Novel battery pack frame joint

Abstract

The utility model discloses a novel battery pack frame joint, which is characterized in that under the condition that an original lower welding seam is not moved, an aluminum type bracket is additionally arranged, a protruding part of the aluminum type bracket is accurately embedded into a middle cross beam, and the aluminum type bracket is tightly connected with an outer frame and the middle cross beam respectively in a riveting manner; compared with a traditional full-welding-seam connection mode, the battery pack connecting structure has the remarkable advantages that firstly, the upper half part of the connector is riveted, so that the connection quality is easier to check and maintain, secondly, the lower half part of the connector is connected through a welding seam, and the connection quality is more stable. According to the battery pack provided by the invention, the risk of rapid expansion under the action of a load due to tiny crack of a welding seam is avoided, the transverse rigidity of the whole battery pack is also effectively improved, the integrity of the internal structure of the battery pack can be better maintained when the battery pack is subjected to lateral impact, and the potential fire risk caused by extrusion of a battery cell is avoided, so that the safety and the reliability of the battery pack are improved.

Description

Technical Field

[0001] This utility model relates to the field of battery pack frame technology, and in particular to a novel battery pack frame connector. Background Technology

[0002] The battery pack is one of the most important components of new energy vehicles. It is not only the power source of electric vehicles but also a determining factor in the overall vehicle performance. The battery pack consists of multiple parts, including the power battery module system, structural system, electrical system, thermal management system, and battery management system. The structural system mainly consists of side frames and crossbeams. The central crossbeam improves the overall rigidity and strength of the battery pack, enabling it to withstand various forces encountered by the vehicle during operation. The side crossbeams play a crucial role in protecting the electrical components within the battery pack structure; failure of these components can lead to battery swelling, fire, or explosion.

[0003] Traditionally, the central crossbeam and the battery pack frame are connected together by full-seam welding. During the welding process, the base material is affected by the welding heat in the heat-affected zone, which reduces the strength performance at that location. The weld connection usually leads to stress concentration at the weld, which will crack under long-term load, resulting in performance degradation. Utility Model Content

[0004] In view of the above problems, this application provides a novel battery pack frame connector that improves the rigidity of the connector and enhances the overall torsional rigidity of the battery pack.

[0005] To achieve the above objectives, this application provides a novel battery pack frame connector, comprising:

[0006] outer frame;

[0007] The central crossbeam is located at the center inside the outer frame;

[0008] An aluminum bracket is fitted inside the middle crossbeam, and the aluminum bracket is connected to the outer frame and the middle crossbeam by riveting.

[0009] In the technical solution of this application embodiment, the overall size of the aluminum bracket is 123mm*53mm, and the thickness of the aluminum bracket is 3mm.

[0010] In the technical solution of this application embodiment, the middle part of the aluminum bracket has a 38mm*53mm U-shaped groove protruding, and the aluminum bracket and the middle crossbeam are embedded through the groove.

[0011] In the technical solution of this application embodiment, a connection hole with a diameter of 5mm is provided at the connection between the aluminum bracket and the middle crossbeam and the outer frame for riveting and fixing.

[0012] In the technical solution of this application embodiment, the upper half of the aluminum bracket is connected to the outer frame by riveting, and the lower half of the aluminum bracket is connected to the outer frame by welding.

[0013] In the technical solution of this application embodiment, a side beam is provided inside the outer frame, and the side beam is located on one side inside the outer frame.

[0014] In the technical solution of this application embodiment, the side beam and the outer frame are connected by welding.

[0015] Unlike existing technologies, the above technical solution adds an aluminum bracket while maintaining the original lower weld. The protruding part of the aluminum bracket can fit into the groove on the surface of the middle crossbeam, achieving a proper fit and improving the stability and tightness of the connection. This simplifies the assembly process and increases production efficiency. Furthermore, a riveting method is used to connect the upper part of the aluminum bracket to the outer frame, facilitating subsequent inspection and maintenance. A 5mm diameter connection hole is provided at the connection points between the aluminum bracket, the middle crossbeam, and the outer frame for more reliable riveting fixation. This not only significantly improves the rigidity of the joint but also greatly enhances the overall torsional stiffness of the entire battery pack. The connection is improved, and compared with the traditional all-welded connection method, the connection method with riveting on the upper part makes the connection quality easier to inspect and maintain. Secondly, the lower part of the aluminum bracket and the outer frame are still connected by welds, which provides additional safety for the overall structure. This not only avoids the risk of rapid expansion of micro-cracks in the welds under load, but also effectively improves the lateral stiffness of the entire battery pack. Especially when subjected to lateral impact, it can avoid structural failure caused by the expansion of micro-cracks, better maintain the integrity of the internal structure of the battery pack, and the overall structure can more effectively disperse and absorb energy, reduce direct damage to the cells, and thus avoid the potential fire risk caused by squeezing the cells.

[0016] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiments below. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0018] Figure 1 A structural diagram of a novel battery pack frame connector as described in a specific embodiment;

[0019] Figure 2 A top view of a novel battery pack frame connector as described in a specific embodiment;

[0020] Figure 3 The diagram shows the aluminum bracket structure as described in the specific implementation method;

[0021] Figure 4 This is a side view of the aluminum bracket described in the specific embodiment;

[0022] Figure 5 This is a top view of the existing technology.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1. Outer frame; 2. Middle crossbeam; 3. Aluminum bracket; 4. Groove; 5. Connecting hole. Detailed Implementation

[0025] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0027] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0028] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0029] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0030] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0031] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to 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 the embodiments of this application.

[0032] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" 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. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0033] Please see Figures 1 to 5 This embodiment discloses a novel battery pack frame connector, comprising:

[0034] Outer frame 1;

[0035] Central crossbeam 2, which is located at the center inside the outer frame 1;

[0036] The aluminum bracket 3 is partially embedded inside the middle crossbeam 2, and the aluminum bracket 3 is connected to the outer frame 1 and the middle crossbeam 2 by riveting.

[0037] The outer frame 1 is typically made of high-strength materials, such as steel or aluminum alloys. These materials have excellent mechanical properties, such as high strength, good toughness, and fatigue resistance, to ensure that they can withstand the weight of the battery pack and provide sufficient structural strength, providing stable support and protection under various working conditions.

[0038] The central crossbeam 2 is located at the center inside the outer frame 1, serving a supporting and fixing function. The outer frame 1 and the central crossbeam 2 together form a robust skeleton capable of bearing the weight of the battery pack and maintaining its shape.

[0039] The aluminum bracket 3 is a lightweight material with good thermal conductivity, which can effectively disperse the heat generated by the battery, improve the heat dissipation performance of the battery, and extend the battery's service life. By embedding the aluminum bracket 3 with the middle crossbeam 2, the two can be tightly connected, increasing the stability of the overall structure.

[0040] The aluminum bracket 3 is riveted to the outer frame 1 and the middle crossbeam 2, which can provide strong connection force, so that the entire battery pack frame joint can remain stable during operation, reduce the risk of damage caused by vibration or impact, and at the same time maintain the flexibility of the connection part to adapt to the slight deformation that may occur in the battery pack during use.

[0041] The riveting connection between the aluminum bracket 3, the outer frame 1, and the middle crossbeam 2 can be fixed by means of blind rivets, solid rivets, etc., to ensure connection strength and stability. At the same time, the riveting connection method can facilitate later maintenance and replacement, and improve the durability of the overall structure.

[0042] Please see Figures 1 to 5The aluminum bracket 3 has an overall size of 123mm*53mm and a thickness of 3mm, which ensures structural strength while reducing surface area and weight. A 38mm*53mm U-shaped groove 4 protrudes from the middle of the aluminum bracket 3. The aluminum bracket 3 and the middle crossbeam 2 are interlocked through this groove 4, increasing the overall rigidity and stability of the structure. This also simplifies and speeds up assembly. When the aluminum bracket 3 needs to be installed onto the middle crossbeam 2, simply align the middle crossbeam 2 and insert it into the U-shaped groove 4 on the aluminum bracket 3 to complete the fixation. Compared to traditional bolt fixing or welding methods, this reduces the need for surface treatment of materials (such as drilling and tapping), thereby lowering production costs, reducing the risk of structural instability due to loose fasteners, enhancing versatility and flexibility, and avoiding impacts on work efficiency.

[0043] Please see Figures 1 to 5 The aluminum bracket 3 is provided with a 5mm diameter connection hole 5 at the connection between it and the middle crossbeam 2 and the outer frame 1 for riveting and fixing. In order to ensure the fixed connection between the aluminum bracket 3 and the middle crossbeam 2 and the outer frame 1, the connection hole 5 is provided at the connection point for accurate positioning. By passing the rivet through the connection hole 5, the aluminum bracket 3 can be firmly connected to the middle crossbeam 2 and the outer frame 1, which can provide strong shear and tensile strength, ensure the stability of the structure under stress, and the riveting fixation does not require additional welding or thread processing, which simplifies the production process and reduces the cost of use. The riveting fixation also has good sealing and corrosion resistance, and is suitable for long-term use under different environmental conditions.

[0044] During actual assembly, workers only need to insert the rivets into the pre-drilled connection holes 5 and then use riveting tools to tighten them, which greatly shortens the assembly time and improves production efficiency.

[0045] Please see Figures 1 to 5The upper half of the aluminum bracket 3 is connected to the outer frame 1 by riveting, and the lower half of the aluminum bracket 3 is connected to the outer frame 1 by welding. This combination of riveting and welding ensures the structural strength and stability. This hybrid connection method guarantees both the strength of the connection and improves the impact resistance of the structure. Riveting is simple to operate and low in cost, and can provide good shear and tensile strength. However, riveting may gradually expand under long-term load due to small cracks, thus affecting the integrity of the structure. Therefore, the lower half of the aluminum bracket 3 is connected to the outer frame 1 by welding. Welding provides a more uniform and continuous connection interface, enhances the integrity and sealing of the structure, provides additional safety, avoids the risk of small cracks in the riveting expanding under long-term load, and improves the impact resistance and durability of the structure. This effectively prevents damage to the internal structure of the battery pack and ensures that the battery pack maintains stability and safety under various operating conditions.

[0046] Please see Figures 1 to 5 The outer frame 1 is internally provided with a side beam, which is located on one side inside the outer frame 1. This side beam is used to improve the overall strength and rigidity of the outer frame 1, ensuring that it can withstand greater loads and provide better stability. The side beam is located on one side inside the outer frame 1, which helps to distribute the force acting on the outer frame 1 and reduce deformation or damage caused by excessive local stress. The side beam can also effectively increase the bending strength and torsional stiffness of the outer frame 1, which can improve the stability of the overall structure. At the same time, the side beam can also support the internal components, providing additional fixing points for battery cells or modules, preventing movement or vibration during operation, and helping to extend the service life of the battery pack.

[0047] Please see Figures 1 to 5 The welded connection between the outer frame 1 and the side beam provides additional support for the overall structure and increases overall rigidity. Especially when subjected to lateral impact, it can better maintain the integrity of the structure. The welded connection forms a continuous, high-strength joint surface, making the outer frame 1 and the side beam tightly connected and jointly bearing forces from all directions. It is more robust than simple mechanical fixing or bonding and can improve the structure's resistance to lateral impact. At the same time, the welded connection also has good durability and corrosion resistance, and can maintain stable performance for a long time in harsh environments.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not 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. These 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, and they should all be covered within the scope of the claims and specification of this application. In particular, as long as there is no structural conflict, the various technical features mentioned in the embodiments can be combined in any way. This application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A novel battery pack frame connector, characterized in that, Comprising: Outer frame; Middle crossbeam, which is located at the center inside the outer frame; Aluminum bracket, a part of the aluminum bracket is embedded inside the middle crossbeam, and the aluminum bracket is connected to the outer frame and the middle crossbeam by riveting.

2. The novel battery pack frame connector according to claim 1, characterized in that, The overall size of the aluminum bracket is 123mm * 53mm, and the thickness of the aluminum bracket is 3mm.

3. The novel battery pack frame connector according to claim 2, characterized in that, A groove with a size of 38mm * 53mm protrudes in the middle part of the aluminum bracket, and the aluminum bracket is embedded with the middle crossbeam through the groove.

4. The novel battery pack frame connector according to claim 3, characterized in that, Connection holes with a diameter of 5mm are provided at the connection positions of the aluminum bracket with the middle crossbeam and the outer frame for riveting and fixing.

5. The novel battery pack frame connector according to claim 4, characterized in that, The upper half of the aluminum bracket is connected to the outer frame by riveting, and the lower half of the aluminum bracket is connected to the outer frame by welding.

6. The novel battery pack frame connector according to claim 5, characterized in that, Side crossbeams are arranged inside the outer frame, and the side crossbeams are located on one side inside the outer frame.

7. The novel battery pack frame connector according to claim 6, characterized in that, The side crossbeam is connected to the outer frame by welding.

8. The novel battery pack frame connector according to claim 3, characterized in that, The cross-section of the groove is in a square shape.

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