the same as the extension direction of the structural beam 40. For example, when the base plate fasteners 55 pass through the base plate 20 and are connected to the end of the crossbeam of the second box unit 13 facing the base plate 20, the arrangement direction of the multiple fasteners 55 can be along the width direction of the box structure 1. When the base plate fasteners 55 pass through the base plate 20 and are connected to the end of the longitudinal beam of the second box unit 13 facing the base plate 20, the arrangement direction of the multiple fasteners 55 can be along the length direction of the box structure 1.

[0068] Please combine Figure 4 The first fastener 51 passes through the structural beam 40 of the first box unit 11 and is connected to the end of the structural beam 40 of the second box unit 13 away from the bottom support plate 20; along the height direction z of the box structure, the end of the bottom support plate fastener 55 away from the bottom support plate 20 is spaced apart from the end of the first fastener 51 near the bottom support plate 20.

[0069] The end of the base plate fastener 55 facing away from the base plate 20 is spaced apart from the end of the first fastener 51 near the base plate 20, so that the base plate fastener 55 has a shorter length, which is only long enough to connect the base plate 20 and the second housing unit 13. On the one hand, it is convenient for installation and operation, and on the other hand, the base plate fastener 55 has a lighter weight, which can have a better weight reduction effect.

[0070] The end of the structural beam 40 of the first housing unit 11 facing away from the bottom support plate 20 may be provided with a threaded hole to facilitate connection with the first fastener 51. To further increase the strength of the threaded hole, a high-strength insert with internal threads or a pre-embedded steel wire sleeve may be provided in the threaded hole to enhance the threaded connection strength and prevent the profile wall from being crushed.

[0071] This configuration connects the first housing unit 11, the second housing unit 13, and the base plate 20 via the first fastener 51 and the base plate fastener 55. The first fastener 51 also reinforces the structural beams 40 of the first housing unit 11 and the ends of the structural beams 40 of the second housing unit 13 that are away from the base plate 20, making these locations less prone to deformation or damage. Along the height z of the housing structure, the ends of the base plate fasteners 55 away from the base plate 20 are spaced apart from the ends of the first fasteners 51 that face the base plate 20. This allows the base plate fasteners 55 to have a shorter length, facilitating installation and improving assembly efficiency. Furthermore, the shorter length of the base plate fasteners 55 results in a lighter housing structure. Thus, the housing structure achieves both low weight and high strength.

[0072] Please combine Figure 5 The second fastener 53 includes a single fastener 57. Along the height direction z of the box structure, the single fastener 57 passes through the structural beam 40 of the third box unit 15 and is connected to the end of the structural beam 40 of the first box unit 11 away from the bottom support plate 20.

[0073] The third housing unit 15 is connected to the first housing unit 11 by individual fasteners 57. The individual fasteners 57 can also reinforce the structural beams 40 of the third housing unit 15 and the end of the structural beams 40 of the first housing unit 11 that are away from the bottom support plate 20, making these locations less prone to deformation or damage.

[0074] In some embodiments, the plurality of housing units 10 may further include a fourth housing unit located on the side of the third housing unit 15 facing away from the bottom support plate 20, and the fourth housing unit is connected to the third housing unit 15 by another housing unit fastener. Specifically, along the height direction z of the housing structure, the other housing unit fastener passes through the structural beam 40 of the fourth housing unit and is connected to the end of the structural beam 40 of the third housing unit 15 facing away from the bottom support plate 20. Perpendicular to the height direction of the housing structure, the end of the other housing unit fastener facing the bottom support plate 20 is spaced apart from the housing unit fasteners connecting the third housing unit 15 and the first housing unit 11. The perpendicular height direction of the housing structure may specifically be the width direction or the length direction of the housing structure.

[0075] In some embodiments, the fourth housing unit may have multiple housing units on the side opposite to the bottom support plate 20, such as a fifth housing unit, a sixth housing unit, etc. The connection method of the fifth housing unit and the fourth housing unit can be referred to the connection method of the fourth housing unit and the third housing unit 15.

[0076] The minimum distance N1 between the end of the single fastener 57 facing the base plate 20 and the first fastener 51 is in the range of 18mm≥N1≥0mm.

[0077] This configuration ensures a shorter force transmission path between the individual fastener 57 and the first fastener 51. It also avoids the formation of continuous stress concentration paths.

[0078] The shortest distance N1 between the end of the single fastener facing the base plate 20 and the first fastener 51 can be 0mm, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, or 18mm.

[0079] An installation gap 65 is formed between the first housing unit 11 and the third housing unit 15, and at least part of the first fastener 51 is located at the installation gap 65 at the end opposite to the bottom support plate 20.

[0080] The presence of the installation interval 65 can prevent the third housing unit 15 from interfering with the first fastener 51, causing the first fastener 51 to deform or loosen, and facilitates the installation of the first fastener 51.

[0081] When installing the fastener assembly 50, the head of the first fastener 51 can be located at the installation interval 65. The shank of the first fastener 51 is installed on the first housing unit 11 and the second housing unit 13. When the first fastener 51 is a bolt, the head of the first fastener 51 can be the flange of the bolt, and at least part of the end of the first fastener 51 facing away from the bottom support plate 20 can refer to the flange of the bolt, and the shank of the first fastener 51 can be the threaded rod of the bolt.

[0082] During assembly, the bottom plate fastener 55 is first inserted into the second housing unit 13 from the side of the bottom plate 20 away from the bottom plate. Since the bottom plate fastener 55 is relatively short, it only extends into the end of the second housing unit 13 closest to the bottom plate. Then, the first housing unit 11 is stacked on the side of the second housing unit 13 away from the bottom plate. The first fastener 51 is inserted into the first housing unit 11 from the side away from the bottom plate, and then extends from the first housing unit 11 into the second housing unit 13. Specifically, the first fastener 51 extends into the end of the second housing unit 13 away from the bottom plate. Next, the third housing unit 15 is stacked on the side of the first housing unit 11 away from the bottom plate. The fastener for the third housing unit 15 is inserted into the first housing unit 11 from the side away from the bottom plate, and then extends from the third housing unit 15 into the first housing unit 11. Specifically, the individual fastener extends into the end of the first housing unit 11 that is away from the bottom support plate.

[0083] The housing unit 10 includes a first boss 16, at least a portion of which is located at the installation interval 65. One end of the first boss 16 is connected to the structural beam 40 of the first housing unit 11, and the other end of the first boss 16 abuts against the structural beam 40 of the third housing unit 15. The unit fastener passes through the structural beam 40 and the first boss 16 of the third housing unit 15 and is connected to the structural beam 40 of the first housing unit 11.

[0084] This facilitates a tight connection between the third housing unit 15 and the first housing unit 11 using individual fasteners. It also ensures a shorter force transmission path between the three housing units 15 and the first housing unit 11. The first boss can bear a portion of the force, preventing the structural beam 40 of the first housing unit 11 from being crushed.

[0085] The end face of the opposite end of the first protrusion 16 can fit into the end face of the structural beam 40 of the third box unit 15.

[0086] Please combine Figure 8 9. The first housing unit 11 includes a mounting component 60, which is mainly used to install fastener assembly 50. The mounting component 60 is installed on the structural beam of the first housing unit 11. The mounting component 60 includes a first sub-component 61 and a second sub-component 63 connected together. The end of the first sub-component 61 facing away from the bottom support plate 20 is connected to a first boss 16. A first through hole 611 penetrates the first boss and the first sub-component 61. The second sub-component 63 is provided with a second through hole 631 spaced apart from the first through hole 611. Both the first through hole 611 and the second through hole 631 penetrate the first housing unit 11 along the height direction z of the housing structure. Part of the first fastener 51 is installed in the second through hole 631, and the end of the unit fastener facing the bottom support plate 20 is installed in the first through hole 611.

[0087] The end of the single fastener facing the base plate 20 is connected to the first fastener 51 by the first sub-component 61 and the second sub-component 63, forming a relatively stable force transmission path. The first boss can prevent the first housing unit 11 from being deformed by pressure when installing the single fastener, thereby improving the load-bearing capacity of the first housing unit 11.

[0088] When the assembly of the housing structure 1 is completed, the end of the first fastener 51 facing away from the bottom support plate 20 is located at the installation interval 65, and the end of the first fastener 51 facing the bottom support plate 20 passes through the second through hole 631 and is connected to the structural beam of the second housing unit 12. The end of the unit fastener facing the bottom support plate 20 passes through the first boss and the first sub-piece 61. By setting the mounting part 60, when installing the fastener assembly 50, the head of the first fastener 51 can be located at the installation interval 65. The shank of the first fastener 51 is installed in the first through hole 611; in other words, the shank of the first fastener 51 passes through the first sub-piece 61. When the first fastener 51 is a bolt, the head of the first fastener 51 can be the flange of the bolt, and the shank of the first fastener 51 can be the threaded rod of the bolt.

[0089] Each individual enclosure unit can be equipped with a mounting component 60 at the location where the fastener assembly passes through. Furthermore, the mounting components 60 of the multi-layer enclosure units can be aligned along the height z direction of the enclosure structure. That is, the first through hole 611 of the upper enclosure unit is aligned with the first through hole 611 of the lower enclosure unit, and the second through hole 631 of the upper enclosure unit is aligned with the second through hole 631 of the lower enclosure unit. This facilitates the installation of the fastener assembly.

[0090] The mounting component 60, the structural beam of the first box unit 11, and the box frame 30 of the first box unit 11 can be die-cast using a die-casting process.

[0091] Please combine Figure 4 The box unit 10 includes a second boss 17, which is connected to the end of the structural beam 40 of the second box unit 13 facing the first box unit 11. The end face of the second boss 17 away from the bottom support plate 20 abuts against the structural beam 40 of the first box unit 11. The first fastener 51 passes through the structural beam 40 and the second boss of the first box unit 11 and is connected to the structural beam 40 of the second box unit 13.

[0092] During installation, the end of the first fastener 51 facing away from the base plate can be located at the installation interval 65. The first fastener 51 is partially installed in the first through hole 611, and simultaneously, the end of the first fastener 51 facing the base plate passes through the second through hole 631, then through the second boss 17, and into the structural beam 40 of the second housing unit 13. In this way, a tight connection between the second housing unit 13 and the first housing unit 11 is achieved through the first fastener 51. The second boss prevents the second housing unit 13 from being deformed during the installation of the first fastener 51.

[0093] Please combine Figure 4 The relationship between the connection length L1 of the single fastener 57 and the structural beam 40 of the first box unit 11 and the height L2 of the first box unit 11 satisfies:

[0094] This design allows the first fastener 51 to effectively connect the first housing unit and the second housing unit while maintaining a relatively short length. It's easy to understand that if the first fastener 51 were too long, resulting in a large connection length L1 between the first fastener 51 and the structural beam 40 of the second housing unit 13, assembly would be difficult. Conversely, if the first fastener 51 were too short, resulting in a short connection length L1 between the first fastener 51 and the structural beam 40 of the second housing unit 13, the connection between the first and second housing units would be poor.

[0095] The relationship between the connection length L1 between the first fastening component and the structural beam 40 of the second box unit 13 and the height L2 of the box unit 10 can be: L1 / L2 can be 1 / 6, 1 / 7, or 1 / 8.

[0096] Please combine Figure 3 The structural beam 40 includes a reinforcing rib 41 and a side wall 43. The reinforcing rib 41 is connected to the side wall 43 and forms a weight-reducing cavity 45 with the side wall 43.

[0097] The reinforcing rib 41 can improve the load-bearing capacity of the structural beam 40, and the weight-reducing cavity 45 can make the box structure lighter, thus better balancing the load-bearing capacity and weight, so that the box structure can have a good load-bearing capacity while having a small weight.

[0098] Please combine Figure 1 and Figure 2 A single box 10 includes a load-bearing member. Along the height direction z of the box structure, at least one of the opposite sides of the box frame 30 is connected to the load-bearing member 18. The thickness M1 of the load-bearing member 18 is greater than the thickness M2 of the side wall 43 of the structural beam 40.

[0099] The load-bearing components need to withstand the main stacking pressure and the bolt preload, thus requiring high strength. The sidewalls 43 of the structural beam 40 mainly provide lateral support and internal partitions for the upper box unit. The thickness M1 of the load-bearing components is greater than the thickness M2 of the sidewalls 43 of the structural beam 40. This differentiated design of the box frame 30 and the structural beam 40 of the box unit ensures high strength in key connection areas while achieving overall structural lightweighting. This helps to maintain a low weight and high strength in the box structure 1, making it less prone to deformation under stress.

[0100] The load-bearing component 18 can be die-cast to the box frame 30 and the structural beam. The thickness M1 of the die-cast load-bearing component 18 is greater than the thickness M2 of the side wall 43 of the structural beam 40. Specifically, the thickness M1 of the load-bearing component 18 can refer to the thickness of the load-bearing component 18 along the height direction of the box structure. The thickness M2 of the side wall 43 of the structural beam 40 can refer to the thickness of the load-bearing component 18 along the extension direction perpendicular to the side wall 43.

[0101] In some embodiments, the thickness M1 of the support member can range from 3mm to 10mm. For example, the thickness M1 of the support member can be 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, or 10mm. Further, the thickness M1 of the support member can range from 3mm to 4mm. The thickness M1 of the support member can be 3mm or 4mm.

[0102] In some embodiments, the thickness M2 of the sidewall 43 of the structural beam 40 can range from 2mm to 6mm. For example, the thickness M2 of the sidewall 43 of the structural beam 40 can be 2mm, 3mm, 4mm, 5mm, or 6mm. Further, the thickness M2 of the sidewall 43 of the structural beam 40 can range from 2mm to 2.5mm. For example, the thickness M2 of the sidewall 43 of the structural beam 40 can be 2.0mm, 2.1mm, 2.2mm, 2.3mm, 2.4mm, or 2.5mm.

[0103] Unit 10 of the box is a die-cast box.

[0104] In some embodiments, the housing unit 10 is a die-cast housing. The housing unit 10 can be obtained by a die-casting process. In some examples, the housing unit 10 is a cast aluminum housing.

[0105] In these embodiments, the housing unit 10 can be a die-cast housing. Compared to sheet metal housings or profile housings, die-cast housings can reduce housing weight, improve housing production efficiency, have better overall integrity, and each structural component can better withstand external pressure. Furthermore, since the die-cast housing is formed through a die-casting process, the various structures within the housing unit 10 can be easily cast, allowing for the creation of structures of various shapes. For example, an integral housing frame 30 and structural beams 40 can be simultaneously cast using the die-casting process. Compared to housing units 10 formed by splicing or welding sheet metal, die-cast housings eliminate splicing processes, resulting in higher production efficiency and lower costs.

[0106] However, traditional die-cast housings have relatively low strength. Taking aluminum as an example, the strength of cast aluminum is lower than that of profiled aluminum. Therefore, profiled aluminum housings inherently possess high strength and do not require reinforcement to maintain this strength. In contrast, cast aluminum housings have lower inherent strength and are prone to deformation or damage. To ensure that each housing unit 10 possesses both light weight and high strength, and to prevent deformation at the joints between multiple housing units 10, a solution is needed.

[0107] The structural beam 40 includes a first beam 401 and a second beam 403 connected to each other. The first beam 401 extends along a first direction x, and the second beam 403 extends along a second direction y. The first direction x and the second direction y have an angle. The connection between the first beam 401 and the second beam 403 is used to install fasteners.

[0108] The connection between the first beam 401 and the second beam 403 is prone to stress concentration and is a relatively weak point. Therefore, fasteners are installed at the connection between the first beam 401 and the second beam 403. The strength of the fasteners can be greater than the strength of the structural beam 40. The fasteners can share part of the force, thereby strengthening the connection between the first beam 401 and the second beam 403.

[0109] In some embodiments, the first beam 401 may include a longitudinal beam, and the first direction x may be the length direction of the box structure 1. The second beam 403 may include a transverse beam, and the second direction y may be the width direction of the box structure 1. The angle between the first direction x and the second direction y may be 90 degrees. With this arrangement, in the upper box unit, the bolt connection points on the transverse beams are located in the middle of two adjacent battery module compartments, while in the lower box unit, the corresponding bolt connection points on the longitudinal beams are located on the side of one battery module compartment or adjacent to the transverse beam. This staggered layout disrupts the continuous stress transmission path.

[0110] The fastener can be an M12 bolt.

[0111] The box structure 1 provided in this application achieves a high-strength and high-stability mechanical connection between layers through the staggered locking connection of the structural beam 40 and the first fastener 51 and the second fastener 53 of the fastener assembly 50. This effectively disperses and bears the multidimensional stress generated by the thermal expansion of the battery and the driving conditions of the vehicle. At the same time, it optimizes the profile wall thickness to balance lightweight and structural strength, and facilitates the integration of thermal management and sealing systems.

[0112] Please combine Figure 10 A battery pack 2 includes the aforementioned housing structure 1. The battery pack 2 has all the beneficial effects of the aforementioned housing structure 1, which will not be repeated here.

[0113] Please combine Figure 10An electrical device 3 includes the aforementioned housing structure 1 or the aforementioned battery pack 2. The electrical device 3 possesses all the beneficial effects of the aforementioned housing structure 1 or the aforementioned battery pack 2, which will not be elaborated further herein.

[0114] It is understood that electrical equipment includes, but is not limited to, electric toys, power tools, electric vehicles, automobiles, ships, spacecraft, etc. Electric toys can include stationary or mobile electric toys, such as game consoles, electric car toys, electric ship toys, and electric airplane toys, etc. Spacecraft can include airplanes, rockets, space shuttles, and spacecraft, etc. Automobiles can include gasoline-powered cars, natural gas-powered cars, and new energy vehicles.

[0115] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0116] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0117] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0118] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A box structure (1), characterized in that, include: Multiple box units (10) are stacked along the height direction (z) of the box structure. Each box unit (10) includes a box frame (30) and a structural beam (40) connected to each other. The structural beam (40) is installed inside the box frame (30). The fastener assembly (50) includes a first fastener (51) and a second fastener (53). In two adjacent box units (10), the first fastener (51) passes through the structural beam (40) of one box unit (10) and is connected to the structural beam (40) of the other box unit (10); at least a portion of the second fastener (53) is installed on the structural beam (40) of the other box unit (10). In particular, at least some of the first fasteners (51) and the second fasteners (53) are spaced apart in the direction perpendicular to the height of the box structure.

2. A box structure (1) according to claim 1, characterized in that Along the height direction (z) of the box structure, the plurality of box units (10) include a third box unit (15), a first box unit (11) and a second box unit (13) stacked in sequence. The box structure (1) also includes a bottom support plate (20), which is located on the side of the second box unit (13) away from the first box unit (11) and is connected to the structural beam (40) of the second box unit (13).

3. The box structure (1) according to claim 2, characterized in that, The second fastener (53) includes a bottom plate fastener (55), which passes through the bottom plate (20) and is connected to one end of the structural beam (40) of the second housing unit (13) near the bottom plate (20).

4. The box structure (1) according to claim 3, characterized in that, The first fastener (51) passes through the structural beam (40) of the first box unit (11) and is connected to the end of the structural beam (40) of the second box unit (13) away from the bottom support plate (20); along the height direction (z) of the box structure, the end of the bottom support plate fastener (55) away from the bottom support plate (20) is spaced apart from the end of the first fastener (51) near the bottom support plate (20).

5. The box structure (1) according to claim 2, characterized in that, The second fastener (53) includes a single fastener (57) along the height direction (z) of the box structure. The single fastener (57) passes through the structural beam (40) of the third box unit (15) and is connected to the end of the structural beam (40) of the first box unit (11) away from the bottom support plate (20).

6. The box structure (1) according to claim 5, characterized in that, The minimum distance N1 between the end of the single fastener (57) facing the base plate (20) and the first fastener (51) is in the range of 18mm≥N1≥0mm.

7. The box structure (1) according to claim 5, characterized in that, An installation gap (65) is formed between the first housing unit (11) and the third housing unit (15), and at least part of the first fastener (51) is located at the end opposite to the bottom plate (20) in the installation gap (65).

8. The box structure (1) according to claim 7, characterized in that, The housing unit (10) includes a first boss (16), at least a portion of which is located in the mounting interval (65). One end of the first boss (16) is connected to the structural beam (40) of the first housing unit (11), and the other end of the first boss (16) abuts against the structural beam (40) of the third housing unit (15). The unit fastener (57) passes through the structural beam (40) of the third housing unit (15) and the first boss (16), and is connected to the structural beam (40) of the first housing unit (11).

9. The box structure (1) according to claim 8, characterized in that, The first housing unit (11) includes a mounting component (60), which is mounted on the structural beam (40) of the first housing unit (11). The mounting component (60) includes a first sub-component (61) and a second sub-component (63) connected together. The first sub-component (61) has a first boss (16) connected to one end away from the bottom support plate (20). A first through hole (611) passes through the first boss (16) and the first sub-component (61). The second sub-component (63) has a second through hole (631) spaced apart from the first through hole (611). Both the first through hole (611) and the second through hole (631) pass through the first housing unit (11) along the height direction (z) of the housing structure. Part of the first fastener (51) is installed in the second through hole (631). The end of the unit fastener (57) facing the bottom support plate (20) is installed in the first through hole (611).

10. The box structure (1) according to claim 5, characterized in that, The box structure (1) includes a second boss (17), which is connected to the end of the structural beam (40) of the second box unit (13) facing the first box unit (11). The end face of the second boss (17) away from the bottom support plate (20) abuts against the structural beam (40) of the first box unit (11). The first fastener (51) passes through the structural beam (40) of the first box unit (11) and the second boss (17), and is connected to the structural beam (40) of the second box unit (13).

11. The box structure (1) according to any one of claims 1 to 10, characterized in that, The relationship between the connection length L1 of the single fastener (57) and the structural beam (40) of the first box unit (11) and the height L2 of the first box unit (11) satisfies: 。 12. The box structure (1) according to any one of claims 1 to 10, characterized in that, The structural beam (40) includes a reinforcing rib (41) and a side wall (43). The reinforcing rib (41) is connected to the side wall (43) and forms a weight-reducing cavity (45) with the side wall (43).

13. The box structure (1) according to any one of claims 1 to 10, characterized in that, The box unit (10) includes a support member (18), and the support member (18) is connected to at least one side of the opposite sides of the box frame (30) along the height direction (z) of the box structure. The thickness M1 of the support member (18) is greater than the thickness M2 of the side wall (43) of the structural beam (40).

14. The box structure (1) according to any one of claims 1 to 10, characterized in that, The box unit (10) is a die-cast box.

15. The box structure (1) according to any one of claims 1 to 10, characterized in that, The structural beam (40) includes a first beam (401) and a second beam (403) connected to each other. The first beam (401) extends along a first direction (x) and the second beam (403) extends along a second direction (y). The first direction (x) and the second direction (y) have an angle. The connection between the first beam (401) and the second beam (403) is used to pass through the fastener.

16. A battery pack (2), characterized in that, Includes the box structure (1) as described in any one of claims 1-15.

17. An electrical appliance (3), characterized in that, Includes the housing structure (1) as described in any one of claims 1-15 or the battery pack (2) as described in claim 16.

Images