Lightweight battery pack box structure

Abstract

The utility model relates to the field of new energy battery packs, in particular to a light-weight battery pack box body structure which comprises an outer box body (1) and a composite material upper cover (2), the composite material upper cover (2) covers the outer box body (1), two module fixing frames (6) are arranged in the outer box body (1), the module fixing frames (6) and the outer box body (1) are integrally formed, and the module fixing frames (6) are arranged in the outer box body (1). A cross beam is arranged between the two module fixing frames (6), battery pack installation expansion structures (10) are arranged on the outer side walls of the front side and the rear side of the outer box body (1), a split type liquid cooling plate (12) is arranged at the bottom of the battery pack and is divided into three layers, and the split type liquid cooling plate (12) is arranged in the middle of the outer box body (1). The aluminum alloy liquid cooling layer, the novel composite material layer and the spraying armor layer are sequentially arranged from top to bottom, and the problem that at the present stage, a battery pack PACK often has the considerable weight, and large challenges are brought to the maneuvering performance of a whole vehicle, the vehicle body chassis load and the energy efficiency utilization rate is solved.

Description

Technical Field

[0001] This utility model relates to the field of new energy battery packs, specifically to a lightweight battery pack housing structure. Background Technology

[0002] With increasing global emphasis on environmental protection and sustainable development, new energy batteries have become a focal point for governments and businesses worldwide. As a crucial component, new energy battery packs are finding increasingly widespread applications in electric vehicles, energy storage systems, and other fields. Compared to traditional automobiles, electric vehicles eliminate the engine as a core component, replacing it with battery cells. Lithium-ion and lithium iron phosphate batteries, due to their high energy density, low self-discharge rate, and long cycle life, have become the preferred choice for developing new energy vehicles; and efficient battery management systems ensure the effective utilization of electrical energy.

[0003] To achieve a driving range of over 500 kilometers for pure electric vehicles, more batteries need to be placed under the vehicle body. However, the weight of the batteries also affects the total driving range of the electric vehicle. At this point, lightweighting of the vehicle body and the battery pack housing becomes particularly important. Reducing the weight of the battery pack housing can significantly reduce the power consumption of the entire vehicle, increase the driving range of the electric vehicle, and improve energy utilization efficiency.

[0004] Currently, most battery pack enclosures on the market use rolled steel structures and rarely use new composite materials. In order to ensure the absolute safety of the battery cells, the battery pack enclosure structure has very high strength requirements from the initial design stage. As a result, the battery pack often has a considerable weight, which undoubtedly poses a significant challenge to the vehicle's handling performance, chassis load, and energy efficiency.

[0005] At present, a lightweight battery pack housing structure is proposed to solve the problems mentioned in the background art. Utility Model Content

[0006] The purpose of this utility model is to provide a lightweight battery pack housing structure. Based on the traditional battery pack structure, a large amount of new high-strength composite materials are used to strengthen the main frame and module fixing beams of the battery pack. This solves the problem that the current battery packs are often quite heavy, which poses a considerable challenge to the vehicle's handling performance, chassis load, and energy efficiency.

[0007] The technical solution of this utility model is as follows:

[0008] A lightweight battery pack housing structure includes an outer housing and a composite material top cover, the composite material top cover covering the outer housing. Two module fixing brackets are provided inside the outer housing, and a crossbeam is provided between the two module fixing brackets. Battery pack mounting expansion structures are provided on the outer side walls of the front and rear sides of the outer housing. A split liquid cooling plate is provided at the bottom of the battery pack. The split liquid cooling plate is divided into three layers, from top to bottom: an aluminum alloy liquid cooling layer, a new composite material layer, and a sprayed armor layer.

[0009] Further specified, the crossbeam is provided with a reinforcing beam, a support frame is provided between the left module fixing frame and the left inner side wall of the outer box, and an independent compartment for the battery pack management system is formed between the left inner side wall of the outer box and the left module fixing bracket, and several component modules and control lines are provided in the independent compartment for the battery pack management system.

[0010] Furthermore, a sealing ring is provided between the outer casing and the composite material top cover.

[0011] Further specifying, the composite material cover includes an aluminum alloy layer and a high-strength carbon fiber composite layer.

[0012] Furthermore, the battery pack mounting expansion structure is provided with several different hole arrangement matrices, and the battery pack mounting expansion structure uses different hole arrangement matrices to meet different installation methods.

[0013] The advantages of this utility model over the current technology are as follows:

[0014] 1. It is equipped with a module fixing frame. During manufacturing, the outer box and the module fixing frame are integrally formed and cannot be disassembled. The outer frame box and the internal module fixing frame are the main load-bearing components, bearing the weight of the module and resisting external impact.

[0015] 2. The battery pack mounting expansion structure uses different hole arrangement matrices to meet different installation methods.

[0016] 3. The split liquid-cooled base plate integrates liquid cooling while ensuring bottom protection. In the event of thermal runaway of the module cell, the bottom liquid-cooled plate will split into several small plates under certain pressure impact, which can play a timely pressure relief function in case of excessive pressure in local areas. Attached Figure Description

[0017] Figure 1 This is a three-dimensional exploded view of the present invention;

[0018] Figure 2 This is a three-dimensional schematic diagram of the double-layer structure of the present invention, consisting of an outer aluminum alloy layer and an inner composite material layer.

[0019] The markings in the diagram correspond to: 1-outer casing, 2-composite material top cover, 3-aluminum alloy layer, 4-high-strength carbon fiber composite layer, 5-sealing ring, 6-module fixing frame, 7-reinforcing beam, 8-support frame, 9-independent compartment of battery pack management system, 10-battery pack installation expansion structure, 11-hole arrangement matrix, 12-split liquid cooling plate. Detailed Implementation

[0020] To enable those skilled in the art to better understand the technical solution of this utility model, the technical solution of this utility model will be further described below in conjunction with the accompanying drawings and embodiments. Example

[0021] like Figure 1 and Figure 2 As shown, a lightweight battery pack housing structure includes an outer housing 1 and a composite material cover 2. The composite material cover 2 covers the outer housing 1 and includes an aluminum alloy layer 3 and a high-strength carbon fiber composite layer 4. A sealing ring 5 is provided between the outer housing 1 and the composite material cover 2 to enhance the sealing performance and ensure that the battery pack meets the qualified protection level requirements. Two module fixing brackets 6 are provided inside the outer housing. The two module fixing brackets 6 are respectively set on the left and right sides inside the outer housing 1 and are integrally formed with the outer housing. A crossbeam is provided between the two module fixing brackets 6, and a reinforcing beam 7 is provided on the crossbeam. The module fixing bracket on the left side is... A support frame 8 is provided between the fixed frame 6 and the left inner side wall of the outer casing 1. An independent compartment 9 for the battery pack management system is formed between the left inner side wall of the outer casing 1 and the left module fixing frame 6. This compartment is used to install key components such as relays, shunts, resistors, fuses, high-voltage control boxes, and the BMS battery management system. The outer structure of the outer casing 1 is made of aluminum alloy, which reduces weight and prevents the impact of cell thermal runaway on the battery management system. The outer casing 1 adopts a double-layer structure with an outer aluminum alloy layer and an inner composite material layer. This ensures high strength while also possessing good high-temperature resistance and excellent ductility.

[0022] When a battery cell experiences thermal runaway, the independent compartment 9 of the battery pack management system will not be immediately affected, preventing the wiring harness and copper busbars from melting and causing insulation failure. At the same time, the BMS can communicate with the VCU in a timely manner to trigger a power-off command, improving the overall safety performance of the battery pack and ensuring the safety of passengers. When the battery management system (high-voltage BDU and low-voltage BMS management system) experiences loose connections due to bolt torque decay, it may spark and melt related electrical components. The independent battery pack management compartment can physically isolate the cells when the battery pack management system experiences thermal runaway, preventing cell thermal runaway and ensuring the safety of passengers. In addition, the crossbeam of the independent battery pack management compartment improves the strength of the battery pack structure and enhances its impact resistance.

[0023] Battery pack mounting expansion structures 10 are provided on the outer side walls of the front and rear sides of the outer casing 1. The material is a double-layer lightweight material consisting of an outer aluminum alloy and an inner new composite material. They are welded to the front and rear sides of the outer casing 1, providing a variety of installation methods for the battery pack. Several different hole arrangement matrices 11 are provided on the battery pack mounting expansion structures 10. The battery pack mounting expansion structures 10 meet different installation methods through different hole arrangement matrices 11. A split liquid cooling plate 12 is provided at the bottom of the battery pack. The split liquid cooling plate 12 is divided into three layers, from top to bottom: an aluminum alloy liquid cooling layer, a new composite material layer, and a sprayed armor layer. While ensuring bottom protection, it integrates liquid cooling function. In the event of thermal runaway of the module cell, the bottom liquid cooling plate 12 will split into several small plates under certain pressure impact, which can play a timely pressure relief function in the event of excessive pressure in a local area.

[0024] The above provides a detailed description of a lightweight battery pack housing structure provided by this utility model. The specific embodiments are only used to help understand the method and core idea of ​​this utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made to this utility model without departing from it, and these improvements and modifications also fall within the protection scope of the claims of this utility model.

Claims

1. A lightweight battery pack housing structure, characterized in that: The device includes an outer casing (1) and a composite material cover (2). The composite material cover (2) covers the outer casing (1). Two module fixing frames (6) are provided inside the outer casing (1). The module fixing frames (6) and the outer casing (1) are integrally formed. A crossbeam is provided between the two module fixing frames (6). Battery pack installation expansion structures (10) are provided on the outer side walls of the front and rear sides of the outer casing (1). A split liquid cooling plate (12) is provided at the bottom of the battery pack. The split liquid cooling plate (12) is divided into three layers, from top to bottom: an aluminum alloy liquid cooling layer, a new composite material layer, and a sprayed armor layer.

2. The lightweight battery pack housing structure according to claim 1, characterized in that: A reinforcing beam (7) is provided on the crossbeam. A support frame (8) is provided between the left module fixing frame (6) and the left inner side wall of the outer box (1). An independent compartment (9) for the battery pack management system is formed between the left inner side wall of the outer box (1) and the left module fixing bracket (6), which is used to install key components such as relays, shunts, resistors, fuses, high voltage control boxes, and BMS battery management systems.

3. The lightweight battery pack housing structure according to claim 1, characterized in that: A sealing ring (5) is provided between the outer casing (1) and the composite material cover (2).

4. The lightweight battery pack housing structure according to claim 1, characterized in that: The composite material cover (2) includes an aluminum alloy layer and a high-strength carbon fiber composite layer.

5. The lightweight battery pack housing structure according to claim 1, characterized in that: The battery pack mounting extension structure (10) is provided with several different hole arrangement matrices (11), and the battery pack mounting extension structure (10) satisfies different installation methods through different hole arrangement matrices (11).

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