Battery pack box structure and power battery pack

Abstract

The application provides a battery pack box structure and a power battery pack, and relates to the technical field of the power battery pack.The battery pack box structure provided by the application can flexibly adjust the containing layer number of the battery cell module unit and the hierarchical combination mode of the battery pack box structure according to different power requirements, realizes the layered battery pack box structure that can be combined as required, improves the modular degree of the power battery pack, facilitates the increase and decrease of the power of the power battery pack, and improves the adaptability when the vehicle is in different working conditions.

Description

Technical Field

[0001] This application relates to power battery pack technology, and more particularly to a battery pack housing structure and a power battery pack. Background Technology

[0002] With the rapid development of electric vehicles and other new energy fields, the standardization and modularity of the power battery pack, as a core component of the vehicle, have become key factors determining overall efficiency and production productivity. As the power source for new energy vehicles, the amount of electrical energy stored in the power battery pack determines the vehicle's driving range. The power battery pack needs to meet the energy demands of new energy vehicles under different operating conditions. For example, short-distance transportation requires less power to maintain lightweight design, while long-distance transportation requires more power to support longer driving range.

[0003] Traditional power battery packs consist of a housing and battery cells housed within the housing. In the traditional approach, the overall capacity of the power battery pack is adjusted by increasing or decreasing the number of battery cells. The pack is then integrated with the housing and installed in new energy vehicles. Once the power battery pack is manufactured, the amount of energy it can store is constant.

[0004] However, the aforementioned power battery packs have a low degree of modularity, resulting in poor adaptability and an inability to meet the graded power requirements of new energy vehicles under different operating conditions. Summary of the Invention

[0005] In view of this, this application provides a battery pack housing structure and a power battery pack, which aims to improve the modularity of the power battery pack, facilitate the increase or decrease of the power battery pack capacity, and improve adaptability to different vehicle operating conditions.

[0006] To achieve the above objectives, this application provides a battery pack housing structure and a power battery pack, which adopts the following technical solution:

[0007] In a first aspect, this application provides a battery pack housing structure, including:

[0008] Upper housing assembly for accommodating at least one layer of battery cell module unit;

[0009] At least one middle-layer housing assembly is provided for housing a layer of battery cell module units. Each of the middle-layer housing assemblies in the at least one middle-layer housing assembly is detachably connected in sequence along the height direction. The at least one middle-layer housing assembly is detachably connected to the bottom of the upper-layer housing assembly.

[0010] The lower housing assembly is used to house a layer of battery cell module units, and the lower housing assembly is detachably connected to the side of the at least one middle housing assembly opposite to the upper housing assembly.

[0011] In one possible implementation, the battery pack housing structure provided in this application includes an upper housing assembly comprising a first side beam, a second side beam, a first panel, and a second panel.

[0012] The first side beam, the second side beam, the first panel, and the second panel are connected end to end in sequence.

[0013] The upper housing assembly further includes a first cold plate, which is connected to the bottom of at least one of the first side beam and the second side beam;

[0014] The first side beam, the second side beam, the first panel, the second panel, and the first cold plate together form a first receiving cavity, which is used to accommodate at least one layer of the battery cell module unit.

[0015] In one possible implementation, the battery pack housing structure provided in this application further includes at least one second cold plate;

[0016] The height of the first panel and the second panel is greater than the height of the first side beam and the second side beam, so that a portion of the first panel and a portion of the second panel extend beyond the outside of the first side beam and the second side beam;

[0017] Each of the at least one second cold plate is arranged along the height direction, and the two ends of the second cold plate are respectively connected to a portion of the first panel and a portion of the second panel extending to the outside of the first side beam and the second side beam, so that the at least one second cold plate divides the first receiving cavity into at least two sub-receiving cavities, each of the sub-receiving cavities being used to accommodate one layer of the battery cell module unit.

[0018] In one possible implementation, the battery pack housing structure provided in this application further includes a U-shaped cover, which covers the at least one second cold plate, and the two ends of the U-shaped cover are respectively connected to the first panel and the second panel.

[0019] The bottom wall of the U-shaped box cover is connected to both the first side beam and the second side beam.

[0020] In one possible implementation, the battery pack housing structure provided in this application has a first mounting surface and a second mounting surface on the first side beam or the second side beam.

[0021] The first mounting surface is a horizontal surface and is used to connect with the second cold plate; the second mounting surface is a vertical surface and is used to connect with the U-shaped box cover.

[0022] A sealing groove is provided between the first mounting surface and the second mounting surface. The sealing groove is used to install a sealant to seal the gap between the U-shaped box cover and the first side beam or the second side beam.

[0023] In one possible implementation, the battery pack housing structure provided in this application includes a middle housing assembly comprising a first mounting frame and a third cold plate;

[0024] The third cold plate is connected to the bottom end of the first mounting frame. The third cold plate and the first mounting frame together form a second receiving cavity, which is used to accommodate one layer of the battery cell module unit.

[0025] In one possible implementation, the battery pack housing structure provided in this application includes a lower housing assembly comprising a second mounting frame and a fourth cold plate.

[0026] The fourth cold plate is connected to the bottom end of the second mounting frame. The fourth cold plate and the second mounting frame together form a third receiving cavity, which is used to accommodate one layer of the battery cell module unit.

[0027] The second mounting frame and one of the adjacent first mounting frames are connected along the height direction.

[0028] In one possible implementation, the battery pack housing structure provided in this application has a first mounting frame with a plurality of first connecting holes along the circumference, and a second mounting frame with a plurality of second connecting holes along the circumference. The first connecting holes and the second connecting holes correspond one-to-one, and the first connecting holes and the second connecting holes are used for connection by connectors.

[0029] In one possible implementation, the battery pack housing structure provided in this application includes a cantilever on the outer wall of the first mounting frame, and a plurality of bushings arranged along the length of the cantilever on the cantilever, the bushings being used to connect to the vehicle body.

[0030] Secondly, this application provides a power battery pack, including the aforementioned battery pack housing structure and at least three layers of cell module units, all of which are disposed within the battery pack housing structure.

[0031] The battery pack housing structure and power battery pack provided in this application include an upper housing assembly, a lower housing assembly, and at least one middle housing assembly; the upper housing assembly is used to house at least one layer of cell module units; the middle housing assembly is used to house one layer of cell module units, and each of the at least one middle housing assembly is detachably connected sequentially along the height direction, and at least one middle housing assembly is detachably connected to the bottom of the upper housing assembly; the lower housing assembly is used to house one layer of cell module units, and the lower housing assembly is detachably connected to the side of at least one middle housing assembly opposite to the upper housing assembly.

[0032] By setting up an upper-layer housing assembly, at least one middle-layer housing assembly, and a lower-layer housing assembly, and making each middle-layer housing assembly detachably connected sequentially along the height direction, and the middle-layer housing assembly detachably connected to the upper-layer housing assembly and the lower-layer housing assembly respectively, the number of cell module units and the hierarchical combination of the battery pack housing structure can be flexibly adjusted according to different power requirements. This achieves a layered battery pack housing structure that can be combined as needed, improves the modularity of the power battery pack, facilitates the increase or decrease of the power battery pack capacity, and improves adaptability to different vehicle operating conditions.

[0033] In addition to the technical problems solved by the embodiments of this application, the technical features constituting the technical solutions, and the beneficial effects brought about by the technical features of these technical solutions described above, other technical problems that can be solved by the technical solutions provided by this application, other technical features contained in the technical solutions, and the beneficial effects brought about by these technical features will be further explained in detail in the specific embodiments. Attached Figure Description

[0034] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0035] Figure 1 This is a schematic diagram of the structure of the power battery pack provided in the embodiments of this application;

[0036] Figure 2 This is a structural schematic diagram of the power battery pack provided in an embodiment of this application from another perspective;

[0037] Figure 3 This is a partial structural schematic diagram of the upper housing assembly provided in an embodiment of this application;

[0038] Figure 4 This is a schematic diagram of the structure of the second cold plate provided in an embodiment of this application;

[0039] Figure 5 An exploded view of the upper housing assembly provided in an embodiment of this application;

[0040] Figure 6 This is a schematic diagram of the upper housing assembly provided in an embodiment of this application;

[0041] Figure 7 This is a partial structural schematic diagram of the first and second mounting surfaces provided in an embodiment of this application;

[0042] Figure 8 This is a schematic diagram of the structure of the middle-layer housing assembly provided in the embodiments of this application;

[0043] Figure 9 This is a schematic diagram of the structure of the lower housing assembly provided in an embodiment of this application;

[0044] Figure 10 An exploded structural diagram of the middle-layer housing assembly and the lower-layer housing assembly provided in the embodiments of this application;

[0045] Figure 11 This is a schematic diagram of the structure of a power battery pack provided in another embodiment of this application.

[0046] Explanation of reference numerals in the attached figures:

[0047] 10. Battery cell module unit; 20. First reinforcing member; 30. Second reinforcing member; 40. Cantilever; 50. Electrical connector; 60. Liquid cooling water nozzle; 100. Upper housing assembly; 101. First receiving cavity; 110. First side beam; 1101. First mounting surface; 1102. Second mounting surface; 1103. Sealing groove; 120. Second side beam; 130. First panel; 140. Second panel; 150. Second cold plate; 160. First crossbeam; 170. U-shaped lid; 180. First cold plate; 200. Middle layer box assembly; 201. Second receiving cavity; 202. Second connecting hole; 210. First mounting frame; 220. Third cold plate; 230. Second crossbeam; 300. Lower layer box assembly; 301. Third receiving cavity; 302. First connecting hole; 310. Second mounting frame; 320. Fourth cold plate; 330. Third crossbeam.

[0048] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0049] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the embodiments of this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of the embodiments of this application.

[0050] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0051] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0052] In the description of the embodiments of this application, it should be understood that the terms "upper", "lower", "front", "rear", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They 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. Therefore, they should not be construed as limitations on this application.

[0053] In the description of the embodiments of this application, "a plurality of" means two or more, unless otherwise specified precisely.

[0054] The terms “first,” “second,” “third,” “fourth,” etc., used in the description of this application and in the above-mentioned figures are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0055] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such that a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or apparatus.

[0056] As mentioned in the background technology, with the rapid development of new energy fields such as electric vehicles, the standardization and modularity of the power battery pack, as the core component of the vehicle, have become key factors determining overall efficiency and production efficiency.

[0057] As the power source for new energy vehicles, the amount of electrical energy stored in the battery pack determines the driving range of these vehicles. The battery pack needs to meet the electrical energy demands of new energy vehicles under different operating conditions. For example, short-distance transportation requires less power to maintain lightweight design, while long-distance transportation requires more power to support longer driving range.

[0058] Traditional power battery packs consist of a casing and battery cells housed within it. In the traditional approach, the overall capacity of the battery pack is adjusted by increasing or decreasing the number of cells before being integrated with the casing and installed in new energy vehicles. Once manufactured, the capacity of this type of battery pack is constant. For example, CTP (Cell To Pack) multilayer battery packs are widely used in new energy vehicles, typically employing a layered stacking of cell modules to expand capacity. However, existing multilayer battery packs often have a fixed number of layers and a fixed layout, lacking adaptability to varying power demands under different operating conditions, often necessitating the development of separate products with different specifications.

[0059] Based on the above-mentioned technical problems, this application provides a battery pack housing structure and a power battery pack. In this technical solution, the battery pack housing structure includes an upper housing assembly, a lower housing assembly, and at least one middle housing assembly. The upper housing assembly is used to house at least one layer of battery cell module units. The middle housing assembly is used to house one layer of battery cell module units. Each of the at least one middle housing assembly is detachably connected sequentially along the height direction. At least one middle housing assembly is detachably connected to the bottom of the upper housing assembly. The lower housing assembly is used to house one layer of battery cell module units. The lower housing assembly is detachably connected to the side of at least one middle housing assembly opposite to the upper housing assembly.

[0060] By setting up an upper-layer housing assembly, at least one middle-layer housing assembly, and a lower-layer housing assembly, and making each middle-layer housing assembly detachably connected sequentially along the height direction, and the middle-layer housing assembly detachably connected to the upper-layer housing assembly and the lower-layer housing assembly respectively, the number of cell module units and the hierarchical combination of the battery pack housing structure can be flexibly adjusted according to different power requirements. This achieves a layered battery pack housing structure that can be combined as needed, improves the modularity of the power battery pack, facilitates the increase or decrease of the power battery pack capacity, and improves adaptability to different vehicle operating conditions.

[0061] It should be noted that, Figures 1 to 11The diagram illustrates a simplified representation of the battery pack housing structure and its components. The specific structures of the battery pack housing and other components within the power battery pack are not limited to these examples. Figures 1 to 11 of examples.

[0062] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments:

[0063] Reference Figure 1 and Figure 2 As shown in the embodiment of this application, a battery pack housing structure is provided for a power battery pack. The battery pack housing structure includes an upper housing assembly 100, a lower housing assembly 300, and at least one middle housing assembly 200. The upper housing assembly 100 is used to accommodate at least one layer of cell module units 10. The middle housing assembly 200 is used to accommodate one layer of cell module units 10. Each of the at least one middle housing assembly 200 is detachably connected in sequence along the height direction. At least one middle housing assembly 200 is detachably connected to the bottom of the upper housing assembly 100. The lower housing assembly 300 is used to accommodate one layer of cell module units 10. The lower housing assembly 300 is detachably connected to the side of at least one middle housing assembly 200 away from the upper housing assembly 100.

[0064] The battery cell module unit 10 includes a battery cell assembly in which multiple battery cells are combined in series or parallel. This application embodiment does not limit the number of battery cells in the battery cell module unit 10.

[0065] In the above embodiments, the upper housing assembly 100 is typically located on the side near the top of the vehicle or the power battery pack. The bottom of the upper housing assembly 100 forms an assembly interface corresponding to the middle housing assembly 200. The interface may be provided with connection holes, positioning holes, or sealing mating surfaces to achieve a detachable connection with the lower middle housing assembly 200. The upper housing assembly 100 may be formed by an aluminum alloy profile frame with aluminum plates, a steel frame with steel plates, or a metal frame combined with a load-bearing plate and a cover plate. The internal clear height of the upper housing assembly 100 shall at least meet the arrangement requirements of one layer of battery cell module units 10 and the assembly gap.

[0066] The middle-layer housing assembly 200 is a support unit disposed between the upper-layer housing assembly 100 and the lower-layer housing assembly 300. Each middle-layer housing assembly 200 is used to accommodate one layer of battery cell module unit 10, and forms an intermediate support unit with an adjustable number of layers through stacking along the height direction. At least one middle-layer housing assembly 200 is arranged sequentially along the height direction, and adjacent middle-layer housing assemblies 200 are connected by detachable connectors to form an upper and lower layered assembly interface, allowing each middle-layer housing assembly 200 to function as both an independent accommodating cavity and a... Together, they form a continuously stacked box structure; the middle box assembly 200 can be made of aluminum alloy frame with aluminum plate, steel frame with plate, or composite material frame with load-bearing plate. The size of the middle box assembly 200 is usually the same as or slightly larger than the height of the corresponding cell module unit 10, so as to reserve space for assembly, thermal expansion and contraction and connection. The height relationship between adjacent middle box assemblies 200 can be configured with equal height, or non-equal height configuration can be adopted according to different cell module unit 10 specifications, so that the middle box assembly 200 can be added or reduced as needed.

[0067] The lower housing assembly 300 is a load-bearing unit located at the bottom of the overall power battery pack structure. It houses one layer of cell module units 10 and serves as a bottom support structure connecting to the lower side of the middle housing assembly 200. In the overall assembly of the power battery pack, the side of the lower housing assembly 300 facing away from the upper housing assembly 100 typically forms an area near the vehicle bottom, base, or mounting beam. The lower housing assembly 300 can adopt a chassis-type bracket housing, a panel-type lower shell, or a structure with a reinforcing base plate. The material can be aluminum alloy, steel, or a combination of aluminum-magnesium alloy and a metal base plate. The dimensions of the lower housing assembly 300 are typically adapted to the cell module units 10 and correspond to the lower connection interface of the middle housing assembly 200.

[0068] For example, such as Figure 1 As shown, in one possible implementation, Figure 1 It includes an upper enclosure assembly 100, a middle enclosure assembly 200, and a lower enclosure assembly 300; or, Figure 1 The middle layer may also include an upper housing assembly 100 and two middle housing assemblies 200, wherein the two middle housing assemblies 200 are detachably connected along the height direction.

[0069] The detachable connections between the upper enclosure assembly 100 and the middle enclosure assembly 200, the middle enclosure assembly 200 and the lower enclosure assembly 300, and the detachable connections between multiple middle enclosure assemblies 200, allow each enclosure assembly to be individually disassembled, replaced, or combined while maintaining load-bearing continuity. It should be noted that each enclosure assembly refers to the upper enclosure assembly 100, the middle enclosure assembly 200, and the lower enclosure assembly 300. These detachable connection structures can be located at the connection edges or positioning surfaces of each enclosure assembly and can be implemented using methods such as bolt fastening, pin positioning, quick-locking connections, snap-fit ​​connections, or compression connections.

[0070] The battery pack housing structure provided in this application embodiment is in which each layer of housing components is assembled through a detachable connection structure to form a stacked relationship along the height direction, and the cell module units 10 are respectively placed in the corresponding housing components and fixed. When it is necessary to adjust the capacity of the power battery pack or adapt to the installation space of different vehicle models, the middle layer housing components 200 can be added or removed according to the target number of layers. During the disassembly and assembly process, only the detachable connection between the corresponding layers needs to be disconnected to complete the replacement and reassembly of a single layer or multiple layers.

[0071] Because each layer of the battery pack assembly is constructed as an independent load-bearing unit and connected in series through standardized detachable interfaces, the battery pack structure can be configured into combinations of different heights as needed, while maintaining continuity and consistency in positioning between layers. This application enables flexible adjustment of the battery pack layers through modular stacking, and provides strong reusability of the battery pack configuration for different capacity specifications, different layout spaces, and different installation methods, thereby adapting to the assembly requirements of multi-layer battery packs in under-mounted, side-mounted, or confined spaces within the vehicle body. This improves the modularity of the power battery pack, facilitates the addition or reduction of power battery pack capacity, and enhances adaptability to different vehicle operating conditions.

[0072] Based on the foregoing embodiments, refer to Figure 3 As shown, the upper box assembly 100 includes a first side beam 110, a second side beam 120, a first panel 130, and a second panel 140; the first side beam 110, the second side beam 120, the first panel 130, and the second panel 140 are connected end to end, the first side beam 110 and the second side beam 120 are arranged opposite to each other, and the first panel 130 and the second panel 140 are arranged opposite to each other.

[0073] The upper housing assembly 100 also includes a first cold plate 180, which is connected to the bottom of at least one of the first side beam 110 and the second side beam 120; the first side beam 110, the second side beam 120, the first panel 130, the second panel 140 and the first cold plate 180 together form a first receiving cavity 101, which is used to accommodate at least one layer of battery cell module unit 10.

[0074] The first side beam 110, the second side beam 120, the first panel 130, the second panel 140, and the first cold plate 180 together constitute the load-bearing structure and heat dissipation structure of the upper box assembly 100. The first side beam 110 and the second side beam 120 are generally defined as two longitudinal beams arranged along the front-rear or left-right direction of the vehicle. The first panel 130 and the second panel 140 are located on the other two adjacent sides and are connected sequentially at the ends to form an upper frame with circumferential boundaries.

[0075] The first side beam 110, the second side beam 120, the first panel 130 and the second panel 140 can be connected end to end by welding, screwing, riveting or integral molding to form a stable outer peripheral structure. The first cold plate 180 is installed at the bottom of the above-mentioned outer peripheral structure, so that the first cold plate 180 can dissipate heat and support the battery cell module unit 10 in the first receiving cavity 101.

[0076] In one possible embodiment, the first side beam 110 and the second side beam 120 can be aluminum alloy extruded profiles or steel-aluminum composite beams, which have high bending stiffness and installation accuracy. The first panel 130 and the second panel 140 can be stamped steel plates, aluminum plates or composite sandwich panels, which are used to improve the lateral sealing of the upper housing assembly 100 and take into account lightweighting. The first cold plate 180 can be an aluminum microchannel cold plate, profile cold plate or brazed cold plate, which is used to conduct heat and dissipate heat to the battery cell module unit 10 under the action of circulating coolant.

[0077] In this embodiment, the first receiving cavity 101 is used to accommodate and position at least one layer of battery cell module unit 10, and on the other hand, it relies on the first cold plate 180 to provide a bottom heat dissipation boundary, so that the heat generated by the battery cell module unit 10 during charging and discharging can be transferred to the first cold plate 180 through the bottom surface of the battery cell module unit 10, and then carried away by the cooling medium.

[0078] The circumferential frame formed by the first side beam 110, the second side beam 120, the first panel 130, and the second panel 140 provides limiting and support for the first receiving cavity 101, maintaining the geometric stability of the cavity under vehicle vibration, impact load, and assembly preload. The first cold plate 180, located at the bottom, also serves as the mounting reference surface and thermal management reference surface for the battery cell module unit 10. At least one layer of battery cell module units 10 is placed within the first receiving cavity 101. A heat conduction path is established between the bottom of the battery cell module unit 10 and the first cold plate 180. The heat generated by the battery cell during charging and discharging is transferred to the first cold plate 180 via the bottom plate of the battery cell module unit 10, and then continuously carried away by the cooling medium, thereby maintaining the temperature uniformity of the battery cell module unit 10 and reducing the risk of localized heat accumulation.

[0079] The upper housing assembly 100 can accommodate at least one layer of battery cell module unit 10 within a limited space, and can also achieve efficient heat dissipation through the bottom first cold plate 180 and provide necessary load-bearing through the frame structure, thereby improving the integration, thermal management capability and installation adaptability of the battery pack housing structure.

[0080] Furthermore, such as Figure 4 and Figure 5 As shown, the upper housing assembly 100 also includes at least one second cold plate 150; the heights of the first panel 130 and the second panel 140 are both greater than the heights of the first side beam 110 and the second side beam 120, so that a portion of the first panel 130 and a portion of the second panel 140 extend to the outside of the first side beam 110 and the second side beam 120.

[0081] At least one second cold plate 150 is arranged along its height, and the two ends of each second cold plate 150 are respectively connected to a portion of the first panel 130 and a portion of the second panel 140 extending to the outside of the first side beam 110 and the second side beam 120, so that the at least one second cold plate 150 divides the first receiving cavity 101 into at least two sub-receiving cavities, each sub-receiving cavity being used to accommodate a layer of battery cell module unit 10. For example, Figure 4 The image shown is of a second cold plate 150.

[0082] The second cold plate 150 is an intermediate cold plate component disposed inside the upper housing assembly 100, used to laterally divide the first receiving cavity 101 and provide thermal management and structural support for different sub-receiving cavities. The second cold plate 150 can further subdivide the first receiving cavity 101 formed by the upper housing assembly 100 into multiple independent sub-receiving cavities for arranging different layers of battery cell module units 10. In this structure, the second cold plate 150 not only plays a role in heat conduction and heat exchange, but also forms a stable partition interface by being fixedly engaged with the ends of the first panel 130 and the second panel 140, thereby improving the adaptability of the upper housing assembly 100 to the multi-layer battery cell module units 10.

[0083] In one possible embodiment, the height of the first panel 130 and the second panel 140 is greater than the height of the first side beam 110 and the second side beam 120. This is to allow the first panel 130 and the second panel 140 to form extended sections above the side beams, thereby providing a reliable connection position for the second cold plate 150. In other words, both ends of the second cold plate 150 are connected to portions of the first panel 130 and the second panel 140 extending outside the first side beam 110 and the second side beam 120, respectively. This avoids the height limitations imposed by the first side beam 110 and the second side beam 120, allowing the second cold plate 150 to be arranged layer by layer at a predetermined height within the first receiving cavity 101. Simultaneously, reducing the use of side beams on the second cold plate 150 contributes to weight reduction and lower manufacturing costs. In one possible embodiment, the second cold plate 150 can be a flat cold plate, a bent cold plate, a plate cold plate with reinforcing ribs, or a cold plate structure with internal flow channels. The material can be aluminum alloy, aluminum-silicon alloy, copper-aluminum composite material, or stainless steel thermally conductive composite material.

[0084] The above-mentioned arrangement can utilize the internal space of the upper housing component 100 in layers without significantly increasing the overall size, thereby improving space utilization and layer adaptability. Furthermore, the separation and heat dissipation function of the second cold plate 150 takes into account thermal management performance, structural stability, and the ease of installation of the multi-layer battery cell module unit 10.

[0085] The upper housing assembly 100 also includes a plurality of first crossbeams 160, which are spaced apart within the first receiving cavity 101. The two ends of each first crossbeam 160 are connected to a first side beam 110 and a second side beam 120, respectively. The plurality of first crossbeams 160 serve as supporting contact surfaces on the sides of the cell module unit 10, enabling uniform load transfer and providing stable support. By adding a plurality of first crossbeams 160 within the first receiving cavity 101, the internal support strength and overall rigidity of the upper housing assembly 100 can be improved without significantly increasing the external dimensions of the housing, thereby improving the structural stability of the multilayer battery pack under load, vibration, and long-term operating conditions.

[0086] The first crossbeam 160 may be set on the first cold plate 180, or on the second cold plate 150, or multiple first crossbeams 160 may be set on both the first cold plate 180 and the second cold plate 150.

[0087] Based on the foregoing embodiments, such as Figure 6 As shown, it also includes a U-shaped box cover 170, which covers at least one second cold plate 150. The two ends of the U-shaped box cover 170 are respectively connected to the first panel 130 and the second panel 140. The bottom wall of the U-shaped box cover 170 is connected to both the first side beam 110 and the second side beam 120.

[0088] In one possible embodiment, the U-shaped cover 170 is a U-shaped covering member used to cover at least one second cold plate 150 and form a partially enclosed space. Its main function is to shield and structurally reinforce the area above at least one sub-accommodation cavity separated by the second cold plate 150 within the first accommodation cavity 101, thereby improving the overall rigidity, sealing performance, and protection against external impacts and environmental loads such as flying stones of the upper box assembly 100 while ensuring the arrangement space of the second cold plate 150.

[0089] The U-shaped cover 170 is typically positioned in the upper region extending between the first panel 130 and the second panel 140, and spans over the outside of at least one second cold plate 150. The two ends of the U-shaped cover 170 are connected to the first panel 130 and the second panel 140, respectively, and the bottom wall is connected to both the first side beam 110 and the second side beam 120, so that the U-shaped cover 170, together with the first side beam 110, the second side beam 120, the first panel 130 and the second panel 140, form a relatively stable top boundary and provide circumferential coverage to the second cold plate 150.

[0090] For example, the U-shaped cover 170 can be made of U-shaped sheet metal, U-shaped extruded profile, or U-shaped composite plate. It may also have local reinforcing ribs, flanges, or sealing edges on its inner side to improve local bending stiffness and connection reliability. By providing the U-shaped cover 170, the area of ​​the second cold plate 150 can be reliably covered, which helps improve the overall sealing integrity, assembly consistency, and vibration resistance of the enclosure, making it more suitable for modular integration of multi-layer battery packs in confined spaces.

[0091] Reference Figure 7 As shown, the first side beam 110 or the second side beam 120 has a first mounting surface 1101 and a second mounting surface 1102; the following description takes the first side beam 110 having a first mounting surface 1101 and a second mounting surface 1102 as an example.

[0092] The first mounting surface 1101 is a horizontal surface and is used to connect with the second cold plate 150. The second mounting surface 1102 is a vertical surface and is used to connect with the U-shaped box cover 170. A sealing groove 1103 is provided between the first mounting surface 1101 and the second mounting surface 1102. The sealing groove 1103 is used to install a seal (not shown in the figure) to seal the gap between the U-shaped box cover 170 and the first side beam 110 or the second side beam 120.

[0093] In one possible embodiment, the first mounting surface 1101 and the second mounting surface 1102 can be understood as two mounting interfaces disposed on the first side beam 110 or the second side beam 120, wherein the first mounting surface 1101 is used to support the second cold plate 150 and provide it with a horizontal assembly reference, the second mounting surface 1102 is used to support the U-shaped box cover 170 and provide it with a vertical fitting reference, and the sealing groove 1103 is disposed in the junction area or adjacent position of the first mounting surface 1101 and the second mounting surface 1102 so as to accommodate the sealing element and form a continuous sealing interface after the U-shaped box cover 170 is connected to the first side beam 110 or the second side beam 120.

[0094] The first mounting surface 1101 can be installed and fixed to the second cold plate 150 from top to bottom by screws, rivets, clamps, or welding structures. The second mounting surface 1102 is usually arranged on the side wall, vertical folded edge, or vertical positioning surface formed by the first side beam 110 or the second side beam 120 after the first side beam 110 or the second side beam 120 is formed, so that the end edge of the U-shaped cover 170 can be fitted and positioned therewith, and the connection can be completed by fasteners, snap-fit ​​structures, or adhesive structures. The sealing groove 1103 enables the sealing element to form a pressure fit between the bottom edge and side edge of the U-shaped cover 170 and the first side beam 110 or the second side beam 120, thereby blocking the gap between the inside of the box and the external environment, and improving the waterproof, dustproof and cooling medium isolation capabilities of the power battery pack.

[0095] For example, the sealing groove 1103 can be designed as a rectangular groove, dovetail groove, arc groove, or stepped groove. The groove width is adapted to the width of the sealing component cross-section, and the groove depth is usually set according to the compression amount of the sealing component, so that the sealing component generates a predetermined compression rate after being pressed by the U-shaped cover 170, thereby ensuring sealing stability. The sealing component can be made of materials such as rubber strips, silicone rings, foam sealing strips, or oil-resistant and coolant-resistant sealant. Among them, rubber strips are suitable for repeated disassembly and assembly, silicone rings are suitable for working conditions with high temperature resistance requirements, foam sealing strips are suitable for large gap compensation, and sealant is suitable for scenarios with high long-term airtightness requirements.

[0096] Reference Figure 8 As shown, the middle-layer housing assembly 200 includes a first mounting frame 210 and a third cold plate 220; the third cold plate 220 is connected to the bottom end of the first mounting frame 210, and the third cold plate 220 and the first mounting frame 210 together form a second receiving cavity 201, which is used to accommodate a layer of battery cell module unit 10.

[0097] In the above embodiments, the first mounting frame 210 is a frame structure used to form the outer support boundary of the middle-layer housing and to support the cell module unit 10 and related connectors. Its main function is to provide an installation reference for the third cold plate 220 and, together with the third cold plate 220, define the space for arranging the cell module unit 10. The third cold plate 220 is a plate-shaped component located at the bottom of the middle-layer housing assembly 200, which has both load-bearing and heat-conducting functions. Its function is to support the cell module unit 10 located in the second receiving cavity 201 and transfer the heat generated by the cell module unit 10 during operation to the outside, thereby forming a continuous interlayer load-bearing and heat dissipation interface with the upper or lower housing assembly 300.

[0098] For example, the first mounting frame 210 can be a rectangular frame, a profile splicing frame, or a shell-type frame to facilitate adaptation to the outer contour of the cell module unit 10; the third cold plate 220 can be a flat cold plate, a liquid cooling plate with built-in flow channels, a stamped heat-conducting plate, or a composite heat dissipation plate to meet the configuration requirements of different heat dissipation schemes. The combination of the first mounting frame 210 and the third cold plate 220 in the middle-layer housing assembly 200 not only forms a stable housing space, but also provides bottom heat dissipation and interlayer transition interfaces for the cell module unit 10, enabling the multi-layer battery pack to increase or decrease the number of layers of the middle-layer housing assembly 200 according to different power requirements, and improving the modularity and space utilization of the entire pack while maintaining structural continuity and installation adaptability.

[0099] For example, when there are multiple middle layer housing components 200, the multiple middle layer housing components 200 are connected sequentially along the height direction, which is actually multiple first mounting frames 210 stacked and connected along the height direction.

[0100] The middle-layer housing assembly 200 can provide an independent mounting cavity and an effective heat dissipation interface for the single-layer cell module unit 10, and can also be repeatedly spliced ​​as a standardized intermediate module. This enables the battery pack housing structure to have better adjustability in the number of layers, consistency in thermal management and structural reusability, and helps to maintain a high degree of adaptability under different vehicle layout spaces and range requirements.

[0101] The middle housing assembly 200 also includes a plurality of second crossbeams 230, which are arranged at intervals within the second receiving cavity 201. The two ends of the second crossbeams 230 are respectively connected to the two inner sidewalls opposite to the first mounting frame 210.

[0102] Multiple second crossbeams 230 are arranged at intervals within the second receiving cavity 201 and connected at their ends to the inner sidewalls of the first mounting frame 210. This enhances the load-bearing capacity and structural rigidity of the middle-layer housing assembly 200 without significantly increasing the overall weight, thereby improving the adaptability of the multi-layer battery pack housing structure to different power specifications and installation scenarios.

[0103] Reference Figure 9 As shown, the lower housing assembly 300 includes a second mounting frame 310 and a fourth cold plate 320; the fourth cold plate 320 is connected to the bottom end of the second mounting frame 310, and the fourth cold plate 320 and the second mounting frame 310 together form a third receiving cavity 301, which is used to accommodate a layer of battery cell module unit 10; the second mounting frame 310 and one of the adjacent first mounting frames 210 are connected along the height direction.

[0104] The lower housing assembly 300 forms a relatively independent battery cell module unit 10 support unit through the combination of the second mounting frame 310 and the fourth cold plate 320. In one possible embodiment, the second mounting frame 310 is used to form the outer support boundary of the lower housing and to provide the installation and stress foundation for the fourth cold plate 320 and the adjacent upper layer. The fourth cold plate 320 serves as the bottom support surface and heat conduction interface of the lower battery cell module unit 10. After the two work together to form the third receiving cavity 301, a layer of battery cell module unit 10 can be stably housed in it.

[0105] The upper end of the second mounting frame 310 can be connected to the adjacent first mounting frame 210 above it, while the lower end is connected to the fourth cold plate 320, thus forming an interlayer support path from bottom to top in the height direction. The two can be detachably connected by bolts, pins, plug-in locking parts, or quick-release connectors, allowing the lower cabinet assembly 300 to form a continuous stacked structure with the middle cabinet assembly 200, facilitating the addition or reduction of the number of layers according to different power requirements. For example, the second mounting frame 310 can be in the form of a rectangular frame, a circumferential frame, or a locally reinforced frame. Its material can be selected from high-strength aluminum alloy profiles, steel welded parts, aluminum-magnesium alloy components, or composite reinforcing materials to balance load-bearing capacity and lightweight requirements. The outer contours of the second mounting frame 310 and the first mounting frame 210 are consistent, which facilitates the provision of connection points and improves connection stability.

[0106] The fourth cold plate 320 can be a flat cold plate, a liquid cooling plate with built-in flow channel, a steel-aluminum composite cold plate, or a heat dissipation plate structure with heat conduction fins. The lower box assembly 300 can be disassembled and installed separately or combined with the middle box assembly 200 to expand according to the vehicle layout space, power demand and maintenance requirements, thereby improving the hierarchical adaptability of the multi-layer battery pack box structure.

[0107] The lower housing assembly 300 also includes multiple third crossbeams 330, which are spaced apart within the third receiving cavity 301. The two ends of each third crossbeam 330 are connected to two inner sidewalls opposite to the second mounting frame 310. This further improves the structural stability of the lower housing assembly 300.

[0108] In one possible embodiment, at least one first reinforcing member 20 is provided between one of the second crossbeams 230 at the end and the inner wall of the second receiving cavity 201; at least one second reinforcing member 30 is provided between one of the third crossbeams 330 at the end and the inner wall of the third receiving cavity 301.

[0109] The first reinforcing member 20 and the second reinforcing member 30 serve to strengthen the connection areas between the second crossbeam 230 and the inner wall of the second receiving cavity 201, and between the third crossbeam 330 and the inner wall of the third receiving cavity 301, thereby improving the bending, torsional, and fatigue resistance of these areas, and dispersing the local stress transmitted to the frame sidewall from the battery module unit 10, the assembly preload, and the vehicle running load. The first reinforcing member 20 and the second reinforcing member 30 can take the form of triangular reinforcing plates, L-shaped reinforcing plates, stiffeners, filler blocks, or connecting pieces, or can be implemented through locally thickened corner pieces, inserts, or integrally formed reinforcing ribs.

[0110] In one possible implementation, refer to Figure 10 As shown, the first mounting frame 210 is provided with a plurality of first connecting holes 302 along the circumference, and the second mounting frame 310 is provided with a plurality of second connecting holes 202 along the circumference. The first connecting holes 302 and the second connecting holes 202 correspond one to one, and the first connecting holes 302 and the second connecting holes 202 are used for connection by a connector (not shown in the figure).

[0111] In one possible embodiment, the first connecting hole 302 and the second connecting hole 202 constitute a connecting hole position for docking adjacent first mounting frame 210 and second mounting frame 310, wherein the first connecting hole 302 is located at the circumferential edge of the first mounting frame 210, and the second connecting hole 202 is located at the corresponding circumferential position of the second mounting frame 310. During assembly, the upper and lower frames are detachably fixed by a connector.

[0112] The first connecting hole 302 can be understood as a through hole or countersunk hole opened on the first mounting frame 210; the second connecting hole 202 can be understood as a corresponding hole opened on the second mounting frame 310, and its function is to form a pairing assembly relationship with the first connecting hole 302 to ensure the positioning accuracy and connection consistency between adjacent frames.

[0113] For example, the first mounting frame 210 typically has multiple first connecting holes 302 arranged around the perimeter beams, corner reinforcement sections or connecting ear plates, while the second mounting frame 310 has multiple second connecting holes 202 arranged around the perimeter at height positions corresponding to the first connecting holes 302. When the middle layer box assembly 200 and the lower layer box assembly 300 are spliced ​​together along the height direction, the axes of the two sets of holes are aligned with each other, and the connectors can pass through the first connecting holes 302 and the second connecting holes 202 in sequence and be locked on the other side with nuts, pressure plates or threaded holes.

[0114] The first connecting hole 302 and the second connecting hole 202 can be round, oblong, or countersunk with a step. The connectors can be high-strength steel bolts, stainless steel bolts, fastening screws with anti-loosening washers, or pins with locking mechanisms. The first connecting hole 302 and the second connecting hole 202 not only provide a clear assembly reference but also constrain the relative positions of the first mounting frame 210 and the second mounting frame 310 through a one-to-one correspondence arrangement, reducing assembly deviations and thus improving connection reliability. This approach can improve assembly efficiency and modular adaptability while ensuring interlayer connection strength, enabling the battery pack housing structure to maintain good connection stability under different layer configurations.

[0115] Reference Figure 1 and Figure 2 As shown, and in combination Figure 11 One of the first mounting frames 210 has a cantilever 40 on its outer side wall. Multiple bushings are arranged along the length of the cantilever 40 and are used to connect to the vehicle body. The cantilever 40 is a load-bearing support member located on the outside of the first mounting frame 210 and extending outwards. Its main function is to provide an external mounting interface for the battery pack housing structure. The bushings can be defined as connecting buffers installed on the cantilever 40, used to form an assemblable, positionable connection interface with a certain vibration damping capability between the battery pack housing structure and the vehicle body.

[0116] By arranging the cantilever 40 on the outer wall of one of the first mounting frames 210, the first mounting frame 210 can form an extended mounting position towards the vehicle body. Multiple bushings arranged along the length of the cantilever 40 can cooperate with mounting holes, brackets, connecting plates or corresponding fasteners on the vehicle body to establish a multi-point support and fixing relationship on the vehicle chassis, longitudinal beams or body mounting area, so as to reliably install the battery pack box structure on the whole vehicle.

[0117] The cantilever 40 can be made of steel plate, aluminum alloy profile, cast aluminum parts, or high-strength composite metal parts to balance strength, quality, and forming process. The bushing can be a metal bushing, a rubber bushing, a rubber-metal composite bushing, or a sleeve with a metal shell.

[0118] The bushing kit can be installed horizontally or vertically to adapt to different mounting interfaces on the vehicle body, thus improving compatibility.

[0119] Based on the aforementioned embodiments, an electrical plug-in 50 is provided on one of the first panel 130 and the second panel 140, which is used for electrical connection with the cell module unit 10; a liquid cooling nozzle 60 is also provided on one of the first panel 130 and the second panel 140, which is connected to the first cold plate 180, the second cold plate 150, the third cold plate 220, and the fourth cold plate 320. The electrical plug-in 50 is used to establish an electrical connection channel between the cell module unit 10 inside the battery pack and the external high-voltage circuit, low-voltage control circuit, or detection circuit; the liquid cooling nozzle 60 is a cooling medium interface component, used to connect the first cold plate 180, the second cold plate 150, the third cold plate 220, and the fourth cold plate 320 with the external cooling circuit, thereby introducing or discharging coolant. This application embodiment does not limit the structure of the electrical plug-in 50 and the liquid cooling nozzle 60.

[0120] This application embodiment also provides a power battery pack, including the above-mentioned battery pack housing structure and at least three layers of cell module units 10, all of which are disposed within the battery pack housing structure.

[0121] By arranging at least three layers of cell module units 10 within the aforementioned adjustable-layer battery pack housing structure, each layer of cell module unit 10 can obtain the load-bearing, limiting, and installation support of the corresponding housing components, thereby achieving higher energy integration within the limited vehicle space. Since the battery pack housing structure itself can adjust the number of layers through the detachable connection of the upper housing component 100, the middle housing component 200, and the lower housing component 300, three or more layers of cell module units 10 can be matched according to the vehicle's range requirements, load requirements, and layout conditions, thereby improving the modularity and adaptability of the power battery pack.

[0122] Finally, it should be noted that those skilled in the art, upon considering the specification and practicing the embodiments disclosed herein, will readily conceive of other embodiments of this application. The embodiments of this application are intended to cover any variations, uses, or adaptations of the embodiments of this application that follow the general principles of the embodiments of this application and include common knowledge or customary technical means in the art not disclosed in the embodiments of this application. They are not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from their scope.

Claims

1. A battery pack housing structure, characterized in that, include: Upper housing assembly (100) for accommodating at least one layer of battery cell module unit (10); At least one middle-layer housing assembly (200) is provided for housing a layer of battery cell module unit (10). Each of the middle-layer housing assemblies (200) is detachably connected in sequence along the height direction. The at least one middle-layer housing assembly (200) is detachably connected to the bottom of the upper-layer housing assembly (100). The lower housing assembly (300) is used to house a layer of battery cell module units (10), and the lower housing assembly (300) is detachably connected to the side of the at least one middle housing assembly (200) opposite to the upper housing assembly (100).

2. The battery pack housing structure according to claim 1, characterized in that, The upper box assembly (100) includes a first side beam (110), a second side beam (120), a first panel (130), and a second panel (140). The first side beam (110), the second side beam (120), the first panel (130), and the second panel (140) are connected end to end in sequence; The upper housing assembly (100) further includes a first cold plate (180), which is connected to the bottom of at least one of the first side beam (110) and the second side beam (120); The first side beam (110), the second side beam (120), the first panel (130), the second panel (140) and the first cold plate (180) together form a first receiving cavity (101), which is used to accommodate at least one layer of the battery cell module unit (10).

3. The battery pack housing structure according to claim 2, characterized in that, It also includes at least one second cold plate (150); The heights of the first panel (130) and the second panel (140) are both greater than the heights of the first side beam (110) and the second side beam (120), so that a portion of the first panel (130) and a portion of the second panel (140) extend beyond the exterior of the first side beam (110) and the second side beam (120); Each of the at least one second cold plate (150) is arranged along the height direction, and the two ends of the second cold plate (150) are respectively connected to a portion of the first panel (130) and a portion of the second panel (140) extending to the outside of the first side beam (110) and the second side beam (120), so that the at least one second cold plate (150) divides the first receiving cavity (101) into at least two sub-receiving cavities, each of the sub-receiving cavities being used to accommodate one layer of the battery cell module unit (10).

4. The battery pack housing structure according to claim 2, characterized in that, It also includes a U-shaped box cover (170), which covers at least one second cold plate (150), and the two ends of the U-shaped box cover (170) are respectively connected to the first panel (130) and the second panel (140); The bottom wall of the U-shaped box cover (170) is connected to both the first side beam (110) and the second side beam (120).

5. The battery pack housing structure according to claim 4, characterized in that, The first side beam (110) or the second side beam (120) has a first mounting surface (1101) and a second mounting surface (1102). The first mounting surface (1101) is a horizontal surface and is used to connect with the second cold plate (150), and the second mounting surface (1102) is a vertical surface and is used to connect with the U-shaped box cover (170); A sealing groove (1103) is provided between the first mounting surface (1101) and the second mounting surface (1102). The sealing groove (1103) is used to install a seal to seal the gap between the U-shaped box cover (170) and the first side beam (110) or the second side beam (120).

6. The battery pack housing structure according to claim 1, characterized in that, The middle-layer housing assembly (200) includes a first mounting frame (210) and a third cold plate (220). The third cold plate (220) is connected to the bottom end of the first mounting frame (210). The third cold plate (220) and the first mounting frame (210) together form a second receiving cavity (201), which is used to accommodate one layer of the battery cell module unit (10).

7. The battery pack housing structure according to claim 6, characterized in that, The lower housing assembly (300) includes a second mounting frame (310) and a fourth cold plate (320). The fourth cold plate (320) is connected to the bottom end of the second mounting frame (310). The fourth cold plate (320) and the second mounting frame (310) together form a third receiving cavity (301), which is used to accommodate one layer of the battery cell module unit (10). The second mounting frame (310) and one of the adjacent first mounting frames (210) are connected along the height direction.

8. The battery pack housing structure according to claim 7, characterized in that, The first mounting frame (210) is provided with a plurality of first connecting holes (302) along the circumferential direction, and the second mounting frame (310) is provided with a plurality of second connecting holes (202) along the circumferential direction. The first connecting holes (302) and the second connecting holes (202) correspond one to one, and the first connecting holes (302) and the second connecting holes (202) are used for connection by connectors.

9. The battery pack housing structure according to claim 6, characterized in that, One of the first mounting frames (210) has a cantilever (40) on its outer side wall, and the cantilever (40) has a plurality of bushings arranged along the length of the cantilever (40), the bushings being used to connect to the vehicle body.

10. A power battery pack, characterized in that, The battery pack housing structure as described in any one of claims 1 to 9 includes at least three layers of cell module units (10), all three layers of cell module units (10) being disposed within the battery pack housing structure.

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