Battery pack and electric device

Abstract

This application relates to the field of battery technology, and more particularly to a battery pack and electrical device. The battery pack includes: an outer casing, including a cover and a lower casing, the cover being disposed on the lower casing, and the cover and the lower casing forming a receiving cavity; the lower casing including a frame and support beams disposed on the frame; multiple battery layers, at least some of which are located within the receiving cavity, and the multiple battery layers are stacked sequentially along the height direction of the outer casing; a connecting structure including a first connector and a second connector, the first connector being used to connect the frames of two adjacent battery layers along the height direction of the outer casing, and the second connector being used to connect the support beams of two adjacent battery layers; the projections of the first connector and the second connector located on the same layer do not coincide along the height direction of the outer casing. This application aims to solve the problems of insufficient interlayer connection strength and poor torsional resistance in multi-layer battery packs.

Description

Technical Field

[0001] This application relates to the field of battery technology, and more particularly to a battery pack and electrical device. Background Technology

[0002] With the rapid development of new energy vehicle technology, the demand for battery systems with high energy density and high structural strength is becoming increasingly urgent. As the core power source for new energy commercial vehicles, multi-layer battery packs must be designed to simultaneously meet multiple requirements such as large-capacity energy storage, lightweight design, high safety, and structural stability.

[0003] In conceiving and implementing this application, the applicant discovered at least the following problems: Battery packs typically need to be integrated into the chassis or frame. Due to space constraints in the vehicle, battery packs require a multi-layer stacking design to achieve higher energy density to meet long-range requirements. However, current multi-layer structures suffer from insufficient interlayer connection strength and poor torsional resistance.

[0004] The preceding description is intended to provide general background information and does not necessarily constitute prior art. Summary of the Invention

[0005] The main objective of this application is to provide a battery pack and electrical equipment to solve problems such as insufficient interlayer connection strength and poor torsional resistance in multilayer battery packs.

[0006] To achieve the above objectives, this application provides a battery pack, comprising:

[0007] The outer box includes a lid and a lower box body. The lid covers the lower box body, and the lid and the lower box body form a receiving cavity. The lower box body includes a frame and a support beam set on the frame.

[0008] Multiple battery layers, at least some of which are located within the housing cavity, are stacked sequentially along the height of the outer casing.

[0009] The connection structure includes a first connector and a second connector. Along the height direction of the outer casing, the first connector is used to connect the frames of two adjacent layers in the multiple battery layers, and the second connector is used to connect the support beams of two adjacent layers in the multiple battery layers.

[0010] Along the height direction of the outer casing, the projections of the first and second connectors located on the same layer do not overlap.

[0011] The beneficial effects of this application are as follows: By setting a first connector to connect the frame of two adjacent battery layers and a second connector to connect the support beams of two adjacent battery layers, multi-point connections of the battery layers at two different locations on the frame and support beams are achieved, effectively improving the reliability of interlayer connections and the overall structural strength. Simultaneously, by staggering the first and second connectors located on the same layer in the height direction (their projections do not overlap), the interlayer load is dispersed and transferred through different connectors, avoiding continuous stress concentration along a single vertical path. This staggered arrangement can disperse the vibration, impact, and torsional stress generated during vehicle operation to different connection paths, significantly improving the overall torsional stiffness and vibration resistance of the battery pack.

[0012] Based on the above technical solution, the following improvements can be made to this application.

[0013] In some alternative implementations, there are multiple first connectors;

[0014] Along the height direction of the outer casing, the projections of multiple first connectors located on adjacent layers do not coincide; and / or,

[0015] There are multiple second connectors;

[0016] Along the height direction of the outer casing, the projections of multiple second connectors located on adjacent layers do not overlap.

[0017] The above-mentioned technical solution has the following advantages or beneficial effects: By staggering the arrangement of multiple first connectors and / or multiple second connectors between adjacent layers in the height direction, the concentrated transmission of interlayer connection stress in the same vertical plane is further avoided, forming a multi-path, decentralized stress transmission network, which is conducive to further improving the overall strength of the box structure. At the same time, this staggered arrangement can also reduce the thickness requirements of single-layer frames and support beams to a certain extent, which is beneficial to lightweight design.

[0018] In some alternative implementations, the multiple battery layers include a first layer, a second layer, a third layer, and a fourth layer, wherein the first layer is located at the bottom of the battery pack and the fourth layer is located at the top of the battery pack;

[0019] The lid is sealed to the frame located on the first layer.

[0020] The above technical solution has the following advantages or beneficial effects: By directly sealing the cover to the first-layer frame at the bottom, there is no need to set up an additional independent sealing frame structure, which simplifies the outer box structure and reduces the number of parts and the overall weight. At the same time, the direct sealing connection between the cover and the first-layer frame ensures the airtightness of the cavity, effectively preventing external liquids and moisture from entering the battery pack and improving the safety performance of the battery pack.

[0021] likeFigure 5 As shown, the specific height H of the cover is along the height direction Z of the battery pack.

[0022] In some alternative implementations, the outer casing also includes panels, which include a front panel and a rear panel;

[0023] Along the length of the outer box, the front panel and the rear panel are respectively located at opposite ends of the first layer frame;

[0024] The lid is placed on the panel and the first layer frame, and multiple edges of the lid are respectively sealed to the top of the panel and the side of the first layer frame.

[0025] The above technical solution has the following advantages or beneficial effects: By setting the front panel and rear panel at opposite ends of the first-layer frame, together with the cover, a closed receiving cavity is formed, achieving protection and sealing of the battery layer in the length direction. Multiple edges of the cover are respectively sealed to the top of the panel and the sides of the first-layer frame, forming a multi-directional, multi-layered sealing structure, further improving the sealing reliability of the battery pack.

[0026] In some alternative implementations, each battery layer includes a battery module and a liquid cooling component, the battery module being located on the liquid cooling component, the liquid cooling component having a liquid cooling channel for heat exchange with the battery module;

[0027] The frame is multi-layered, and the position of the frame of each layer corresponds to the position of the battery layer of the corresponding layer, and the frame of each layer surrounds at least part of the periphery of the liquid cooling component of the corresponding layer.

[0028] The support beams are multi-layered, with at least two support beams on each layer. Along the length of the outer box, at least two support beams on each layer are located at opposite ends of the frame of the corresponding layer. The support beams located at the ends of the frame of the same layer and the frame of the same layer surround the periphery of the liquid cooling component of the corresponding layer.

[0029] The above technical solution has the following advantages or beneficial effects: By surrounding at least part of the periphery of the liquid cooling component with a frame and placing support beams at opposite ends of the frame, a three-dimensional enclosure structure for the battery module and the liquid cooling component is formed. The frame and support beams together constitute the load-bearing skeleton of each battery layer, providing installation support for the battery module and the liquid cooling component, and enhancing the structural rigidity of each battery layer. The liquid cooling component is equipped with liquid cooling channels, which can effectively manage the thermal of the battery module and ensure that the battery operates within a suitable temperature range.

[0030] In some alternative embodiments, the frame is provided with a first mounting hole and a second mounting hole;

[0031] The first connector passes through the first mounting hole on the same layer and the first mounting hole on the next layer on the same layer, so as to connect the frames of adjacent layers.

[0032] The first connector passes through the second mounting hole on the same layer and the second mounting hole on the layer above it, so as to connect the frames of adjacent layers.

[0033] The support beam is provided with a third mounting hole and a fourth mounting hole. The second connector passes through the third mounting hole located on the same layer and the third mounting hole on the next layer of the same layer, so as to connect the support beams of adjacent layers.

[0034] The second connector passes through the fourth mounting hole on the same floor and the fourth mounting hole on the floor above it, so as to connect the support beams of the two adjacent floors.

[0035] The above technical solution has the following advantages or beneficial effects: By setting the first and second mounting holes on the frame, and the third and fourth mounting holes on the support beam, the first and second connectors can pass through the mounting holes of the corresponding layers to achieve connection between adjacent layers. This mounting hole arrangement simplifies the inter-layer connection operation and facilitates the assembly and maintenance of the battery pack. Simultaneously, each layer of the frame and support beam has two sets of mounting holes, one above the other, for connection with the layer above and the layer below, respectively, achieving independence and scalability of the inter-layer connection.

[0036] In some alternative embodiments, there is a height difference between the first mounting hole and the second mounting hole located on the same layer;

[0037] There is a height difference between the third and fourth mounting holes located on the same layer;

[0038] The first and third mounting holes on the same layer are at the same height, and the second and fourth mounting holes on the same layer are at the same height.

[0039] The above technical solution has the following advantages or beneficial effects: By setting a height difference between the first and second mounting holes on the same floor, and between the third and fourth mounting holes, a staggered arrangement (projections do not overlap) of the first and second connectors on the same floor in the height direction is achieved. Simultaneously, by ensuring that the first and third mounting holes are at the same height, and the second and fourth mounting holes are at the same height, the frame and support beams are connected to adjacent floors at the same height via the first and second connectors, respectively, forming a frame-support beam collaborative inter-layer connection system, which is beneficial for the uniform transfer of load between the frame and support beams.

[0040] In some alternative embodiments, the frame includes a first side frame and a recessed side frame connected together, a first mounting hole is provided in the recessed side frame, and a second mounting hole is provided in the first side frame.

[0041] The support beam includes a connected second frame and a convex frame, a third mounting hole is located on the second frame, and a fourth mounting hole is located on the convex frame.

[0042] The height of the first border is the same as the height of the convex border, and the height of the concave border is the same as the height of the second border.

[0043] The above technical solution has the following advantages or beneficial effects: By adopting a first frame and concave frame structure for the frame and a second frame and convex frame structure for the support beam, the complementary cooperation of the concave and convex frames in the height direction achieves spatial misalignment between the frame and the support beam, as well as misalignment of the mounting holes for the connectors. The height of the first frame is consistent with the height of the convex frame, and the height of the concave frame is consistent with the height of the second frame, allowing the frame and support beam to form a flat mating surface during assembly. This facilitates the sequential stacking and connection of multiple battery layers, while ensuring the misalignment effect of the connection structure in the height direction.

[0044] In some alternative implementations, at least one of the first connector and the second connector is a threaded fastener;

[0045] At least one of the first mounting hole, the second mounting hole, the third mounting hole, and the fourth mounting hole is a threaded hole.

[0046] The above technical solution has the following advantages or beneficial effects: by using threaded fasteners as connectors and cooperating with threaded holes to achieve interlayer connection, the connection is reliable, easy to assemble and disassemble, and facilitates the assembly, maintenance, and repair of the battery pack. The threaded connection method can provide a stable preload, ensuring the long-term reliability of the interlayer connection.

[0047] In addition, this application also includes an electrical device, including a battery pack.

[0048] The battery pack and electrical equipment provided in this application include a battery pack; the battery pack includes: an outer casing, including a cover and a lower casing, the cover covering the lower casing and the cover and the lower casing forming a receiving cavity, the lower casing including a frame and a support beam disposed on the frame; multiple battery layers, at least some of which are located within the receiving cavity, and the multiple battery layers are stacked sequentially along the height direction of the outer casing; a connecting structure including a first connector and a second connector, the first connector being used to connect the frames of two adjacent layers of the multiple battery layers along the height direction of the outer casing, and the second connector being used to connect the support beams of two adjacent layers of the multiple battery layers; along the height direction of the outer casing, the projections of the first connector and the second connector located on the same layer do not overlap.

[0049] By using a first connector to connect the frame of two adjacent battery layers and a second connector to connect the support beams of two adjacent battery layers, multi-point connections between the battery layers at two different locations—the frame and the support beams—are achieved, effectively improving the reliability of interlayer connections and the overall structural strength. Simultaneously, by staggering the first and second connectors located on the same layer in the height direction (their projections do not overlap), interlayer loads are distributed and transferred through different connectors, avoiding continuous stress concentration along a single vertical path. This staggered arrangement can disperse vibration, impact, and torsional stress generated during vehicle operation to different connection paths, significantly improving the overall torsional stiffness and vibration resistance of the battery pack. Attached Figure Description

[0050] 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 some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0051] Figure 1 This is a schematic diagram of the battery pack structure provided in an embodiment of this application;

[0052] Figure 2 This is a schematic diagram of the battery pack structure with the cover removed, provided in an embodiment of this application.

[0053] Figure 3 A cross-sectional view of the battery pack provided in an embodiment of this application from a first perspective;

[0054] Figure 4 A cross-sectional view of the battery pack provided in an embodiment of this application from a second perspective;

[0055] Figure 5 This is a schematic diagram of the structure of the battery pack cover provided in an embodiment of this application;

[0056] Figure 6 This is a schematic diagram of the structure of the first layer in the battery pack provided in an embodiment of this application;

[0057] Figure 7 This is a schematic diagram of the structure of a battery pack after the battery module is placed in the first layer, as provided in an embodiment of this application.

[0058] Figure 8 This is an assembly diagram of the first and second layers of the battery pack provided in an embodiment of this application;

[0059] Figure 9 This is a schematic diagram of a first partial assembly of the first and second layers of a battery pack provided in an embodiment of this application;

[0060] Figure 10 This is a schematic diagram of a second partial assembly of the first and second layers of a battery pack provided in an embodiment of this application.

[0061] Explanation of reference numerals in the attached figures:

[0062] 100-battery pack;

[0063] 110 - Outer casing; 111 - Cover; 112 - Lower casing; 1121 - Frame; 1122 - Support beam; 1101 - First mounting hole; 1102 - Second mounting hole; 1103 - Third mounting hole; 1104 - Fourth mounting hole; 1123 - First frame; 1124 - Recessed frame; 1125 - Second frame; 1126 - Protruding frame; 113 - Front panel; 114 - Rear panel;

[0064] 120 - Battery layer; 121 - First layer; 122 - Second layer; 123 - Third layer; 124 - Fourth layer; 1201 - Battery module; 1202 - Liquid cooling component;

[0065] 130 - Connection structure; 131 - First connector; 132 - Second connector. Detailed Implementation

[0066] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, 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 some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. All other obtained embodiments are within the scope of protection of this application. In the absence of conflict, the following embodiments and features can be combined with each other.

[0067] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0068] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0069] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0070] With the rapid development of new energy vehicle technology, the demand for battery systems with high energy density and high structural strength is becoming increasingly urgent. As the core power source for new energy commercial vehicles, multi-layer battery packs must be designed to simultaneously meet multiple requirements such as large-capacity energy storage, lightweight design, high safety, and structural stability.

[0071] Battery packs typically need to be integrated into the chassis or frame. Due to space constraints in the vehicle, battery packs require multi-layer stacking designs to achieve higher energy density and meet the demands for long driving range. However, current multi-layer structures suffer from insufficient interlayer bonding strength and poor torsional resistance.

[0072] To overcome the shortcomings of existing technologies, the battery pack and electrical equipment provided in this application achieve multi-point connections between battery layers at two different locations on the frame and support beams by setting a first connector to connect the frames of two adjacent battery layers and a second connector to connect the support beams of two adjacent battery layers. This effectively improves the reliability of interlayer connections and the overall structural strength. Simultaneously, by staggering the first and second connectors located on the same layer in the height direction (their projections do not overlap), the interlayer load is distributed and transferred through different connectors, avoiding continuous stress concentration along a single vertical path. This staggered arrangement can disperse the vibration, impact, and torsional stress generated during vehicle operation to different connection paths, significantly improving the overall torsional stiffness and vibration resistance of the battery pack.

[0073] The contents of this application will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can have a clearer and more detailed understanding of the contents of this application.

[0074] Figure 1 This is a schematic diagram of the battery pack structure provided in an embodiment of this application. Figure 2 This is a schematic diagram of the battery pack structure with the cover removed, provided in an embodiment of this application. Figure 3 This is a first-view cross-sectional view of the battery pack provided in an embodiment of this application. Figure 4 This is a cross-sectional view of the battery pack provided in an embodiment of this application from a second perspective. Figure 5 This is a schematic diagram of the structure of the battery pack cover provided in an embodiment of this application.

[0075] like Figures 1 to 5 As shown, this application provides a battery pack 100, including:

[0076] The outer box 110 includes a box cover 111 and a lower box body 112. The box cover 111 covers the lower box body 112, and the box cover 111 and the lower box body 112 form a receiving cavity. The lower box body 112 includes a frame 1121 and a support beam 1122 disposed on the frame 1121.

[0077] Multiple battery layers 120, at least some of which are located within the receiving cavity, are stacked sequentially along the height direction of the outer casing 110.

[0078] The connection structure 130 includes a first connector 131 and a second connector 132. Along the height direction of the outer casing 110, the first connector 131 is used to connect the frame 1121 of two adjacent layers in the multiple battery layers 120, and the second connector 132 is used to connect the support beam 1122 of two adjacent layers in the multiple battery layers 120.

[0079] Along the height direction of the outer casing 110, the projections of the first connector 131 and the second connector 132 located on the same layer do not overlap.

[0080] By configuring the first connector 131 to connect the frame 1121 of two adjacent battery layers 120 and the second connector 132 to connect the support beam 1122 of two adjacent battery layers 120, multi-point connections of the battery layers 120 at two different locations, namely the frame 1121 and the support beam 1122, are achieved, effectively improving the reliability of interlayer connections and the overall structural strength. Simultaneously, by staggering the first connector 131 and the second connector 132 located in the same layer in the height direction (their projections do not overlap), the interlayer load is dispersed and transferred through different connectors, avoiding continuous stress concentration along a single vertical path. This staggered arrangement can disperse the vibration, impact, and torsional stress generated during vehicle operation to different connection paths, significantly improving the overall torsional stiffness and vibration resistance of the battery pack 100.

[0081] Specifically, the multilayer battery pack 100 solves the problem of insufficient torsional resistance caused by stress concentration in traditional interlayer connections by using a staggered connection structure 130 (the projections of the first connector 131 and the second connector 132 do not overlap).

[0082] Traditional vertical alignment of interlayer connectors causes loads to be transmitted along a single path, easily leading to stress concentration areas. Staggered arrangement, however, disperses loads through asymmetrical paths, reducing stress concentration. For example, when a commercial vehicle experiences a vertical impact on a bumpy road, the staggered connectors decompose the impact force into stresses in multiple directions, preventing single-point failure. Simultaneously, the coordinated design of frame 1121 and support beam 1122 further enhances the rigidity of the interlayer connection, suppressing the swaying of the upper module. This design significantly improves the overall torsional stiffness of the battery pack, reduces the risk of frame 1121 deformation, and optimizes space utilization by reducing the number of redundant connectors through asymmetrical arrangement. Furthermore, the staggered connection structure 130 disperses vibration energy, reducing fatigue damage to the battery cells from high-frequency vibrations and extending the service life of the battery pack 100.

[0083] It should be noted that the battery pack 100 includes an outer casing 110 and multiple battery layers 120 located inside the outer casing 110.

[0084] The outer casing 110 includes a cover 111 and a lower casing 112. The cover 111 covers the lower casing 112, and the cover 111 and the lower casing 112 form a receiving cavity. The lower casing 112 serves as the basic load-bearing structure of the battery pack 100, and the cover 111 serves as the sealing structure. Together, they form a closed receiving cavity, providing installation space and protection for the battery layer 120. The lower casing 112 includes a frame 1121 and a support beam 1122 disposed on the frame 1121.

[0085] It should be noted that the outer casing 110 refers to the external encapsulation structure of the battery pack 100, which is used to house the battery layer 120 and provide protection.

[0086] In some examples, the outer casing 110 may be made of metal or composite material, and the casing cover 111 may be fixedly connected to the lower casing 112 by bolts.

[0087] For example, a frame structure consisting of a lid 111 and a lower box body 112.

[0088] Specifically, it should be noted that the cover 111 refers to the top sealing component of the outer casing 110, which is used to cover the battery module 1201 and provide top protection.

[0089] For example, the lid 111 and the lower box body 112 are connected by a metal or composite material cover plate by welding or snap-fit.

[0090] For example, the lower housing 112 is generally a rectangular frame structure with an open top. The lid 111 is placed over the opening, and the lid 111 and the lower housing 112 are sealed together by sealant or gasket, forming a receiving cavity.

[0091] The cavity refers to the internal space enclosed by the cover 111 and the lower casing 112, which is used to install the battery module 1201 and related structures.

[0092] For example, the box contains an enclosed space for housing the four-layer battery module 1201.

[0093] The receiving cavity is a closed cavity space used to house internal components such as the battery module 1201, and to provide waterproof, dustproof and impact-resistant protection for the internal components.

[0094] In some embodiments, the cover 111 can be made of sheet metal (such as aluminum or steel) through a stamping process, or it can be made of composite materials (such as carbon fiber reinforced composites or glass fiber reinforced composites) to meet the dual requirements of lightweight and strength. The lower housing 112 can be made of aluminum alloy profiles by welding or bolting, and has good structural strength and corrosion resistance.

[0095] The lower housing 112 is roughly rectangular in shape and has an opening at the top. The lid 111 is placed over the opening of the lower housing 112 and together with the lower housing 112, forms a closed receiving cavity.

[0096] It should be noted that frame 1121 refers to the support structure of battery layer 120, which is used to fix the module and transfer load.

[0097] For example, a rectangular or U-shaped metal structure consisting of a frame and beams.

[0098] It should be noted that the support beam 1122 refers to the longitudinal or transverse reinforcing structure installed on the frame 1121, which is used to enhance the stability of the inter-layer connection.

[0099] It should be noted that the multi-layer battery pack 100 refers to a battery pack 100 structure containing at least two layers of battery modules 1201, used to meet high energy density energy storage requirements. Multiple battery layers 120 refer to groups of battery modules 1201 stacked along the height direction Z, used to achieve capacity expansion.

[0100] For example, a commercial vehicle battery pack 100 includes a four-layer battery module 1201.

[0101] In some examples, the battery layer 120 includes at least four layers, each containing a battery module 1201 and a liquid cooler 1202.

[0102] Multiple battery layers 120 are at least partially located within the receiving cavity, along the height direction Z of the outer casing 110 (i.e., Figure 4 The battery layers 120 are stacked sequentially (in the Z direction shown). The multiple battery layers 120 include a first layer 121, a second layer 122, a third layer 123, and a fourth layer 124, wherein the first layer 121 is located at the bottom of the battery pack 100, and the fourth layer 124 is located at the top of the battery pack 100.

[0103] It is understood that the number of battery layers 120 is not limited to four layers. In other embodiments, the number of battery layers 120 can be two, three, or more than four layers.

[0104] It should be noted that the connection structure 130 refers to the mechanical structure used to connect adjacent battery layers 120, including a first connector 131 and a second connector 132. Exemplarily, it is an interlayer fixing device consisting of threaded fasteners and mounting holes.

[0105] Specifically, the connection structure 130 includes a first connector 131 and a second connector 132. Along the height direction (Z direction) of the outer casing 110, the first connector 131 is used to connect the frames 1121 of two adjacent layers in the plurality of battery layers 120, and the second connector 132 is used to connect the support beams 1122 of two adjacent layers in the plurality of battery layers 120. Along the height direction of the outer casing 110, the projections of the first connector 131 and the second connector 132 located on the same layer do not overlap. That is, in the same battery layer 120, the positions of the first connector 131 used to connect the layer with the frame 1121 of the layer above (or below) and the second connector 132 used to connect the layer with the support beam 1122 of the layer above (or below) are staggered in the height direction, and their projections on the horizontal plane do not overlap.

[0106] This staggered arrangement allows interlayer loads to be distributed and transmitted through different connection paths. When the battery pack 100 is subjected to vibration, impact, or torsional loads generated by vehicle movement, part of the load is transmitted along the frame 1121 through the first connector 131, and another part is transmitted along the support beam 1122 through the second connector 132. Because the first connector 131 and the second connector 132 are staggered in the height direction, the load is not continuously concentrated along the same vertical path, thus avoiding stress concentration. This is especially important for commercial vehicles used in complex road conditions such as bumpy roads and sharp turns.

[0107] It should be noted that the first connector 131 refers to a component used to connect two adjacent frame layers 1121, such as a screw or rivet. For example, a threaded bolt passing through mounting holes in two adjacent frame layers 1121.

[0108] It should be noted that the second connector 132 refers to a component used to connect two adjacent support beams 1122, such as a screw or rivet. For example, a threaded bolt passing through the mounting holes of two adjacent support beams 1122.

[0109] It should be noted that non-overlapping projections mean that the projection areas of the first connector 131 and the second connector 132 do not intersect in the height direction.

[0110] For example, the projection area of ​​the upper first connector 131 is completely separated from the projection area of ​​the lower second connector 132. This staggered design allows the frames 1121 and support beams 1122 of adjacent layers to transfer loads through asymmetrical paths, forming a three-dimensional stress dispersion network. The frames 1121 and support beams 1122 of the outer casing 110 are integrated into a single structure by welding or lap jointing, ensuring the stability of the interlayer connections.

[0111] In some alternative implementations, there are multiple first connectors 131;

[0112] Along the height direction of the outer casing 110, the projections of multiple first connectors 131 located on adjacent layers do not coincide; and / or,

[0113] There are multiple second connectors 132;

[0114] Along the height direction of the outer casing 110, the projections of multiple second connectors 132 located on adjacent layers do not overlap.

[0115] The above-mentioned technical solution has the following advantages or beneficial effects: By staggering the arrangement of multiple first connectors 131 and / or multiple second connectors 132 between adjacent layers in the height direction, the stress concentration of interlayer connections in the same vertical plane is further avoided, forming a multi-path, decentralized stress transfer network, which is conducive to further improving the overall strength of the box structure. At the same time, this staggered arrangement can also reduce the thickness requirements of the single-layer frame 1121 and the support beam 1122 to a certain extent, which is beneficial to lightweight design.

[0116] Specifically, multiple first connectors 131 and second connectors 132 are staggered along the height direction Z, so that the frame 1121 and support beam 1122 of adjacent two layers transmit loads through an asymmetric path.

[0117] For example, in two adjacent frame layers 1121, the four first connectors 131 of the upper layer and the four first connectors 131 of the lower layer are completely separated in the vertical direction, forming a multi-directional stress dispersion network. This design further optimizes the inter-layer load distribution and avoids single-point stress concentration by increasing the number of connectors and arranging them in a staggered manner.

[0118] It should be noted that the multiple first connectors 131 refer to multiple components used to connect two adjacent frame layers 1121, such as multiple threaded fasteners.

[0119] For example, each frame 1121 in the four-layer battery pack 100 is provided with 4 to 6 threaded bolts.

[0120] It should be noted that non-overlapping projections mean that the projection areas of multiple first connectors 131 do not overlap in the height direction. For example, the projection positions of the four bolts of the upper frame 1121 are offset from the projection positions of the four bolts of the lower frame 1121.

[0121] Furthermore, there are multiple first connectors 131, and the projections of multiple first connectors 131 located on adjacent layers do not overlap along the height direction of the outer casing 110. There are multiple second connectors 132, and the projections of multiple second connectors 132 located on adjacent layers do not overlap along the height direction of the outer casing 110. That is, between two adjacent battery layers 120, the positions of multiple first connectors 131 used to connect the two frame layers 1121 are staggered in the height direction; the positions of multiple second connectors 132 used to connect the two support beams 1122 are also staggered in the height direction.

[0122] It should be noted that the staggered arrangement of multiple connectors can be either evenly spaced but offset layer by layer along the 100mm length of the battery pack, or randomly staggered with non-uniform spacing, as long as the projections do not overlap. For standardized manufacturing, the connector holes in each layer can be designed to alternate with a fixed offset (e.g., half a hole spacing). Furthermore, the staggered spacing can be optimized using finite element analysis to achieve the most uniform stress distribution. When there are many connectors, they can also be grouped, with staggered arrangements within each group and symmetrical arrangements between groups, to balance assembly convenience and stress uniformity.

[0123] like Figures 1 to 5 As shown, in some optional embodiments, the plurality of battery layers 120 include a first layer 121, a second layer 122, a third layer 123 and a fourth layer 124, wherein the first layer 121 is located at the bottom of the battery pack 100 and the fourth layer 124 is located at the top of the battery pack 100.

[0124] The lid 111 is sealed to the frame 1121 located on the first layer 121.

[0125] The above technical solution has the following advantages or beneficial effects: By directly sealing the cover 111 to the frame 1121 of the first layer 121 at the bottom, there is no need to set up an additional independent sealing frame structure, which simplifies the structure of the outer box 110 and reduces the number of parts and the overall weight. At the same time, the direct sealing connection between the cover 111 and the frame 1121 of the first layer 121 ensures the airtightness of the cavity, effectively preventing external liquids and moisture from entering the battery pack 100 and improving the safety performance of the battery pack 100.

[0126] In this embodiment, the plurality of battery layers 120 includes a first layer 121, a second layer 122, a third layer 123, and a fourth layer 124. The first layer 121 is located at the bottom of the battery pack 100, and the fourth layer 124 is located at the top of the battery pack 100. It is understood that in other embodiments, the number of battery layers 120 may be set to two, three, five, or more layers according to actual needs, and this application does not impose any limitation on this.

[0127] The number of battery layers 120 is not limited to four layers. It can be designed to have two, three, or more layers depending on the vehicle space and energy requirements. At this time, the cover 111 is still sealed to the bottom layer (first layer 121) frame 1121, and the intermediate layers are connected to each other through the frame 1121 and the support beam 1122.

[0128] The cover 111 is sealed to the frame 1121 located on the first layer 121. The sealing connection can be achieved by means of sealant, gasket, sealing strip, etc.

[0129] In this embodiment, a sealing strip is provided between the box cover 111 and the side of the frame 1121 of the first layer 121, and the sealing is achieved by the elastic deformation of the sealing strip.

[0130] For example, the sealing strip can be made of materials with good elasticity and weather resistance, such as rubber and silicone.

[0131] For example, the sealing method between the lid 111 and the first layer 121 frame 1121 can be sealant, rubber sealing strip, metal sealing ring, or laser welding. Welding can improve sealing durability but is not easy to disassemble. For ease of maintenance, it is recommended to use a replaceable sealing strip in conjunction with a clamping structure. In addition, the lid 111 itself can be designed with a "U" or "V" shaped cross section to enhance bending stiffness, while its shape forms multiple sealing interfaces with the bottom frame 1121.

[0132] like Figure 5 As shown, along the height direction Z of the battery pack 100, the specific height H of the cover 111 is.

[0133] In some alternative embodiments, the outer casing 110 also includes panels, including a front panel 113 and a rear panel 114;

[0134] Along the length of the outer casing 110, the front panel 113 and the rear panel 114 are respectively located at opposite ends of the frame 1121 of the first layer 121;

[0135] The lid 111 is placed on the panel and the frame 1121 of the first layer 121, and the multiple edges of the lid 111 are respectively sealed to the top of the panel and the side of the frame 1121 of the first layer 121.

[0136] The above technical solution has the following advantages or beneficial effects: By having the front panel 113 and rear panel 114 respectively positioned at opposite ends of the first layer 121 frame 1121, together with the cover 111, a closed receiving cavity is formed, achieving protection and sealing of the battery layer 120 along its length. Multiple edges of the cover 111 are respectively sealed to the top of the panel and the sides of the first layer 121 frame 1121, forming a multi-directional, multi-layered sealing structure, further improving the sealing reliability of the battery pack 100.

[0137] Specifically, the outer casing 110 also includes panels, which include a front panel 113 and a rear panel 114. Along the length direction X of the outer casing 110, the front panel 113 and the rear panel 114 are respectively disposed at opposite ends of the frame 1121 of the first layer 121. A lid 111 is disposed on the panels and the frame 1121 of the first layer 121, and multiple edges of the lid 111 are respectively sealed to the top of the panels and the sides of the frame 1121 of the first layer 121.

[0138] With this structure, the lid 111, front panel 113, rear panel 114, and frame 1121 of the first layer 121 together form a closed receiving cavity. The lid 111 is directly and sealed to the frame 1121 of the first layer 121, eliminating the need for an additional independent sealing frame structure and simplifying the structure of the outer box 110.

[0139] Specifically, by reducing the number of layers 122, 123, and 124, the frame 1121 structure can be shorter than the frame 1121 of the first layer 121, thus reducing the number of components and the overall weight. Meanwhile, multiple edges of the cover 111 are sealed to the top of the panel and the sides of the first layer 121 frame 1121, forming a multi-directional, multi-layered sealing structure, further improving the sealing reliability of the battery pack 100.

[0140] The panels are located at both ends of the first layer 121 frame 1121, and the lid 111 is fixed to the panels and the first layer 121 frame 1121 via a sealing connection. For example, the edge of the lid 111 is connected to the top of the panel and the side of the frame 1121 by screws, and is coated with sealant to prevent liquid leakage. This design enhances the overall sealing of the package through the coordinated fixing of the panels and the lid 111, while the structural support of the panels improves the stability of the first layer 121 frame 1121.

[0141] It should be noted that the panel refers to the side sealing plate of the outer casing 110, which is used to fix the frame 1121 and enhance the structural strength.

[0142] For example, a metal panel consisting of a front panel 113 and a rear panel 114.

[0143] It should be noted that the sealed connection refers to the connection method between the lid 111 and the panel and frame 1121, such as fixing with screws and sealant. For example, the edge of the lid 111 is connected to the panel and frame 1121 with screws and coated with sealant.

[0144] In some embodiments, the panel can be integrally formed with the first layer 121 frame 1121, or it can be fixed by bolts or welding for easy replacement.

[0145] In some embodiments, electrical interfaces, vents or maintenance windows may be provided on the front panel 113 and the rear panel 114, but a sealed design (such as using a sealing plug or a waterproof connector) must be ensured.

[0146] In some embodiments, the sealing between the cover 111 and the top of the panel and the side of the frame 1121 can be achieved using a continuous sealing strip or a segmented sealing strip, with an arc transition at the corners to avoid stress concentration at sharp corners. Additionally, if the battery pack 100 is long, reinforcing ribs or crossbeams can be added in the middle, but it must be ensured that they do not interfere with the interlayer connection structure 130.

[0147] Figure 6 This is a schematic diagram of the structure of the first layer in the battery pack provided in the embodiments of this application. Figure 7 This is a schematic diagram of the structure of the battery pack after the battery module is placed in the first layer, as provided in the embodiment of this application.

[0148] like Figures 2 to 7 As shown, in some optional embodiments, each battery layer 120 includes a battery module 1201 and a liquid cooler 1202, the battery module 1201 is located on the liquid cooler 1202, and the liquid cooler 1202 has a liquid cooling channel for exchanging heat with the battery module 1201.

[0149] The frame 1121 is multi-layered, and the position of each frame 1121 corresponds to the position of the battery layer 120 of the corresponding layer, and the frame 1121 of each layer surrounds at least part of the periphery of the liquid cooler 1202 of the corresponding layer.

[0150] The support beams 1122 are multi-layered, with at least two support beams 1122 per layer. Along the length of the outer box 110, at least two support beams 1122 per layer are located at opposite ends of the frame 1121 of the corresponding layer. The support beams 1122 located at the ends of the frame 1121 of the same layer and the frame 1121 of the same layer surround the periphery of the liquid cooling component 1202 of the corresponding layer.

[0151] The above technical solution has the following advantages or beneficial effects: By surrounding at least part of the periphery of the liquid cooling component 1202 with the frame 1121 and the support beams 1122 located at opposite ends of the frame 1121, a three-dimensional enclosure structure for the battery module 1201 and the liquid cooling component 1202 is formed. The frame 1121 and the support beams 1122 together constitute the load-bearing skeleton of each battery layer 120, providing installation support for the battery module 1201 and the liquid cooling component 1202, and enhancing the structural rigidity of each battery layer 120. The liquid cooling component 1202 is provided with liquid cooling channels, which can effectively manage the thermal of the battery module 1201 and ensure that the battery operates within a suitable temperature range.

[0152] Specifically, each battery layer 120 includes a battery module 1201 and a liquid cooler 1202. The battery module 1201 is located on the liquid cooler 1202, which has a liquid cooling channel for heat exchange with the battery module 1201. A coolant (such as water or an aqueous ethylene glycol solution) flows through the liquid cooling channel. Through heat exchange between the coolant and the battery module 1201, cooling or heating of the battery module 1201 is achieved, ensuring that the battery module 1201 operates within a suitable temperature range and improving battery life and safety.

[0153] The frame 1121 has a multi-layer structure. The position of each frame 1121 corresponds to the position of the battery layer 120 of the corresponding layer, and the frame 1121 of each layer surrounds at least part of the periphery of the liquid cooler 1202 of the corresponding layer.

[0154] The support beams 1122 have a multi-layer structure, with at least two support beams 1122 in each layer. Along the length direction X of the outer casing 110, at least two support beams 1122 in each layer are located at opposite ends of the corresponding layer's frame 1121. The support beams 1122 located at the ends of the same layer's frame 1121, together with the same layer's frame 1121, surround the periphery of the corresponding layer's liquid cooling component 1202, forming a three-dimensional enclosure structure for the battery module 1201 and the liquid cooling component 1202.

[0155] In some embodiments, the liquid cooling component 1202 can be designed as a flat liquid cooling plate with serpentine or parallel flow channels machined inside, and the flow channel cross-section can be rectangular or circular.

[0156] In some embodiments, the liquid cooling component 1202 may also be an extruded hollow profile with welded end caps to form flow channels. A thermally conductive pad or thermally conductive adhesive may be added between the battery module 1201 and the liquid cooling component 1202 to improve thermal contact.

[0157] In some embodiments, when the frame 1121 surrounds the liquid cooling component 1202, a limiting boss or an elastic buffer pad may be provided on the inner wall of the frame 1121 to absorb manufacturing tolerances and vibration impacts.

[0158] In some embodiments, the number of support beams 1122 can be increased according to the weight of the battery module 1201. For example, three support beams 1122 (two ends and one middle) are set for each layer. The middle support beam 1122 also needs to be equipped with a second connector 132 to achieve inter-layer connection, and still needs to meet the requirement that its projection does not overlap with the first connector 131 of the same layer.

[0159] Figure 8 This is an assembly diagram of the first and second layers of the battery pack provided in an embodiment of this application. Figure 9 This is a partial assembly diagram of the first and second layers of the battery pack provided in an embodiment of this application. Figure 10 This is a schematic diagram of a second partial assembly of the first and second layers of a battery pack provided in an embodiment of this application.

[0160] like Figures 1 to 10 As shown, in some optional embodiments, the frame 1121 is provided with a first mounting hole 1101 and a second mounting hole 1102;

[0161] The first connector 131 passes through the first mounting hole 1101 on the same layer and the first mounting hole 1101 on the next layer on the same layer, so that the frames 1121 of the two adjacent layers are connected.

[0162] The first connector 131 passes through the second mounting hole 1102 on the same layer and the second mounting hole 1102 on the layer above it, so as to connect the frames 1121 of the two adjacent layers.

[0163] The support beam 1122 is provided with a third mounting hole 1103 and a fourth mounting hole 1104. The second connector 132 passes through the third mounting hole 1103 located on the same layer and the third mounting hole 1103 of the next layer on the same layer, so as to connect the support beams 1122 of adjacent layers.

[0164] The second connector 132 passes through the fourth mounting hole 1104 on the same floor and the fourth mounting hole 1104 on the floor above it, so that the support beams 1122 of the two adjacent floors are connected.

[0165] The above technical solution has the following advantages or beneficial effects: By providing a first mounting hole 1101 and a second mounting hole 1102 on the frame 1121, and a third mounting hole 1103 and a fourth mounting hole 1104 on the support beam 1122, the first connector 131 and the second connector 132 can pass through the mounting holes of the corresponding layers to achieve connection between adjacent layers. This mounting hole arrangement simplifies the interlayer connection operation and facilitates the assembly and maintenance of the battery pack 100. Simultaneously, each layer of the frame 1121 and support beam 1122 has two sets of mounting holes, one above the other, for connection with the layer above and the layer below, respectively, achieving independence and expandability of the interlayer connection.

[0166] Specifically, the frame 1121 is provided with a first mounting hole 1101 and a second mounting hole 1102. A first connector 131 passes through the first mounting hole 1101 on the same layer and the first mounting hole 1101 on the next layer, connecting adjacent frames 1121. The first connector 131 also passes through the second mounting hole 1102 on the same layer and the second mounting hole 1102 on the layer above, connecting adjacent frames 1121.

[0167] In other words, each frame 1121 is provided with a first mounting hole 1101 for connecting to the next layer and a second mounting hole 1102 for connecting to the previous layer, and the two sets of mounting holes are located at different positions in the height direction.

[0168] The support beam 1122 is provided with a third mounting hole 1103 and a fourth mounting hole 1104. The second connector 132 passes through the third mounting hole 1103 located on the same floor and the third mounting hole 1103 of the floor below it, so as to connect the support beams 1122 of adjacent floors. The second connector 132 passes through the fourth mounting hole 1104 located on the same floor and the fourth mounting hole 1104 of the floor above it, so as to connect the support beams 1122 of adjacent floors.

[0169] In some embodiments, the first mounting hole 1101, the second mounting hole 1102, the third mounting hole 1103 and the fourth mounting hole 1104 can be through holes or blind holes. If threaded holes are used, it is convenient to use bolts; if plain holes are used, they can be used with rivets or bolts with nuts.

[0170] In some embodiments, to ensure positioning accuracy, positioning pin holes or positioning grooves can be added to the frame 1121 and the support beam 1122, and the connectors can be installed after alignment by positioning pins.

[0171] In addition, the arrangement of mounting holes is not limited to a single independent hole. They can be designed as elongated holes to adjust for assembly errors, or as multiple rows of holes to provide different connection position options, thereby adapting to different floor heights or different load requirements.

[0172] For the bottom layer (first layer 121), no connection is required below it, so its first mounting hole 1101 and third mounting hole 1103 can be omitted or used only as mounting holes for fixing to the base frame; for the top layer (fourth layer 124), no connection is required above it, so its second mounting hole 1102 and fourth mounting hole 1104 can be omitted.

[0173] In some alternative embodiments, there is a height difference between the first mounting hole 1101 and the second mounting hole 1102 located on the same layer;

[0174] There is a height difference between the third mounting hole 1103 and the fourth mounting hole 1104 located on the same layer;

[0175] The first mounting hole 1101 and the third mounting hole 1103, which are located on the same layer, have the same height, and the second mounting hole 1102 and the fourth mounting hole 1104, which are located on the same layer, have the same height.

[0176] The above technical solution has the following advantages or beneficial effects: By setting a height difference between the first mounting hole 1101 and the second mounting hole 1102 on the same layer, and setting a height difference between the third mounting hole 1103 and the fourth mounting hole 1104, the staggered arrangement (projection does not overlap) of the first connector 131 and the second connector 132 on the same layer in the height direction is achieved. At the same time, by making the first mounting hole 1101 and the third mounting hole 1103 at the same height, and the second mounting hole 1102 and the fourth mounting hole 1104 at the same height, it is ensured that the frame 1121 and the support beam 1122 are connected to the adjacent layer at the same height position through the first connector 131 and the second connector 132 respectively, forming a cooperative interlayer connection system of the frame 1121 and the support beam 1122, which is conducive to the uniform transfer of load between the frame 1121 and the support beam 1122.

[0177] Specifically, there is a height difference between the first mounting hole 1101 and the second mounting hole 1102 located on the same layer; there is also a height difference between the third mounting hole 1103 and the fourth mounting hole 1104 located on the same layer. The first mounting hole 1101 and the third mounting hole 1103 located on the same layer are at the same height, and the second mounting hole 1102 and the fourth mounting hole 1104 located on the same layer are at the same height. Through this height setting, the first connector 131 and the second connector 132 on the same layer are staggered in the height direction.

[0178] It is understandable that there is a height difference between the first mounting hole 1101 and the second mounting hole 1102, and a height difference between the third mounting hole 1103 and the fourth mounting hole 1104; simultaneously, the first mounting hole 1101 and the third mounting hole 1103 are at the same height, and the second mounting hole 1102 and the fourth mounting hole 1104 are at the same height. Thus, when the first connector 131 passes through the first mounting hole 1101 to connect to an adjacent layer, the second connector 132 passes through the third mounting hole 1103 at the same height, and both work together but connect the frame 1121 and the support beam 1122 respectively; while when the first connector 131 passes through the second mounting hole 1102, the second connector 132 passes through the fourth mounting hole 1104 at a different height. This height matching ensures that the frame 1121 and the support beam 1122 cooperate in bearing load within the same layer, while achieving inter-layer misalignment due to the use of different height holes between upper and lower layers. This relationship is a direct structural implementation method for connector projections not overlapping.

[0179] In some embodiments, the specific value of the height difference should not be less than the thickness of the connector head or washer, and is typically 1 to 2 times the connector diameter. For example, for an M10 bolt, the height difference can be 10mm to 20mm. This height difference can also be adjusted according to the cross-sectional dimensions of the frame 1121 and the support beam 1122 to balance space utilization and strength. If a larger misalignment is required, a multi-level stepped structure can be designed on the frame 1121 and the support beam 1122 to make the height difference between the upper and lower connecting holes larger. In addition, the consistent height of the first mounting hole 1101 and the third mounting hole 1103 ensures that the frame 1121 and the support beam 1122 are subjected to force simultaneously on the same horizontal plane, which is beneficial for even load distribution and avoids any part bearing the load alone.

[0180] In some alternative embodiments, the frame 1121 includes a first side frame 1123 and a concave side frame 1124 connected together, a first mounting hole 1101 is provided in the concave side frame 1124, and a second mounting hole 1102 is provided in the first side frame 1123.

[0181] The support beam 1122 includes a connected second frame 1125 and a convex frame 1126, a third mounting hole 1103 is provided in the second frame 1125, and a fourth mounting hole 1104 is provided in the convex frame 1126.

[0182] The height of the first border 1123 is the same as the height of the convex border 1126, and the height of the concave border 1124 is the same as the height of the second border 1125.

[0183] The above technical solution has the following advantages or beneficial effects: By adopting a first side frame 1123 and a concave side frame 1124 for the frame 1121, and a second side frame 1125 and a convex side frame 1126 for the support beam 1122, the complementary cooperation of the concave side frame 1124 and the convex side frame 1126 in the height direction achieves spatial misalignment between the frame 1121 and the support beam 1122, as well as misalignment of the mounting holes for the connectors. The height of the first side frame 1123 is the same as the height of the convex side frame 1126, and the height of the concave side frame 1124 is the same as the height of the second side frame 1125, so that the frame 1121 and the support beam 1122 can form a flat mating surface during assembly, which facilitates the sequential stacking and connection of the multi-layer battery layers 120, while ensuring the misalignment effect of the connection structure 130 in the height direction.

[0184] Specifically, such as Figure 9 As shown, frame 1121 includes a first side frame 1123 and a concave side frame 1124 connected together. A first mounting hole 1101 is provided in the concave side frame 1124, and a second mounting hole 1102 is provided in the first side frame 1123. Support beam 1122 includes a second side frame 1125 and a convex side frame 1126 connected together. A third mounting hole 1103 is provided in the second side frame 1125, and a fourth mounting hole 1104 is provided in the convex side frame 1126. The height of the first side frame 1123 is the same as the height of the convex side frame 1126, and the height of the concave side frame 1124 is the same as the height of the second side frame 1125.

[0185] Through this structural design, the concave frame 1124 and the convex frame 1126 complement each other in the height direction. When the frame 1121 and the support beam 1122 are assembled together, the position of the concave frame 1124 (the position of the first mounting hole 1101) corresponds to the position of the convex frame 1126 (the position of the fourth mounting hole 1104) in height, and the position of the first frame 1123 (the position of the second mounting hole 1102) corresponds to the position of the second frame 1125 (the position of the third mounting hole 1103) in height. Thus, when the first connector 131 passes through the first mounting hole 1101 to connect to the adjacent layer frame 1121, its height position is different from that of the second connector 132 passing through the fourth mounting hole 1104 to connect to the adjacent layer support beam 1122; when the first connector 131 passes through the second mounting hole 1102 to connect to the adjacent layer frame 1121, its height position is different from that of the second connector 132 passing through the third mounting hole 1103 to connect to the adjacent layer support beam 1122. This achieves a staggered arrangement of the first connector 131 and the second connector 132 in the same layer in the height direction.

[0186] like Figure 6 As shown, in some embodiments, the top of the frame 1121 located in the first layer 121 is horizontal and does not involve the first border 1123 and the concave border 1124.

[0187] In some embodiments, the first layer 121, which is the bottom structure of the battery pack 100, includes a front panel 113, a rear panel 114, frames 1121 on both sides of the width direction Y of the battery pack 100, and three support beams 1122 spaced apart along the length direction X of the battery pack 100, wherein the liquid cooling component 1202 of the first layer 121 is the bottom plate of the entire battery pack 100.

[0188] Furthermore, the cross-section of the frame is not limited to a simple "L" shaped bend; it can be designed as a "Z" shape or a "stepped" shape, forming multiple height levels through multiple bends. If casting or extrusion processes are used, profiles with protrusions and recesses can be integrally formed, reducing welding steps. In terms of materials, the frame 1121 and support beam 1122 can be made of high-strength aluminum alloy or steel, achieving complex cross-sections through extrusion molding, ensuring strength while reducing weight. Simultaneously, a buffer pad can be installed in the gap between the concave frame 1124 and the convex frame 1126 to absorb assembly errors and vibrations.

[0189] In some alternative embodiments, at least one of the first connector 131 and the second connector 132 is a threaded fastener;

[0190] At least one of the first mounting hole 1101, the second mounting hole 1102, the third mounting hole 1103, and the fourth mounting hole 1104 is a threaded hole.

[0191] The above technical solution has the following advantages or beneficial effects: by using threaded fasteners as connectors and cooperating with threaded holes to achieve interlayer connection, the connection is reliable, easy to assemble and disassemble, and facilitates the assembly, maintenance, and repair of the battery pack 100. The threaded connection method can provide a stable preload, ensuring the long-term reliability of the interlayer connection.

[0192] In this embodiment, both the first connector 131 and the second connector 132 are threaded fasteners (such as bolts, screws, etc.). The first mounting hole 1101, the second mounting hole 1102, the third mounting hole 1103, and the fourth mounting hole 1104 are all threaded holes. The mating connection between the threaded fasteners and the threaded holes provides a stable preload, ensuring the long-term reliability of the interlayer connection, while also facilitating disassembly and assembly, and making it convenient for the assembly and maintenance of the battery pack 100.

[0193] In some embodiments, in addition to common threaded fasteners (such as socket head cap screws and head cap screws), anti-loosening threads (such as nylon insert lock nuts and adhesive-coated bolts) can be used to prevent loosening caused by vehicle vibration. Besides threaded holes, mounting holes can also be smooth holes fitting a combination of bolt and nut, but threaded holes are more compact and require no additional nut space. For corrosion protection, the connectors can undergo surface treatments (such as Dacromet coating, galvanizing, or phosphating). Furthermore, a locating bushing can be added inside the threaded hole, allowing the bolt to not only provide tightening force but also act as a locating pin, further improving interlayer alignment accuracy.

[0194] It should be noted that this embodiment describes the assembly method of the battery pack 100.

[0195] First, the frame 1121 and support beam 1122 of the first layer 121 are installed in the predetermined position. The liquid cooling component 1202 and battery module 1201 of the first layer 121 are installed in the space enclosed by the frame 1121 and support beam 1122. The front panel 113 and the rear panel 114 are respectively installed at the opposite ends of the frame 1121 of the first layer 121.

[0196] Then, the frame 1121 and support beam 1122 of the second layer 122 are placed above the first layer 121. The first connector 131 passes through the first mounting hole 1101 on both the second layer 122 frame 1121 and the first layer 121 frame 1121, connecting the second layer 122 frame 1121 to the first layer 121 frame 1121. The second connector 132 passes through the third mounting hole 1103 on both the second layer 122 support beam 1122 and the first layer 121 support beam 1122, connecting the second layer 122 support beam 1122 to the first layer 121 support beam 1122. Since the first mounting hole 1101 and the third mounting hole 1103 are at the same height, the first connector 131 and the second connector 132 are located at the same height in the vertical direction.

[0197] Next, the frame 1121 and support beam 1122 of the third layer 123 are placed above the second layer 122. The first connector 131 passes through the second mounting holes 1102 on the frame 1121 of the third layer 123 and the second mounting holes 1102 on the frame 1121 of the second layer 122, connecting the frame 1121 of the third layer 123 to the frame 1121 of the second layer 122. The second connector 132 passes through the fourth mounting holes 1104 on the support beam 1122 of the third layer 123 and the support beam 1122 of the second layer 122, connecting the support beam 1122 of the third layer 123 to the support beam 1122 of the second layer 122. Since the second mounting holes 1102 and the fourth mounting holes 1104 are at the same height, the first connector 131 and the second connector 132 are located at the same height in the vertical direction. However, there is a height difference between the second mounting hole 1102 and the first mounting hole 1101, and a height difference between the fourth mounting hole 1104 and the third mounting hole 1103. Therefore, the first connector 131 and the second connector 132 used to connect the third layer 123 and the second layer 122 are offset in the height direction from the first connector 131 and the second connector 132 used to connect the second layer 122 and the first layer 121.

[0198] Following the above method, complete the assembly of the fourth layer, 124, and subsequent layers in sequence.

[0199] Finally, the lid 111 is placed on the panel and the frame 1121 of the first layer 121, and a seal is achieved through a sealing connection.

[0200] The battery pack provided in this application includes an outer casing, which includes a cover and a lower casing. The cover is disposed on the lower casing, and the cover and the lower casing form a receiving cavity. The lower casing includes a frame and a support beam disposed on the frame. Multiple battery layers, at least some of which are located within the receiving cavity, are stacked sequentially along the height direction of the outer casing. A connecting structure includes a first connector and a second connector. Along the height direction of the outer casing, the first connector is used to connect the frames of two adjacent battery layers, and the second connector is used to connect the support beams of two adjacent battery layers. Along the height direction of the outer casing, the projections of the first connector and the second connector located on the same layer do not overlap.

[0201] By using a first connector to connect the frame of two adjacent battery layers and a second connector to connect the support beams of two adjacent battery layers, multi-point connections between the battery layers at two different locations—the frame and the support beams—are achieved, effectively improving the reliability of interlayer connections and the overall structural strength. Simultaneously, by staggering the first and second connectors located on the same layer in the height direction (their projections do not overlap), interlayer loads are distributed and transferred through different connectors, avoiding continuous stress concentration along a single vertical path. This staggered arrangement can disperse vibration, impact, and torsional stress generated during vehicle operation to different connection paths, significantly improving the overall torsional stiffness and vibration resistance of the battery pack.

[0202] In addition, this application embodiment also provides an electrical device, including a vehicle body and the aforementioned battery pack 100.

[0203] This electrical equipment can be used in new energy commercial vehicles, such as electric buses, electric vehicles, and electric heavy trucks. The battery pack 100 can be integrated into the vehicle's chassis or frame, achieving higher energy density within a limited vehicle space through a multi-layer stacking design. Thanks to the aforementioned battery pack 100, this electrical equipment exhibits excellent structural stability and resistance to vibration and impact under complex road conditions, while also achieving high energy density and lightweight design.

[0204] It is understandable that this electrical equipment is not limited to new energy commercial vehicles, but can also be used for any electrical equipment that requires high energy density and high structural strength battery packs, such as electric passenger vehicles, electric construction machinery, and energy storage equipment.

[0205] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0206] Furthermore, 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. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0207] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A battery pack, characterized in that, include: The outer box (110) includes a box cover (111) and a lower box body (112). The box cover (111) covers the lower box body (112), and the box cover (111) and the lower box body (112) form a receiving cavity. The lower box body (112) includes a frame (1121) and a support beam (1122) disposed on the frame (1121). Multiple battery layers (120), at least a portion of the multiple battery layers (120) are located within the receiving cavity, and the multiple battery layers (120) are stacked sequentially along the height direction of the outer casing (110); The connection structure (130) includes a first connector (131) and a second connector (132). Along the height direction of the outer casing (110), the first connector (131) is used to connect the frames (1121) of two adjacent layers in the plurality of battery layers (120), and the second connector (132) is used to connect the support beams (1122) of two adjacent layers in the plurality of battery layers (120). Along the height direction of the outer casing (110), the projections of the first connector (131) and the second connector (132) located on the same layer do not overlap.

2. The battery pack according to claim 1, characterized in that, The first connector (131) is multiple; Along the height direction of the outer casing (110), the projections of multiple first connectors (131) located on adjacent layers do not coincide; and / or, The second connector (132) is multiple; Along the height direction of the outer casing (110), the projections of multiple second connectors (132) located on adjacent layers do not overlap.

3. The battery pack according to claim 1 or 2, characterized in that, The plurality of battery layers (120) include a first layer (121), a second layer (122), a third layer (123) and a fourth layer (124), wherein the first layer (121) is located at the bottom of the battery pack and the fourth layer (124) is located at the top of the battery pack; The lid (111) is sealed to the frame (1121) located in the first layer (121).

4. The battery pack according to claim 3, characterized in that, The outer casing (110) also includes a panel, which includes a front panel (113) and a rear panel (114). Along the length of the outer casing (110), the front panel (113) and the rear panel (114) are respectively located at opposite ends of the frame (1121) of the first layer (121); The lid (111) is placed on the panel and the frame (1121) of the first layer (121), and multiple edges of the lid (111) are respectively sealed to the top of the panel and the side of the frame (1121) of the first layer (121).

5. The battery pack according to claim 1 or 2, characterized in that, Each of the battery layers (120) includes a battery module (1201) and a liquid cooler (1202), the battery module (1201) being located on the liquid cooler (1202), the liquid cooler (1202) having a liquid cooling channel for exchanging heat with the battery module (1201); The frame (1121) is multi-layered, and the position of the frame (1121) of each layer corresponds to the position of the battery layer (120) of the corresponding layer, and the frame (1121) of each layer surrounds at least a portion of the periphery of the liquid cooling component (1202) of the corresponding layer. The support beam (1122) is multi-layered, with at least two support beams (1122) in each layer. Along the length of the outer box (110), at least two support beams (1122) in each layer are located at opposite ends of the frame (1121) of the corresponding layer. The support beams (1122) located at the ends of the frame (1121) of the same layer and the frame (1121) of the same layer surround the periphery of the liquid cooling component (1202) of the corresponding layer.

6. The battery pack according to claim 1 or 2, characterized in that, The frame (1121) is provided with a first mounting hole (1101) and a second mounting hole (1102). The first connector (131) passes through the first mounting hole (1101) on the same layer and the first mounting hole (1101) on the next layer of the same layer, so that the frames (1121) of the two adjacent layers are connected; The first connector (131) passes through the second mounting hole (1102) located on the same layer and the second mounting hole (1102) on the upper layer of the same layer, so that the frames (1121) of the two adjacent layers are connected; The support beam (1122) is provided with a third mounting hole (1103) and a fourth mounting hole (1104). The second connector (132) passes through the third mounting hole (1103) located on the same layer and the third mounting hole (1103) of the next layer on the same layer, so that the support beams (1122) of the two adjacent layers are connected. The second connector (132) passes through the fourth mounting hole (1104) located on the same layer and the fourth mounting hole (1104) of the layer above it, so that the support beams (1122) of the two adjacent layers are connected.

7. The battery pack according to claim 6, characterized in that, There is a height difference between the first mounting hole (1101) and the second mounting hole (1102) located on the same layer; There is a height difference between the third mounting hole (1103) and the fourth mounting hole (1104) located on the same layer; The first mounting hole (1101) and the third mounting hole (1103) located on the same layer have the same height, and the second mounting hole (1102) and the fourth mounting hole (1104) located on the same layer have the same height.

8. The battery pack according to claim 7, characterized in that, The frame (1121) includes a first side frame (1123) and a concave side frame (1124) connected together. The first mounting hole (1101) is provided in the concave side frame (1124), and the second mounting hole (1102) is provided in the first side frame (1123). The support beam (1122) includes a connected second frame (1125) and a convex frame (1126), the third mounting hole (1103) is provided on the second frame (1125), and the fourth mounting hole (1104) is provided on the convex frame (1126). The height of the first border (1123) is the same as the height of the convex border (1126), and the height of the concave border (1124) is the same as the height of the second border (1125).

9. The battery pack according to claim 6, characterized in that, At least one of the first connector (131) and the second connector (132) is a threaded fastener; At least one of the first mounting hole (1101), the second mounting hole (1102), the third mounting hole (1103), and the fourth mounting hole (1104) is a threaded hole.

10. An electrical appliance, characterized in that, Includes the battery pack as described in any one of claims 1-9.

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