A new energy vehicle battery pack protective shell with a honeycomb reinforcing structure

Abstract

The application discloses a new energy automobile battery pack protective shell with a honeycomb reinforcing structure and relates to the technical field of battery pack shells. The shell is composed of a bottom plate and four side plates vertically extending upwards from the edges of the bottom plate. Adjacent two side plates are connected through a round corner. A support plate is arranged in the relative space between the bottom plate and the side plate. A honeycomb reinforcing bottom support is fixed in the relative space between the support plate and the bottom plate. Two vertically distributed first vertical plates and two second vertical plates are arranged on the inner sides of the four side plates. A side reinforcing frame one, a side reinforcing frame two and a honeycomb reinforcing side wall are fixed in the relative space between the first vertical plate, the second vertical plate and the side plate. The shell can be comprehensively reinforced on the four sides and the bottom. The overall stress is uniformly dispersed and conducted to the whole shell through the honeycomb structure, so that the local stress concentration is avoided to cause the shell to crack and deform. The structural strength of the shell is effectively improved, the shell is prevented from being easily deformed, and the overall protection performance is improved.

Description

Technical Field

[0001] This invention relates to the field of battery pack housing technology, and in particular to a protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure. Background Technology

[0002] The protective casing of a new energy vehicle battery pack is a structural safety component used to protect the battery system. Its structural strength directly determines the vehicle's safety, lifespan, and range. Specifically, the battery pack casing must withstand the impact forces from vibrations, shocks, bumps, rapid acceleration, and sudden braking during vehicle operation. It must also withstand impact forces from side collisions, frontal collisions, rear-end collisions, bottoming out, and being run over. It must ensure that the internal battery cells do not deform, short-circuit, or catch fire, and it must also prevent cell compression, punctures, and leakage after a collision.

[0003] Existing protective casings for new energy vehicle batteries mostly employ a single-layer structure with simple internal reinforcing ribs, resulting in limited overall structural strength. When subjected to external impact, stress tends to concentrate in localized areas, leading to cracking and deformation after prolonged use. This reduces protective performance, fails to evenly distribute and buffer impact forces, and does not effectively protect the internal battery modules. Both structural stability and safety require improvement. Therefore, this application provides a protective casing for new energy vehicle battery packs with a honeycomb reinforcement structure to meet these requirements. Summary of the Invention

[0004] To address the aforementioned issues, this application provides a protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure.

[0005] To achieve the above objectives, this application provides the following technical solution: a protective shell for a new energy vehicle battery pack with a honeycomb reinforcement structure, comprising a shell composed of a base plate and four side plates extending vertically upward from the edge of the base plate, with adjacent side plates connected by rounded corners, a support plate provided in the space between the base plate and the side plates, and a honeycomb reinforced base fixed in the space between the support plate and the base plate.

[0006] The four side panels have two vertically distributed first upright panels and two second upright panels on their inner sides. The first upright panel, the second upright panel and the side panel are fixed with side reinforcement frame one and side reinforcement frame two and honeycomb reinforced side wall in the relative space between them.

[0007] The ends of two adjacent side reinforcement frames are fixed together by hexagonal connecting columns. The ends of the first and second upright plates are fixed to the hexagonal connecting columns, which are fixed to the support plate and are all directly opposite the inner side of the rounded corners.

[0008] Furthermore, the honeycomb reinforced base includes a reinforcing frame facing the edge of the support plate, a central fixing frame located at the center of the inner side of the reinforcing frame, and a honeycomb base connecting the reinforcing frame and the central fixing frame. The central fixing frame is arranged in a cross structure, and the number of honeycomb bases is four.

[0009] Furthermore, the honeycomb reinforced sidewall includes a reinforcing rib plate one fixed to the inner side of the first side reinforcement frame, a reinforcing rib plate two fixed to the inner side of the second side reinforcement frame, multiple honeycomb combination plates one and multiple honeycomb combination plates two. The reinforcing rib plate one and the reinforcing rib plate two are horizontally distributed, and the upper and lower sides of the reinforcing rib plate one and the reinforcing rib plate two are respectively fixed to the first side reinforcement frame one and the second side reinforcement frame two through the honeycomb combination plates one and the honeycomb combination plates two.

[0010] Furthermore, multiple reinforcing ribs 1 and 2 are fixed inside the central frame. The reinforcing ribs 1 and 2 are vertically distributed, and the cross-sections of the reinforcing ribs 1 and 2 are both trapezoidal. Both reinforcing ribs 1 and 2 abut against the lower surface of the support plate.

[0011] Furthermore, both ends of the first and second reinforcing ribs extend vertically upward to form symmetrically distributed extensions 1 and 2. Extensions 1 and 2 extend to the inner sides of the first and second side reinforcing frames, respectively, and both extensions 1 and 2 penetrate the first and second reinforcing ribs. Multiple honeycomb composite panels 1 and 2 located inside the first and second side reinforcing frames are located on both sides of extensions 1 and 2.

[0012] Furthermore, rounded corner reinforcement plates are attached to the inner side of each rounded corner portion, and buffer supports are fixed to the side of each hexagonal connecting column opposite the rounded corner reinforcement plate. The rounded corner reinforcement plates have an arc-shaped structure, and the buffer supports have an isosceles trapezoidal structure.

[0013] The inner side of each rounded corner reinforcing plate protrudes towards the upper bottom side of the buffer support to form a sliding rod. Each upper bottom side of the buffer support is fitted with a rubber sleeve, which has a V-shaped structure. The ends of the sliding rods are located inside the rubber sleeves.

[0014] Furthermore, the inner sides of the rounded corner reinforcing plates all protrude towards the buffer support to form a protruding part on the plane. The protruding parts are all parallel to the inclined surface of the buffer support, and the two inclined surfaces of the buffer support and the protruding parts are all connected to pressure springs through mounting pads.

[0015] In summary, the technical effects and advantages of this invention are as follows:

[0016] This invention utilizes a combination of a honeycomb-reinforced base and honeycomb-reinforced side panels to comprehensively reinforce the inner perimeter and bottom of the outer casing. This allows overall stress to be evenly distributed and transmitted throughout the casing via the honeycomb structure, preventing localized stress concentration that could lead to cracking and deformation. This effectively improves the overall structural strength of the casing, preventing easy deformation and enhancing overall protective performance, making it suitable for the bumpy and impact conditions encountered by new energy vehicles during operation. Furthermore, the reinforced base and honeycomb-reinforced side panels are lightweight, reducing the overall weight of the battery pack protective casing and thus reducing the load on the new energy vehicle. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art 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.

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0019] Figure 2 This is a schematic diagram of the second perspective structure of the present invention.

[0020] Figure 3 This is a schematic diagram of the structure of the outer shell of the present invention after disassembly.

[0021] Figure 4 For the present invention Figure 3 Enlarged structural diagram at point A in the middle.

[0022] Figure 5 This is a schematic diagram of the structure of the invention from a second perspective after the outer shell has been disassembled.

[0023] Figure 6 This is a schematic diagram of the structure of the outer shell, side reinforcement frame one, and side reinforcement frame two after disassembly.

[0024] Figure 7 This is a schematic diagram of the outer side and support plate of the present invention after disassembly.

[0025] Figure 8 This is a schematic diagram showing the disassembled outer shell, support plate, side reinforcement frame one, and side reinforcement frame two of the present invention.

[0026] Figure 9 This is a schematic diagram of the connection structure between the first side reinforcement frame and the second side reinforcement frame of the present invention.

[0027] Figure 10 This is a schematic diagram of the connection structure between the hexagonal connecting column and the rounded corner reinforcing plate of the present invention.

[0028] Figure 11This is a schematic diagram of the hexagonal connecting column distribution structure of the present invention.

[0029] Figure 12 This is a schematic diagram of the hexagonal connecting column and rounded corner reinforcing plate after disassembly.

[0030] Figure 13 For the present invention Figure 12 Enlarged structural diagram at point B.

[0031] In the diagram: 1. Base plate; 2. Side plate; 21. Rounded corner; 3. Support plate; 4. First upright plate; 5. Second upright plate; 6. Reinforcing frame; 7. Central support frame; 8. Honeycomb base support; 9. Side reinforcing frame one; 91. Reinforcing rib plate one; 10. Side reinforcing frame two; 101. Reinforcing rib plate two; 11. Hexagonal connecting column; 12. Honeycomb composite panel one; 13. Honeycomb composite panel two; 14. Rounded corner reinforcing plate; 141. Sliding rod; 142. Protrusion; 143. Compression spring; 144. Mounting shim; 15. Buffer support; 151. Rubber sleeve; 16. Reinforcing rib one; 161. Extension one; 17. Reinforcing rib two; 171. Extension two. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Example 1: Reference Figure 1 and Figure 2 The protective shell for a new energy vehicle battery pack with a honeycomb reinforcement structure shown includes an outer shell composed of a base plate 1 and four side plates 2 extending vertically upward from the edge of the base plate 1. Adjacent side plates 2 are connected by rounded corners 21. A support plate 3 is provided in the space between the base plate 1 and the side plates 2. A honeycomb reinforced base support is fixed in the space between the support plate 3 and the base plate 1.

[0034] like Figure 3 , Figure 5 As shown, the inner side of the four side panels 2 is provided with two vertically distributed first upright panels 4 and two second upright panels 5. The first upright panel 4, the second upright panel 5 and the side panel 2 are fixed with side reinforcement frame 9 and side reinforcement frame 10 and honeycomb reinforced side wall.

[0035] In practical use of this invention, the support plate 3, the first upright plate 4, and the second upright plate 5 form a space inside the outer casing through which a car battery can be placed. In this embodiment, the combination of the honeycomb reinforced bottom support and the honeycomb reinforced side panels provides comprehensive reinforcement and strengthening around the inner perimeter and bottom of the outer casing, effectively improving the overall structural strength of the outer casing, preventing easy deformation of the outer casing, and enhancing overall protective performance.

[0036] like Figure 4 As shown, the ends of two adjacent side reinforcement frames 9 and 10 are fixed together by hexagonal connecting posts 11. The ends of the first upright plate 4 and the second upright plate 5 are fixed to the hexagonal connecting posts 11. The hexagonal connecting posts 11 are fixed to the support plate 3, and the hexagonal connecting posts 11 are all directly opposite the inner side of the rounded corner 21.

[0037] The hexagonal connecting column 11 can complete the centralized connection and fixation at the corner positions. Based on the stability of its own hexagonal structure, it can better distribute and transmit the force between the adjacent side reinforcement frame 9 and side reinforcement frame 10. Compared with the traditional cylindrical connecting structure, the hexagonal structure has a more uniform force distribution, is less prone to bending deformation, strengthens the structural stability at the corner positions, and further improves the overall integrity of the internal structure.

[0038] Specifically, such as Figure 5 As shown, in this invention, the honeycomb reinforced base includes a reinforcing frame 6 facing the edge of the support plate 3, a central support frame 7 located at the center of the inner side of the reinforcing frame 6, and a honeycomb base 8 connecting the reinforcing frame 6 and the central support frame 7. The central support frame 7 is arranged in a cross structure, and there are four honeycomb bases 8.

[0039] By combining the central support frame 7, the honeycomb base support 8, and the reinforcing frame 6, the three can form a complete planar reinforcement structure under the support plate 3, which improves the bending resistance of the bottom structure and can evenly distribute the force transmitted from the center of the support plate 3. While maintaining the lightweight characteristics of the honeycomb reinforced base support structure, it can effectively prevent the bottom shell from deforming under the weight of the battery and external impact.

[0040] like Figure 6 As shown, the honeycomb reinforced sidewall includes a reinforcing rib plate 91 fixed to the inside of the side reinforcement frame 9, a reinforcing rib plate 101 fixed to the inside of the side reinforcement frame 10, multiple honeycomb combination plates 12 and multiple honeycomb combination plates 13. The reinforcing rib plate 91 and the reinforcing rib plate 101 are horizontally distributed, and the upper and lower sides of the reinforcing rib plate 91 and the reinforcing rib plate 101 are fixed to the side reinforcement frame 9 and the side reinforcement frame 10 through the honeycomb combination plates 12 and the honeycomb combination plates 13, respectively.

[0041] The reinforcing ribs 91 and 101 can provide lateral reinforcement to the side reinforcement frames 9 and 10. Combined with the honeycomb composite panels 12 and 13, they can evenly distribute the lateral force across the entire honeycomb reinforced sidewall, thus avoiding localized dents and deformations on the sides of the shell and maintaining the lightweight structure of the honeycomb reinforced sidewall without excessively increasing the overall weight of the shell.

[0042] It is worth noting that the cavity design of the honeycomb structure can effectively disperse and buffer impact energy, preventing external forces from directly acting on the battery cells inside the battery pack and improving the protection effect of the battery. Therefore, the present invention, through the combination of multiple honeycomb base supports 8, honeycomb combination plate one 12, and honeycomb combination plate two 13, can evenly distribute and transmit overall stress to the entire shell through the honeycomb structure, avoiding local stress concentration that could lead to shell cracking and deformation, effectively improving the service life and safety performance of the protective shell, and adapting to the bumpy and impact conditions during the driving of new energy vehicles. Furthermore, the multiple honeycomb base supports 8, honeycomb combination plate one 12, and honeycomb combination plate two 13 also make the honeycomb reinforced base support and honeycomb reinforced sidewalls lightweight, reducing the weight of the entire battery pack protective shell and reducing the load on new energy vehicles.

[0043] like Figure 7 , Figure 8 As shown, multiple reinforcing ribs 16 and 17 are fixed inside the central frame 7. These ribs are vertically distributed and have trapezoidal cross-sections, enhancing their structural stability. Both ribs 16 and 17 abut against the lower surface of the support plate 3, providing direct and stable support to the center of the support plate 3, thus improving its structural strength and preventing it from sinking or bending under the weight of the battery.

[0044] like Figure 8 As shown, both ends of reinforcing rib 16 and reinforcing rib 17 extend vertically upwards to form symmetrically distributed extensions 161 and 171. Extensions 161 and 171 extend to the inner sides of side reinforcing frames 9 and 10, respectively, and both extend 161 and 171 penetrate reinforcing plates 91 and 101. Multiple honeycomb composite panels 12 and 13 located inside side reinforcing frames 9 and 10 are located on both sides of extensions 161 and 171. The combined arrangement of extensions 161 and 171 directly transfers the supporting force of the bottom honeycomb reinforced support structure to the honeycomb reinforced side frame structure, forming a uniformly distributed overall frame inside the shell. The forces between the horizontally and vertically distributed frames can be mutually transferred and dispersed, effectively alleviating the problem of local stress concentration.

[0045] Example 2: Figure 9 , Figure 10 As shown in Embodiment 1, when the car battery pack is subjected to an external impact, the rounded corner 21 is prone to stress concentration and cracking under the impact force. To avoid this situation, in this invention, rounded corner reinforcement plates 14 are attached to the inner side of the rounded corner 21, and buffer supports 15 are fixed to the side of the hexagonal connecting post 11 opposite to the rounded corner reinforcement plate 14. The rounded corner reinforcement plate 14 has an arc-shaped structure, and the buffer supports 15 have an isosceles trapezoidal structure. The inner side of the rounded corner reinforcement plate 14 protrudes towards the upper bottom side of the buffer support 15 to form a sliding rod 141. A rubber sleeve 151 is embedded in the upper bottom side of the buffer support 15. The rubber sleeve 151 has a V-shaped structure, and the end of the sliding rod 141 is located inside the rubber sleeve 151.

[0046] Therefore, when the rounded corner 21 of the outer shell is subjected to an external impact, the force will be transmitted to the rounded corner reinforcement plate 14. The rounded corner reinforcement plate 14 drives the slide rod 141 to compress the V-shaped rubber sleeve 151. The rubber sleeve 151 can absorb some of the impact energy through its own elastic deformation, play a role in buffering and unloading force, and reduce the probability of deformation and cracking at the rounded corner 21.

[0047] like Figure 11 , Figure 12 and Figure 13 As shown, the inner side of the rounded corner reinforcement plate 14 protrudes towards the buffer support 15 to form a protrusion 142 on the plane. The protrusions 142 are parallel to the inclined surface of the buffer support 15, and the two inclined surfaces of the buffer support 15 and the protrusions 142 are connected to the compression springs 143 through mounting washers 144. Furthermore, when the rounded corner 21 is impacted, the compression springs 143 will simultaneously undergo compression deformation to further absorb the impact energy. Combined with the buffering effect of the rubber sleeve 151 in this embodiment, the impact resistance of the rounded corner is greatly improved, and the protective effect is further enhanced.

[0048] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A protective shell for a new energy vehicle battery pack with a honeycomb reinforcement structure, comprising a shell consisting of a base plate (1) and four side plates (2) extending vertically upward from the edge of the base plate (1), wherein adjacent side plates (2) are connected by rounded corners (21), characterized in that: A support plate (3) is provided in the space between the bottom plate (1) and the side plate (2), and a honeycomb reinforced base is fixed in the space between the support plate (3) and the bottom plate (1). The four side panels (2) are provided with two vertically distributed first upright panels (4) and two second upright panels (5) on the inner side. The first upright panel (4), the second upright panel (5) and the side panel (2) are fixed with side reinforcement frame one (9) and side reinforcement frame two (10) and honeycomb reinforced side wall in the relative space between the first upright panel (4), the second upright panel (5) and the side panel (2). The ends of two adjacent side reinforcement frames (9) and (10) are fixed together by hexagonal connecting columns (11). The ends of the first upright plate (4) and the second upright plate (5) are fixed on the hexagonal connecting columns (11). The hexagonal connecting columns (11) are fixed on the support plate (3), and the hexagonal connecting columns (11) are all facing the inside of the rounded corner (21).

2. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 1, characterized in that: The honeycomb reinforced base includes a reinforcing frame (6) facing the edge of the support plate (3), a central support frame (7) located at the center of the inner side of the reinforcing frame (6), and a honeycomb base (8) connecting the reinforcing frame (6) and the central support frame (7). The central support frame (7) is arranged in a cross structure, and there are four honeycomb bases (8).

3. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 2, characterized in that: The honeycomb reinforced sidewall includes a reinforcing rib plate 1 (91) fixed to the inside of the side reinforcement frame 1 (9), a reinforcing rib plate 2 (101) fixed to the inside of the side reinforcement frame 2 (10), multiple honeycomb combination plates 1 (12) and multiple honeycomb combination plates 2 (13). The reinforcing rib plate 1 (91) and the reinforcing rib plate 2 (101) are horizontally distributed, and the upper and lower sides of the reinforcing rib plate 1 (91) and the reinforcing rib plate 2 (101) are fixed to the side reinforcement frame 1 (9) and the side reinforcement frame 2 (10) respectively through the honeycomb combination plates 1 (12) and the honeycomb combination plates 2 (13).

4. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 3, characterized in that: The inner side of the central frame (7) is fixed with multiple reinforcing ribs 1 (16) and 2 (17). The reinforcing ribs 1 (16) and 2 (17) are vertically distributed. The cross-sections of the reinforcing ribs 1 (16) and 2 (17) are trapezoidal, and the reinforcing ribs 1 (16) and 2 (17) abut against the lower surface of the support plate (3).

5. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 4, characterized in that: The first reinforcing bar (16) and the second reinforcing bar (17) extend vertically upward at both ends to form symmetrically distributed extensions (161) and extensions (171). The first extension (161) and the second extension (171) extend to the inner side of the first side reinforcing frame (9) and the second side reinforcing frame (10), respectively. The first extension (161) and the second extension (171) penetrate the first reinforcing plate (91) and the second reinforcing plate (101). The multiple honeycomb composite panels (12) and the second honeycomb composite panels (13) located inside the first side reinforcing frame (9) and the second side reinforcing frame (10) are located on both sides of the first extension (161) and the second extension (171).

6. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 1, characterized in that: The inner side of each rounded corner (21) is fitted with a rounded corner reinforcement plate (14), and each hexagonal connecting column (11) is fixed with a buffer support (15) on the side opposite to the rounded corner reinforcement plate (14). The rounded corner reinforcement plate (14) has an arc-shaped structure, and the buffer support (15) has an isosceles trapezoidal structure. The inner side of the rounded corner reinforcing plate (14) protrudes towards the upper bottom side of the buffer support (15) to form a sliding rod (141). The upper bottom side of the buffer support (15) is fitted with a rubber sleeve (151). The rubber sleeve (151) is V-shaped. The end of the sliding rod (141) is located inside the rubber sleeve (151).

7. The protective housing for a new energy vehicle battery pack with a honeycomb reinforcement structure according to claim 6, characterized in that: The inner side of the rounded corner reinforcing plate (14) protrudes towards the buffer support (15) to form a protruding part (142) on the plane. The protruding part (142) is parallel to the inclined surface of the buffer support (15). The two inclined surfaces of the buffer support (15) and the protruding part (142) are connected to a pressure spring (143) through a mounting pad (144).

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