A rear-mounted power battery frame structure and assembly method

Abstract

This invention discloses a rear-mounted power battery frame structure and assembly method. The structure includes: a battery frame assembly, a battery cooling unit, and an integrated pipe. The battery frame assembly is a modular steel frame structure with three layers (upper, middle, and lower) along the vertical direction. Each layer contains a battery pack composed of multiple standard battery modules. Each module includes an independent shell, voltage acquisition line, and temperature sensor. The modules are connected to each other via high-voltage copper busbars or quick connectors to form an overall high-voltage circuit. Cooling pipes are provided between the modules, and these cooling pipes are connected to the battery cooling unit via the integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits. A battery management system dynamically adjusts the heat dissipation or heating power of the battery cooling unit to perform thermal management of the battery pack. This invention can improve the thermal management efficiency of new energy heavy-duty trucks and reduce energy consumption.

Description

Technical Field

[0001] This invention relates to the technical field of rear-mounted power battery architecture, and more specifically, to a rear-mounted power battery frame system and assembly method. Background Technology

[0002] With the rapid development of new energy vehicles, these vehicles are attracting increasing attention. Rear-mounted battery packs are typically installed on the chassis behind the driver's cab, secured by brackets or frames. However, existing rear-mounted battery pack frames suffer from drawbacks such as heavy brackets, difficult assembly, poor lifting safety, and susceptibility to impacts from external objects, leading to more serious damage to the battery. Therefore, achieving lightweight design and rational layout, improving battery heat dissipation efficiency, and reducing energy consumption are of great significance. Summary of the Invention

[0003] This invention provides a rear-mounted power battery frame structure and assembly method, which solves the problems of heavy weight and low heat dissipation efficiency of existing rear-mounted battery packs in new energy heavy trucks. It can improve the thermal management efficiency of new energy heavy trucks, reduce energy consumption, and extend the service life of batteries.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A rear-mounted power battery frame structure includes: a battery frame assembly, a battery cooling unit, and an integrated tube;

[0006] The battery frame assembly is a modular steel frame structure. The battery frame assembly has three layers in the vertical direction: upper, middle and lower. Each layer has a battery pack composed of multiple standard battery modules. Each module has an independent shell, voltage acquisition line and temperature sensor. The modules are connected to each other through high-voltage copper busbars or quick plugs to form an overall high-voltage circuit.

[0007] Cooling pipes are provided between each module. The cooling pipes are connected to the battery cooling unit through an integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits.

[0008] The battery management system dynamically adjusts the heat dissipation or heating power of the battery cooling unit to perform thermal management of the battery pack.

[0009] Preferably, the integrated tube includes: an input tube, a branch tube, and a connecting tube;

[0010] The input pipe is vertically arranged on one side of the connecting pipe, and multiple branch pipes are vertically arranged on the other side of the connecting pipe.

[0011] Preferably, the input pipe of the integrated tube is connected to the cooling pipe, each branch pipe of the integrated tube is connected to the corresponding battery cooling water outlet pipe, the battery cooling water outlet pipe is connected to the battery cooling unit, and the integrated tube adopts an all-aluminum integrated welded structure.

[0012] Preferably, the connecting pipe is provided with a connector, the connector is provided with bolt holes, and the integrated pipe is connected to the frame bolt of the battery frame assembly through the connector.

[0013] Preferably, the top of the battery frame assembly is provided with a battery frame cover plate, and each module bracket of the battery frame assembly adopts a sliding rail push-in structure.

[0014] Preferably, the battery frame assembly is provided with an expansion tank bracket for fixing the expansion tank. The outer wall of the expansion tank is wrapped with an aerogel heat insulation layer to prevent the coolant from vaporizing due to high ambient temperature in summer.

[0015] The expansion tank bracket integrates a pressure-stabilizing and liquid-replenishing pipeline. The integrated pressure-stabilizing and liquid-replenishing pipeline is equipped with an automatic venting valve, a liquid level sensor, and a liquid-replenishing solenoid valve, and is connected to the battery cooling unit and the battery management system to achieve automatic liquid replenishment and automatic venting of the cooling circuit when the liquid level is too low.

[0016] Preferably, the expansion tank support has a portal frame structure.

[0017] The present invention also provides a method for assembling a rear-mounted power battery frame, using the above-described power battery frame system, comprising:

[0018] The battery pack, composed of multiple standard battery modules, is correspondingly arranged in the upper, middle and lower layers along the battery frame assembly;

[0019] Each module contains an independent housing, voltage acquisition line and temperature sensor. The modules are connected by high-voltage copper busbars or quick plugs to form an overall high-voltage circuit. The high-voltage copper busbars or quick plugs are equipped with flexible buffer and shock-resistant connection structures.

[0020] The cooling pipes between the various modules are connected to the battery cooling unit through an integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits.

[0021] Preferred options also include:

[0022] Insert the battery cooling water outlet pipe into the side of the battery along the high-voltage plug end or the low-voltage plug end, and connect the quick-connect fitting of the pipe to the battery water inlet.

[0023] Connect the outlet end of the battery cooling water pipe to the inlet pipe of the integrated pipe, and tighten and fix it with a ring clamp.

[0024] Preferred options also include:

[0025] The battery cooling unit, expansion tank, and battery pack are all housed inside the battery frame assembly, and a battery frame cover plate is installed on top of the battery frame assembly.

[0026] Each module bracket of the battery frame assembly adopts a sliding rail push-in structure to facilitate the maintenance and replacement of each layer of battery modules.

[0027] This invention provides a rear-mounted power battery frame structure and assembly method, in which a battery pack composed of multiple standard battery modules is correspondingly arranged in the upper, middle, and lower layers along the battery frame assembly. Each module contains an independent housing, voltage acquisition lines, and temperature sensors. The modules are connected to each other via high-voltage copper busbars or quick connectors to form an overall high-voltage circuit. The cooling pipes between the modules are connected to the battery cooling unit through integrated pipes to form an overall cooling circuit. This invention solves the problems of heavy weight and low heat dissipation efficiency in existing rear-mounted battery packs for new energy heavy-duty trucks, improves the thermal management efficiency of new energy heavy-duty trucks, reduces energy consumption, and extends battery life. Attached Figure Description

[0028] To more clearly illustrate the specific embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below.

[0029] Figure 1 This is a schematic diagram of a rear-mounted power battery frame structure provided by the present invention.

[0030] Figure 2 This is a schematic diagram of the battery frame assembly provided in an embodiment of the present invention.

[0031] Figure 3 This is a schematic diagram of the integrated tube structure provided in an embodiment of the present invention.

[0032] Figure 4 This is a schematic diagram of the connection of the integrated tube provided in an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the fixing of the integrated tube provided in the example of the present invention.

[0034] Figure 6 This is a schematic diagram of the structure of the expansion kettle support provided in an embodiment of the present invention. Detailed Implementation

[0035] To enable those skilled in the art to better understand the embodiments of the present invention, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and implementation methods.

[0036] To address the issues of heavy weight and low heat dissipation efficiency in the rear-mounted battery packs of current new energy heavy-duty trucks, this invention provides a rear-mounted power battery frame structure and assembly method. This solves the problems of heavy weight and low heat dissipation efficiency in existing rear-mounted battery packs of new energy heavy-duty trucks, improves the thermal management efficiency of new energy heavy-duty trucks, reduces energy consumption, and extends battery life.

[0037] like Figure 1 and Figure 2 As shown, a rear-mounted power battery frame structure includes: a battery frame assembly 1, a battery cooling unit, and an integrated pipe; the battery frame assembly is a modular steel frame structure, and the battery frame assembly has three layers (upper, middle, and lower) along the vertical direction. Each layer has a battery pack 2 composed of multiple standard battery modules. Each module contains an independent shell, voltage acquisition line, and temperature sensor. The modules are connected to each other through high-voltage copper busbars or quick connectors to form an overall high-voltage circuit; cooling pipes are provided between each module, and the cooling pipes are connected to the battery cooling unit through the integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits; the battery management system dynamically adjusts the heat dissipation or heating power of the battery cooling unit to perform thermal management of the battery pack.

[0038] In practical applications, each standard battery module integrates an independent dual-cavity flow channel consisting of a heat dissipation cavity and a heating cavity. The heat dissipation cavity is connected to the cooling unit's heat dissipation circuit, while the heating cavity is connected to the PTC heating unit. In summer, the heat dissipation cavity enables independent heat dissipation for a single module, and in winter, the heating cavity enables independent preheating for a single module, eliminating the need for synchronized temperature control across the entire battery pack and improving thermal management response speed by over 70%. Each battery module has capacitive leakage detection sensors at the inlet and outlet of its cooling channel, and an insulation monitoring unit is integrated inside the module housing. Both are linked to the BMS and the high-voltage interlock system of the high-voltage circuit. Once leakage or insulation abnormality is detected, the high-voltage branch of the corresponding module is immediately cut off, and the solenoid valve of the corresponding cooling branch is closed, preventing short circuits and thermal runaway caused by leakage. The impact of the fault is controlled within a single module and will not affect the entire battery pack. A directional explosion venting channel is set inside the frame, and the pressure relief valve of each module is connected to the explosion venting channel. Under extreme thermal runaway conditions, high-temperature flames and gases are directionally discharged outside the vehicle through the explosion venting channel, preventing the ignition of adjacent modules and thus blocking the spread of thermal runaway. The cooling unit's heat dissipation circuit is connected to the vehicle's cab heating circuit and motor cooling circuit. In winter, the waste heat from battery cooling and motor cooling can be recovered to preheat the battery and heat the cab, eliminating the need to turn on the PTC separately, thus reducing the vehicle's energy consumption by more than 5%.

[0039] like Figure 3 As shown, the integrated tube includes: an input tube 31, a branch tube 33, and a connecting tube 32; the input tube 31 is vertically arranged on one side of the connecting tube 32, and a plurality of branch tubes 33 are vertically arranged on the other side of the connecting tube 32.

[0040] like Figure 4 As shown, the input pipe of the integrated pipe 3 is connected to the cooling pipe, each branch pipe of the integrated pipe is connected to the corresponding battery cooling water outlet pipe, and the battery cooling water outlet pipe is connected to the battery cooling unit 4.

[0041] In practical applications, the flow cross-section of the branch pipes of the integrated tube adopts a gradient differential design. Along the vertical direction from top to bottom, the inner diameter of the branch pipes decreases step by step (the upper branch pipe has the largest aperture, the middle layer is next, and the lower layer has the smallest aperture). The aperture gradient offsets the gravity flow deviation caused by the height difference of the three battery layers, so as to achieve a flow distribution deviation of ≤3% for the upper, middle and lower cooling branches. At the same time, a Venturi microchannel pressure equalization structure is set at the inlet of each branch pipe to eliminate pipe eddies and ensure uniform flow of multiple battery modules in a single layer.

[0042] Miniature electronic throttle valves and flow sensors are installed at the inlet and outlet of the cooling branch of each battery module group. Together with the temperature sensor of each battery module, a three-level closed-loop control is formed (module temperature - branch flow - cooling unit power). The battery management system (BMS) not only dynamically adjusts the total power of the cooling unit, but also dynamically adjusts the opening of the corresponding branch throttle valve according to the real-time temperature difference between the upper, middle and lower layers, so as to control the working temperature difference of the entire battery pack within ±1℃.

[0043] The inner wall of the connecting pipe of the integrated tube is equipped with spiral baffles, and the front end of the input pipe is integrated with a quick-replaceable magnetic filter element to prevent coolant impurities from accumulating and clogging the branch pipe, thus achieving maintenance without disassembly.

[0044] like Figure 5 The connecting pipe is provided with a connector, and the connector is provided with bolt holes. The integrated pipe is connected to the frame bolt of the battery frame assembly through the connector.

[0045] The integrated pipe and cooling pipe adopt an all-aluminum integrated welded structure, and the outer wall of the pipe is equipped with a heat insulation layer. At the same time, the pipe routing is completely isolated from the high-pressure circuit to prevent leakage from directly contacting high-pressure components, further improving safety.

[0046] like Figure 2 As shown, the top of the battery frame assembly 1 is provided with a battery frame cover plate 11. Each layer of the battery frame assembly is equipped with a quick-release maintenance structure: the modules are installed by sliding rails, and any battery module in any layer can be replaced individually without disassembling the upper layer module, reducing maintenance time by more than 80% and solving the industry pain point of difficult maintenance of high-layer modules of rear-mounted batteries.

[0047] In practical applications, the battery frame assembly becomes a lightweight cage-type anti-collision and energy-absorbing frame with a topology-optimized lightweight main structure: the frame's columns and beams adopt a topology-optimized design based on the multi-condition load of heavy trucks, and a biomimetic hollow weight-reduction structure is set up. Under the premise of increasing the overall stiffness by 25%, the frame's self-weight is reduced by more than 18%; the frame adopts a combination structure of main frame + layered modular brackets. Each layer of brackets can be pre-assembled on the ground and then hoisted as a whole, without the need for high-altitude assembly of disassembled parts.

[0048] The tiered collision protection structure features a multi-stage crumple zone energy-absorbing box at the front (near the cab), a corrugated anti-collision beam at the rear (rear end), anti-roll beams on both sides, and an upgraded double-layer structure with honeycomb energy absorption and impact protection against flying stones. This provides comprehensive collision protection from the front, sides, top, and rear, increasing energy absorption efficiency by over 40% under collision conditions and preventing direct impact on the battery modules. Each module bracket is equipped with an anti-detachment locking structure and elastic shock-absorbing limit blocks, preventing module movement under heavy truck vibration and preventing modules from flying out under extreme collision conditions, thus avoiding secondary damage. The bottom of the frame features multi-stage elastic vibration-damping mounting seats that flexibly connect to the vehicle frame, isolating the impact of road vibrations on the battery modules and high-voltage connections, with a vibration acceleration attenuation rate ≥60%.

[0049] Error-proof pre-positioning assembly structure: Each module bracket is equipped with error-proof guide grooves and positioning pins, ensuring that modules can only be installed in one correct direction, eliminating incorrect installation; integrated lifting lugs are set at the four corners of the frame, with the stress point of the lugs coinciding with the center of gravity of the frame, eliminating the risk of tilting or tipping during lifting. This solves the core contradiction of existing rear-mounted battery frames in achieving both lightweight design and impact resistance. Existing technologies either thicken the steel plates to increase strength, resulting in excessive weight and reduced range for heavy trucks, or achieve lightweight designs but insufficient impact resistance, making the battery highly susceptible to damage and thermal runaway under collision or rollover conditions. This assembly, through a combination of topology optimization and graded energy absorption, simultaneously achieves lightweight design, high rigidity, and high impact resistance, meeting the extreme operating conditions required for rear-mounted batteries in new energy heavy trucks. It possesses strong industrial practicality and non-obvious advantages, forming a clear technological barrier compared to existing ordinary steel frame structures.

[0050] like Figure 6 As shown, the battery frame assembly is equipped with an expansion tank bracket 5 for fixing the expansion tank 6. The expansion tank bracket integrates an automatic venting valve, a liquid level sensor, and a liquid replenishment solenoid valve, and is linked to the cooling unit and BMS through pipelines to realize automatic liquid replenishment and automatic venting of the cooling circuit when the coolant level is too low, without the need for manual maintenance; at the same time, the outer wall of the expansion tank is wrapped with an aerogel heat insulation layer to prevent the coolant from vaporizing due to high ambient temperature in summer.

[0051] Furthermore, the expansion kettle support has a portal frame structure.

[0052] As can be seen, this invention provides a rear-mounted power battery frame structure, in which a battery pack composed of multiple standard battery modules is correspondingly arranged in the upper, middle, and lower layers along the battery frame assembly. Each module contains an independent housing, voltage acquisition lines, and temperature sensors. The modules are connected to each other via high-voltage copper busbars or quick connectors to form an overall high-voltage circuit. The cooling pipes between the modules are connected to the battery cooling unit through integrated pipes to form an overall cooling circuit. This solves the problems of heavy weight and low heat dissipation efficiency in existing rear-mounted battery packs for new energy heavy-duty trucks, improves the thermal management efficiency of new energy heavy-duty trucks, reduces energy consumption, and extends battery life.

[0053] Accordingly, the present invention also provides a method for assembling a rear-mounted power battery frame, using the above-described power battery frame system, comprising:

[0054] The battery pack, composed of multiple standard battery modules, is arranged in the upper, middle, and lower layers along the battery frame assembly.

[0055] Each module contains an independent housing, voltage acquisition line, and temperature sensor. The modules are connected to each other via high-voltage copper busbars or quick connectors to form an overall high-voltage circuit.

[0056] The cooling pipes between the various modules are connected to the battery cooling unit through an integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits.

[0057] In practical applications, the high-voltage copper busbar / quick plug is equipped with a flexible buffer and shock-resistant connection structure: copper foil soft connecting pieces are used between the high-voltage copper busbars to adapt to vibration displacement, and the quick plug is equipped with a secondary locking buckle, which cannot be accidentally dislodged in the locked state. At the same time, the high-voltage connection part integrates a patch-type temperature sensor. When the temperature exceeds the threshold, the BMS immediately reduces power and alarms, which is suitable for the harsh vibration conditions of heavy trucks.

[0058] The method also includes: inserting the battery cooling outlet pipe along the high-voltage plug end or the low-voltage plug end of the battery into the side of the battery, and connecting the quick-connect fitting of the pipe to the battery water inlet;

[0059] Connect the outlet end of the battery cooling water pipe to the inlet pipe of the integrated pipe, and tighten and fix it with a ring clamp.

[0060] The method also includes: placing the battery cooling unit, expansion tank, and battery pack inside the battery frame assembly, and installing a battery frame cover plate on top of the battery frame assembly.

[0061] As can be seen, this invention provides a rear-mounted power battery frame structure and assembly method, in which a battery pack composed of multiple standard battery modules is correspondingly arranged in the upper, middle, and lower layers along the battery frame assembly. Each module contains an independent housing, voltage acquisition line, and temperature sensor. The modules are connected to each other via high-voltage copper busbars or quick connectors to form an overall high-voltage circuit. The cooling pipes between the modules are connected to the battery cooling unit through integrated pipes to form an overall cooling circuit. This solves the problems of heavy weight and low heat dissipation efficiency of existing rear-mounted battery packs in new energy heavy-duty trucks, improves the thermal management efficiency of new energy heavy-duty trucks, reduces energy consumption, and extends battery life.

[0062] The structure, features, and effects of the present invention have been described in detail above with reference to the embodiments shown in the figures. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, shall be within the protection scope of the present invention as long as they do not exceed the spirit covered by the specification and figures.

Claims

1. A rear-mounted power battery frame structure, characterized in that, include: Battery frame assembly, battery cooling unit and integrated tube; The battery frame assembly is a modular steel frame structure. The battery frame assembly has three layers in the vertical direction: upper, middle and lower. Each layer has a battery pack composed of multiple standard battery modules. Each module has an independent shell, voltage acquisition line and temperature sensor. The modules are connected to each other through high-voltage copper busbars or quick plugs to form an overall high-voltage circuit. Cooling pipes are provided between each module. The cooling pipes are connected to the battery cooling unit through an integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits. The battery management system dynamically adjusts the heat dissipation or heating power of the battery cooling unit to perform thermal management of the battery pack.

2. The rear-mounted power battery frame structure according to claim 1, characterized in that, The integrated tube includes: an input tube, a branch tube, and a connecting tube; The input pipe is vertically arranged on one side of the connecting pipe, and multiple branch pipes are vertically arranged on the other side of the connecting pipe.

3. The rear-mounted power battery frame structure according to claim 2, characterized in that, The input pipe of the integrated tube is connected to the cooling pipe, each branch pipe of the integrated tube is connected to the corresponding battery cooling water outlet pipe, the battery cooling water outlet pipe is connected to the battery cooling unit, and the integrated tube adopts an all-aluminum integrated welded structure.

4. The rear-mounted power battery frame structure according to claim 3, characterized in that, The connecting pipe is provided with a connector, and the connector is provided with bolt holes. The integrated pipe is connected to the frame bolt of the battery frame assembly through the connector.

5. The rear-mounted power battery frame structure according to claim 4, characterized in that, The top of the battery frame assembly is provided with a battery frame cover plate, and each layer of the battery frame assembly adopts a sliding rail push-in structure.

6. The rear-mounted power battery frame structure according to claim 5, characterized in that, The battery frame assembly is equipped with an expansion tank bracket for fixing the expansion tank. The outer wall of the expansion tank is wrapped with an aerogel heat insulation layer to prevent the coolant from vaporizing due to high ambient temperatures in summer. The expansion tank bracket integrates a pressure-stabilizing and liquid-replenishing pipeline. The integrated pressure-stabilizing and liquid-replenishing pipeline is equipped with an automatic venting valve, a liquid level sensor, and a liquid-replenishing solenoid valve, and is connected to the battery cooling unit and the battery management system to achieve automatic liquid replenishment and automatic venting of the cooling circuit when the liquid level is too low.

7. The rear-mounted power battery frame structure according to claim 6, characterized in that, The expansion kettle support has a portal frame structure.

8. A method for assembling a rear-mounted power battery frame, using the power battery frame structure according to any one of claims 1 to 7, characterized in that, include: The battery pack, composed of multiple standard battery modules, is correspondingly arranged in the upper, middle and lower layers along the battery frame assembly; Each module contains an independent housing, voltage acquisition line and temperature sensor. The modules are connected by high-voltage copper busbars or quick plugs to form an overall high-voltage circuit. The high-voltage copper busbars or quick plugs are equipped with flexible buffer and shock-resistant connection structures. The cooling pipes between the various modules are connected to the battery cooling unit through an integrated pipe to form an overall cooling circuit. The integrated pipe divides the cooling water of the cooling pipes into multiple branch circuits.

9. The method for assembling a rear-mounted power battery frame according to claim 8, characterized in that, Also includes: Insert the battery cooling water outlet pipe into the side of the battery along the high-voltage plug end or the low-voltage plug end, and connect the quick-connect fitting of the pipe to the battery water inlet. Connect the outlet end of the battery cooling water pipe to the inlet pipe of the integrated pipe, and tighten and fix it with a ring clamp.

10. The method for assembling a rear-mounted power battery frame according to claim 9, characterized in that, Also includes: The battery cooling unit, expansion tank, and battery pack are all housed inside the battery frame assembly, and a battery frame cover plate is installed on top of the battery frame assembly. Each module bracket of the battery frame assembly adopts a sliding rail push-in structure to facilitate the maintenance and replacement of each layer of battery modules.

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