A battery pack cover structure

Abstract

This utility model belongs to the field of battery pack structure technology and discloses a battery pack cover structure, including an upper plate and a lower plate spaced apart, and a set of vertical ribs disposed between the upper plate and the lower plate. The set of vertical ribs includes multiple supporting vertical ribs spaced apart in a first direction, and each supporting vertical rib extends along a second direction and connects to the upper plate and the lower plate. The double-layer structure of the upper and lower plates ensures the overall rigidity of the cover structure, while solving the problem of complex design and stamping difficulties caused by similar box covers. It can ensure the rigidity of the cover structure without increasing its weight.

Description

Technical Field

[0001] This utility model belongs to the field of battery pack structure technology, specifically relating to a battery pack cover structure. Background Technology

[0002] The battery pack is located at the bottom of the new energy vehicle, above the passenger compartment. Currently, most cell-to-body (CTB) battery pack designs on the market are integrated with the body, with the battery pack cover serving as the passenger compartment floor. This means that the design allows passengers to step directly on the battery pack cover. If the battery pack cover has low rigidity and is insufficient to support the occupants or heavy objects, the cover is prone to deformation and contact with the internal battery and electrical modules. Over time, this greatly increases the risk of battery and electrical module breakage or insulation failure. Therefore, the battery pack cover design of CTB models directly affects the safety of the occupants.

[0003] Currently, the common design for CTB battery pack covers uses a single-layer stamped steel plate. It typically uses high-strength steel material with a thickness far exceeding that of non-CTB battery pack covers, combined with the cover's ribbed design, to meet the cover's rigidity requirements. This results in an overall heavy cover that does not meet the current lightweight requirements for the entire vehicle and battery pack. Utility Model Content

[0004] The purpose of this invention is to provide a battery pack cover structure to solve the problem of the conflict between strength and lightweight in existing battery pack covers mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a battery pack cover structure, comprising an upper plate and a lower plate spaced apart, and a set of vertical ribs disposed between the upper plate and the lower plate. The set of vertical ribs includes a plurality of supporting vertical ribs spaced apart in a first direction, each supporting vertical rib extending along a second direction and connected to the upper plate and the lower plate.

[0006] The double-layer structure of the upper and lower plates ensures the overall rigidity of the cover structure, while solving the problem of complex design and ribs that make forming difficult in similar box covers. It can ensure the rigidity of the cover structure without increasing its weight.

[0007] Furthermore, the upper cover structure includes a plurality of profile units arranged sequentially in the second direction, the profile unit comprising:

[0008] The first plate portion, the upper plate portion is formed by splicing together the first plate portions of multiple profile units;

[0009] The second plate portion is formed by splicing together the second plate portions of multiple profile units to form the lower plate portion;

[0010] The vertical reinforcement section includes at least one supporting vertical reinforcement.

[0011] Furthermore, the upright rib section includes multiple supporting upright ribs, and one of the supporting upright ribs is arranged along the edge of the profile unit.

[0012] Furthermore, the profile unit is made of aluminum alloy.

[0013] By replacing steel alloy with aluminum alloy, the overall weight of the top cover is effectively reduced under the same stiffness conditions, thereby improving the lightweighting of the battery pack and the entire vehicle.

[0014] Furthermore, the profile unit is manufactured using an integral extrusion molding process.

[0015] Furthermore, the lower plate has an extension portion that extends outward relative to the outer edge of the upper plate, and the extension portion has multiple fixing holes.

[0016] Furthermore, the upper cover structure is connected to the internal crossbeam of the battery pack via a connecting structure, the connecting structure comprising:

[0017] Multiple mounting hole groups, the mounting hole groups including a first hole formed on the upper plate and a second hole formed on the lower plate, the axes of the first hole and the second hole coincide;

[0018] The bushing component includes a main body extending along the axis of the second hole and a first flange extending circumferentially outward from one end of the main body, and a stepped through hole extending along the axis of the second hole is formed in the bushing component.

[0019] The stud member includes a screw portion extending along the axis of the second hole and a second flange portion formed at one axial end of the screw portion, and a threaded hole structure for the screw portion to be screwed into is formed on the crossbeam inside the battery pack.

[0020] Furthermore, the connection structure also includes:

[0021] A rivet nut is installed on the internal crossbeam of the battery pack and includes a nut portion extending along the axis of a second hole and a third flange portion formed at one axial end of the nut portion. The third flange portion is located in the axial direction between the bushing member and the internal crossbeam of the battery pack, and the threaded hole of the nut portion is configured as a threaded hole structure for the screw portion to be screwed into.

[0022] A sealing member is disposed radially outside the third flange.

[0023] Furthermore, the diameter of the first hole is larger than the diameter of the second hole.

[0024] Furthermore, adjacent profile units are joined together by welding. Attached Figure Description

[0025] Figure 1 This is a top view of the upper cover structure;

[0026] Figure 2 This is a cross-sectional view of the upper cover structure;

[0027] Figure 3 This is a cross-sectional view of the upper cover structure.

[0028] Figure 4 This is a schematic diagram of the cross-sectional view of the profile unit connection;

[0029] Figure 5 This is a schematic diagram showing the location of the fixing holes;

[0030] Figure 6 Front view of the connection between the top cover structure and the internal crossbeams of the battery pack;

[0031] Figure 7 for Figure 6 Enlarged cross-sectional view at point A in the middle.

[0032] In the picture:

[0033] 1. Top cover structure;

[0034] 10. Profile unit; 10a. First plate section; 10b. Second plate section;

[0035] 100. Upper plate; 101. Lower plate; 101a. Extension section; 102. Supporting ribs; 103. Fixing holes;

[0036] 20. Mounting hole assembly; 200. First hole; 201. Second hole;

[0037] 300, Bushing component; 300a, Main body; 300b, First flange; 301, Stepped through hole;

[0038] 400, Stud component; 400a, Screw portion; 400b, Second flange portion;

[0039] 500, Rivet nut; 500a, Nut portion; 500b, Third flange portion; 501, Sealing component;

[0040] 600. Internal crossbeam of the battery pack. Detailed Implementation

[0041] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0042] A battery pack cover structure 1, as shown in the figure Figure 1 and 2 The system includes an upper plate 100 and a lower plate 101 spaced apart. Both the upper plate 100 and the lower plate 101 are generally rectangular plates extending along a first direction and a second direction. The first direction is the length direction of the upper plate 100, and the second direction is the width direction of the upper plate 100. For example, the upper plate 100 and the lower plate 101 have chamfered structures to accommodate the frame structure of the battery pack. In some embodiments, the cross-sectional area of ​​the upper plate 100 is smaller than the cross-sectional area of ​​the lower plate 101. Specifically, the lower plate 101 has an extension portion 101a extending outward from the edge of the upper plate 100. As an example where both the upper plate 100 and the lower plate 101 are rectangular plates, the extension portion 101a is a rectangular ring. This extension portion has multiple fixing holes 103 to cooperate with fasteners such as bolts to connect the upper cover structure 1 and the battery pack frame (see reference). Figure 1 and Figure 5 Continue to refer to Figure 2 and combined Figure 3 The upper cover structure 1 also includes a set of vertical ribs disposed between the upper plate 100 and the lower plate 101, and the set of vertical ribs constitutes a connection structure between the upper plate 100 and the lower plate 101. Specifically, the set of vertical ribs consists of a plurality of support ribs 102 spaced apart in a first direction. Each support rib 102 extends along a second direction, and the upper and lower end faces of the support ribs are respectively connected to the upper plate 100 and the lower plate 101. That is, the upper plate 100 and the lower plate 101 are connected by the set of vertical ribs to form a complete upper cover structure 1. The double-layer structure design of the upper plate 100 and the lower plate 101 ensures the overall rigidity of the upper cover structure 1, and at the same time solves the problem of difficult molding caused by complex shapes and ribs in similar box covers.

[0043] In some embodiments, refer to Figure 1 The aforementioned cover structure 1 includes a plurality of profile units 10 arranged sequentially in a first direction. The plurality of profile units 10 are joined together by welding to form the cover structure 1. For example, the aforementioned cover structure 1 is formed by joining four profile units 10. At the same time, the connection position of adjacent profile units 10 constitutes the connection edge of the profile units 10. The connection unit extends along a second direction. Adjacent profile units 10 are welded at the connection edge to realize the splicing between the profile units 10. Specifically, refer to Figure 4The aforementioned profile unit 10 is manufactured by integral extrusion molding and includes a first plate portion 10a, a second plate portion 10b, and vertical ribs. Both the first plate portion 10a and the second plate portion 10b are approximately small rectangular plates. The first plate portions 10a of multiple profile units 10 are spliced ​​to form the aforementioned upper plate 100, meaning the dimensions of the first plate portions 10a in the second direction are equal to those of the upper plate 100. The second plate portions 10b of multiple profile units 10 are spliced ​​to form the aforementioned lower plate 101, meaning the dimensions of the second plate portions 10b in the second direction are equal to those of the lower plate 101. Continuing to refer to… Figure 4 Each profile unit 10 has a vertical rib portion consisting of at least one supporting vertical rib 102. That is, the vertical rib portions of multiple profile units 10 together constitute the above-mentioned vertical rib group. In some embodiments, the above-mentioned vertical rib portion includes at least one supporting vertical rib 102 disposed at the connecting edge position of the profile unit 10. During the splicing process of the profile unit 10, a weld bead is formed between the supporting vertical ribs 102 at the connecting edge position in adjacent profile units 10. Adjacent profile units 10 are subjected to friction stir welding at the weld bead position to achieve the splicing of adjacent profile units 10.

[0044] Reference Figure 6 and Figure 7 The aforementioned upper cover structure 1 also includes a connecting structure for connecting the upper cover structure 1 and the internal crossbeam 600 structure of the battery pack. In some embodiments, the connecting structure includes a fixing structure and multiple mounting hole groups 20, wherein the multiple mounting hole groups 20 extend along the internal crossbeam 600 of the battery pack (i.e., extend in the second direction), and each mounting hole group 20 includes a first hole 200 disposed on the upper plate 100 and a second hole 201 disposed on the lower plate 101, and the central axes of the first hole 200 and the second hole 201 coincide, that is, the first hole 200 and the second hole 201 are disposed at corresponding positions on the upper plate 100 and the lower plate 101. In some examples, in order to facilitate the installation of the fixing structure, the diameter of the first hole 200 is larger than the diameter of the second hole 201, so as to facilitate the insertion of components such as the bushing component 300. Continuing to refer to Figure 7 The aforementioned fixing structure includes a bushing member 300 and a connecting stud. The bushing member 300 includes a main body portion 300a extending along the axis of the second hole 201 and a first flange portion 300b extending circumferentially outward from one axial end of the main body portion 300a. The outer wall surface of the main body portion 300a fits against the surface of the second hole 201. Simultaneously, the first flange portion 300b constitutes an axial limiting structure during the assembly of the bushing member 300. Continuing to refer to… Figure 7The bushing component 300 has a stepped through hole 301 extending along the axis of the second hole 201. The connecting stud includes a screw portion extending along the axis of the second hole 201 and a second flange portion 400b formed at one axial end of the screw portion. Meanwhile, the internal crossbeam 600 of the battery pack has a threaded hole structure extending along the axis of the second hole 201. During assembly of the fixing structure and the internal crossbeam 600 of the battery pack, the screw portion 400a of the stud component 400 passes through the stepped through hole 301 of the bushing component 300 and is screwed into the threaded hole structure of the internal crossbeam 600 of the battery pack. The step on the stepped through hole 301 limits the second flange portion 400b of the stud component 400, thereby achieving the connection between the bushing component 300 and the internal crossbeam 600 of the battery pack. The connection of beam 600, that is, the connection between the internal crossbeam 600 of the battery pack and the upper cover structure 1, in some embodiments, the above-mentioned fixing structure also includes a rivet nut 500 and a sealing member 501, wherein the rivet nut 500 is fixed to the internal crossbeam 600 of the battery pack by riveting. Specifically, the rivet nut 500 includes a nut portion 500a extending along the axis of the second hole 201 and a third flange portion 500b formed at one axial end of the nut portion 500a, wherein the internal threaded hole of the nut portion 500a is configured as the threaded hole structure for the screw portion 400a to be screwed in, and at the same time, an area for the nut portion 500a to be screwed in is formed on the internal crossbeam 600 of the battery pack. The third flange portion 500b extends along the upper surface of the internal crossbeam 600 of the battery pack. Continuing to refer to Figure 7 The third flange portion 500b is located in the axial direction between the bushing member 300 and the internal crossbeam 600 of the battery pack. The sealing member 501 (e.g., a sealing ring) is disposed on the radially outer side of the third flange portion 500b, that is, a seal is formed between the end face of the bushing member 300 and the end face of the internal crossbeam 600 of the battery pack (hereinafter referred to as the crossbeam) by the sealing member 501.

[0045] When assembling the top cover structure 1 and the internal crossbeam 600 of the battery pack, the rivet nut 500 is first fixed to the top of the crossbeam by rivet, the sealing member 501 is fixed to the outside of the rivet nut 500, and then the bushing member 300 is installed in the mounting hole group 20, and the first flange portion 300b of the bushing member 300 forms a limit.

[0046] Then, the crossbeam and the upper cover structure 1 are positioned and aligned, the stud component 400 is installed into the rivet nut 500, and the fixing hole 103 on the lower plate 101 is also fixed to the top of the battery pack frame with bolts.

[0047] The aforementioned top cover structure 1 has only a single layer of aluminum plate at the fixing hole 103 and mounting hole group 20, but it is connected to the battery pack by bolts to enhance the rigidity of the fixing position. The other positions are equipped with a double-layer plate body 100 and a lower plate body 101, which can also provide good rigidity and meet the strength requirements of the CTB battery pack top cover.

[0048] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A battery pack upper cover structure, characterized by, The system includes an upper plate (100) and a lower plate (101) spaced apart, and a set of vertical ribs disposed between the upper plate (100) and the lower plate (101). The set of vertical ribs includes a plurality of support ribs (102) spaced apart in a first direction. Each support rib (102) extends along a second direction and is connected to the upper plate (100) and the lower plate (101).

2. The battery pack upper cover structure according to claim 1, characterized in that: The upper cover structure (1) includes a plurality of profile units (10) arranged sequentially in a first direction, the profile unit (10) including: The first plate body (10a) is formed by splicing together the first plate body (10a) of multiple profile units (10); The second plate portion (10b) is formed by splicing the second plate portions (10b) of multiple profile units (10); The vertical reinforcement section includes at least one supporting vertical reinforcement (102).

3. The battery pack upper cover structure of claim 2, wherein: The vertical support section includes a plurality of supporting vertical supports (102), and one of the supporting vertical supports (102) is disposed along the connecting edge of the profile unit (10).

4. The battery pack upper cover structure of claim 2, wherein: The profile unit (10) is made of aluminum alloy.

5. The battery pack upper cover structure of claim 2, wherein: The profile unit (10) is manufactured by an integral extrusion molding process.

6. The battery pack upper cover structure of claim 1, wherein: The lower plate (101) has an extension (101a) that extends outward relative to the outer edge of the upper plate (100), and the extension (101a) has a plurality of fixing holes (103).

7. The battery pack upper cover structure of claim 1, wherein: The upper cover structure (1) is connected to the internal crossbeam (600) of the battery pack via a connecting structure, the connecting structure comprising: Multiple mounting hole groups (20), the mounting hole groups (20) including a first hole (200) formed on the upper plate (100) and a second hole (201) formed on the lower plate (101), the first hole (200) and the second hole (201) having coincident axes; The bushing member (300) includes a main body portion (300a) extending along the axis of the second hole (201) and a first flange portion (300b) extending circumferentially outward from one end of the main body portion (300a), and a stepped through hole (301) extending along the axis of the second hole (201) is formed in the bushing member (300). The stud member (400) includes a screw portion (400a) extending along the axis of the second hole (201) and a second flange portion (400b) formed at one axial end of the screw portion (400a), and the internal crossbeam (600) of the battery pack is provided with a threaded hole structure for the screw portion (400a) to be screwed into.

8. The battery pack upper cover structure of claim 7, wherein: The connection structure further includes: A rivet nut (500) is mounted on the internal crossbeam (600) of the battery pack and includes a nut portion (500a) extending along the axis of the second hole (201) and a third flange portion (500b) formed at one axial end of the nut portion (500a). The third flange portion (500b) is located in the axial direction between the bushing member (300) and the internal crossbeam (600) of the battery pack, and the threaded hole in the nut portion (500a) is configured as a threaded hole structure for the screw portion (400a) to be screwed in. A sealing member (501) is arranged radially outward of the third flange portion (500b).

9. The battery pack upper cover structure of claim 8, wherein: The first hole (200) has a larger diameter than the second hole (201).

10. A battery pack cover structure according to claim 2, characterized in that: The profile units (10) are connected by welding.

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