Battery pack bottom protection plate, battery pack assembly and vehicle

Abstract

This utility model discloses a battery pack bottom protector, a battery pack assembly, and a vehicle. The battery pack bottom protector includes an upper fiber resin layer, a metal plate, and a lower fiber resin layer. The metal plate is disposed between the upper and lower fiber resin layers. The resin content in the lower fiber resin layer is not less than the resin content in the upper fiber resin layer. In this embodiment of the battery pack bottom protector, when the battery pack is subjected to external impact, the lower fiber resin layer can absorb and dissipate most of the impact energy, reducing the probability of the lower and upper fiber resin layers being punctured due to excessive deformation, thereby reducing the probability of the metal plate being exposed and corroding.

Description

Technical Field

[0001] This utility model relates to the technical field of battery packs, specifically to a battery pack bottom protection plate and its manufacturing method, battery pack components, and vehicles. Background Technology

[0002] As a core component of electric vehicles, the battery pack's safety is paramount. With the rapid development of the electric vehicle industry, battery pack structural materials have also been updated and iterated. However, incidents of battery pack bottom impacts causing battery runaway and subsequent vehicle fires still occur frequently. To protect the battery pack from impacts, a bottom guard plate made of materials such as aluminum alloy, high-strength steel, and fiber-reinforced materials is typically installed at the bottom of the battery pack. However, these bottom guard plates have various problems. For example, aluminum alloy bottom guard plates have weak resistance to extreme impacts, high-strength steel bottom guard plates are too heavy, and fiber-reinforced material bottom guard plates are costly and have complex manufacturing processes.

[0003] Related technologies have proposed bottom protection plates composed of fiber resin layers and metal plates, which improve the impact resistance of bottom protection plates to a certain extent. However, due to insufficient strength and toughness, the bottom protection plates are thick and heavy. When the bottom of the battery pack is subjected to external impact, the fiber resin layer deforms too much and is easily punctured, resulting in the metal plate being exposed and corroding. Utility Model Content

[0004] This utility model aims to at least partially solve one of the technical problems in the related art.

[0005] Therefore, embodiments of this utility model propose a bottom protective plate for a battery pack. When the battery pack is subjected to external impact, the lower fiber resin layer can absorb most of the impact energy and dissipate it, reducing the probability that the lower and upper fiber resin layers will be punctured due to excessive deformation, thereby reducing the probability of exposed metal plates and corrosion.

[0006] The battery pack bottom cover plate of this utility model embodiment includes an upper fiber resin layer, a metal plate and a lower fiber resin layer. The metal plate is disposed between the upper fiber resin layer and the lower fiber resin layer and is covered by the upper fiber resin layer and the lower fiber resin layer. The resin content in the lower fiber resin layer is not less than the resin content in the upper fiber resin layer.

[0007] In some embodiments, the elongation at break of the resin in both the upper fiber resin layer and the lower fiber resin layer is greater than or equal to 50%.

[0008] In some embodiments, the elongation at break of the resin is 80% to 200%.

[0009] In some embodiments, the thickness of the lower fiber resin layer is greater than or equal to the thickness of the upper fiber resin layer.

[0010] In some embodiments, the thickness of the upper fiber resin layer is 0.1 mm to 1 mm.

[0011] In some embodiments, the thickness of the lower fiber resin layer is 0.1 mm to 10 mm.

[0012] In some embodiments, the battery pack bottom cover further includes a foam layer disposed on the side of the upper fiber resin layer away from the metal plate and connected to the upper fiber resin layer.

[0013] In some embodiments, the foam layer is bonded to the upper fiber resin layer or formed onto the upper fiber resin layer by a foaming process.

[0014] In some embodiments, the thickness of the foam layer is 2 mm to 10 mm.

[0015] In some embodiments, the thickness of the metal plate is 0.4 mm to 2 mm.

[0016] In some embodiments, the upper fiber resin layer, the metal plate, and the lower fiber resin layer are integrally formed using a resin transfer molding process.

[0017] The battery pack assembly of this utility model includes a battery pack and a bottom protective plate of any of the above embodiments, wherein the upper fiber resin layer is closer to the battery pack than the lower fiber resin layer.

[0018] The vehicle of this utility model embodiment includes the battery pack assembly described in the above embodiment.

[0019] This utility model's battery pack bottom protector is suitable for protecting vehicle battery packs. The upper and lower fiber resin layers cover both sides of the metal plate, preventing the metal plate from being exposed and preventing rust and corrosion. It also inhibits metal plate deformation upon impact. Because the lower fiber resin layer has a higher resin content than the upper fiber resin layer, it improves the lower fiber resin layer's toughness and impact energy absorption capacity. When the battery pack is subjected to external impact, the lower fiber resin layer can absorb and dissipate most of the impact energy, reducing the probability of the lower and upper fiber resin layers being punctured due to excessive deformation, thereby reducing the likelihood of exposed metal plates and rust. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of a battery pack assembly according to an embodiment of the present invention.

[0021] Figure label:

[0022] 10. Bottom protective plate; 1. Upper fiber resin layer; 2. Metal plate; 3. Lower fiber resin layer; 4. Foam layer;

[0023] 20. Battery pack. Detailed Implementation

[0024] The embodiments of this utility model are described in detail below, with examples of the embodiments shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0025] like Figure 1 As shown, the battery pack bottom cover plate 10 of this utility model embodiment includes an upper fiber resin layer 1, a metal plate 2 and a lower fiber resin layer 3. The metal plate 2 is disposed between the upper fiber resin layer 1 and the lower fiber resin layer 3 and is covered by the upper fiber resin layer 1 and the lower fiber resin layer 3, that is, the metal plate 2 is not exposed. The resin content in the lower fiber resin layer 3 is not less than the resin content in the upper fiber resin layer 1.

[0026] The battery pack bottom guard plate 10 of this utility model embodiment is suitable for protecting the battery pack 20 of a vehicle. The metal plate 2 can improve the overall strength and rigidity of the bottom guard plate 10. The upper fiber resin layer 1 and the lower fiber resin layer 3 cover both sides of the metal plate 2, which can prevent the metal plate 2 from being exposed and prevent the metal plate 2 from rusting and corroding. At the same time, it can suppress the deformation of the metal plate 2 when subjected to impact.

[0027] When the bottom protective plate 10 is applied to the battery pack 20, the upper fiber resin layer 1 is closer to the battery pack 20 than the lower fiber resin layer 3. In other words, when the battery pack 20 is impacted, the lower fiber resin layer 3 is the impact surface. Since the resin content of the lower fiber resin layer 3 is relatively higher than that of the upper fiber resin layer 1 (for example, the number of fiber layers and / or thickness of the lower fiber resin layer is greater than that of the upper fiber resin layer), the toughness and impact energy absorption capacity of the lower fiber resin layer 3 can be improved, thereby enhancing the impact resistance of the battery pack bottom protective plate 10. When the battery pack 20 is subjected to external impact, the lower fiber resin layer 3 can absorb most of the impact energy and dissipate it, reducing the probability of the lower fiber resin layer 3 and the upper fiber resin layer 1 being punctured due to excessive deformation, thus reducing the probability of the metal plate 2 being exposed and corroding. The resin content of the upper fiber resin layer 1 is relatively low, therefore the thickness of the upper fiber resin layer 1 is reduced, resulting in a thinner overall bottom protective plate and reduced weight.

[0028] Preferably, the resin content of the lower fiber resin layer 3 is greater than the resin content of the upper fiber resin layer 1.

[0029] Optionally, the fibers of the upper fiber resin layer 1 and the lower fiber resin layer 3 are glass fibers, carbon fibers, polyethylene fibers or aramid fibers.

[0030] Optionally, the metal plate 2 can be a steel plate or an aluminum plate.

[0031] Therefore, the metal plate 2 can be made of steel, which has high strength and high rigidity, improving the impact resistance of the bottom protection plate 10 while reducing material costs. Alternatively, the metal plate 2 can be made of aluminum, which is relatively lightweight and has good corrosion resistance, making it more conducive to achieving a lightweight design for the battery pack bottom protection plate 10.

[0032] In some embodiments, the elongation at break of the resin in both the upper fiber resin layer 1 and the lower fiber resin layer 3 is greater than or equal to 50%.

[0033] In other words, both the upper fiber resin layer 1 and the lower fiber resin layer 3 are made of highly elastic resin, which makes the upper fiber resin layer 1 and the lower fiber resin layer 3 more resilient. When the bottom protective plate 10 deforms under impact, the upper fiber resin layer 1 and the lower fiber resin layer 3 are less likely to crack, which can improve the service life of the upper fiber resin layer 1 and the lower fiber resin layer 3. At the same time, the lower fiber resin layer 3 can absorb more impact energy through deformation, which can better protect the battery pack 20.

[0034] In some embodiments, the elongation at break of the resin is 80% to 200%.

[0035] Optionally, the elongation at break of the resin is 80%, 90%, 100%, 110%, 120%, 130%, 140%, 150%, 160%, 170%, 180%, 190%, or 200%.

[0036] In some embodiments, the thickness of the lower fiber resin layer 3 is greater than or equal to the thickness of the upper fiber resin layer 1, thereby allowing for a further reduction in the thickness of the base plate while ensuring its strength.

[0037] It is known that the overall thickness of the bottom protective plate 10 needs to be limited to a certain range to match the installation space at the bottom of the battery pack 20. Since the lower fiber resin layer 3 is the impact-bearing surface, by setting the thickness of the lower fiber resin layer 3 to be greater than or equal to the thickness of the upper fiber resin layer 1, the lower fiber resin layer 3 can absorb more impact energy relative to the upper fiber resin layer 1. When subjected to impact, the lower fiber resin layer 3 can absorb and dissipate the impact energy to the maximum extent, thereby rationally distributing the thickness of each layer of the bottom protective plate 10 structure and maximizing the impact resistance of the bottom protective plate 10.

[0038] Preferably, the thickness of the lower fiber resin layer 3 is greater than the thickness of the upper fiber resin layer 1.

[0039] In some embodiments, the thickness of the upper fiber resin layer 1 is 0.1 mm to 1 mm.

[0040] Optionally, the thickness of the upper fiber resin layer 1 is 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm or 1mm.

[0041] In some embodiments, the thickness of the lower fiber resin layer 3 is 0.1 mm to 10 mm.

[0042] Preferably, the thickness of the lower fiber resin layer 3 is 1mm to 8mm, for example, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm or 8mm.

[0043] By limiting the thickness of the upper fiber resin layer 1 and the lower fiber resin layer 3 to the above range, the protective function of the upper fiber resin layer 1 and the lower fiber resin layer 3 on the metal plate 2 can be satisfied, preventing the metal plate 2 from rusting or corroding, while also meeting the impact resistance requirements of the bottom protective plate 10.

[0044] In addition, by rationally distributing the thickness of the upper fiber resin layer 1 and the lower fiber resin layer 3, the lower fiber resin layer 3 becomes more capable of absorbing impact, thereby maximizing the overall impact resistance of the bottom protective plate 10.

[0045] In some embodiments, such as Figure 1 As shown, the battery pack bottom cover plate 10 also includes a foam layer 4, which is disposed on the side of the upper fiber resin layer 1 away from the metal plate 2 and is connected to the upper fiber resin layer 1.

[0046] By providing a foam layer 4 on the side of the upper fiber resin layer 1 near the battery pack 20, the foam layer 4 directly contacts the battery pack 20. When the battery pack 20 is impacted, the foam layer 4 can deform to buffer and absorb energy, thus better protecting the battery pack 20. Simultaneously, because the foam layer 4 can deform, meaning the bottom protective plate 10 makes soft contact with the battery pack 20 through the foam layer 4, the deformation of the foam layer 4 can compensate for manufacturing tolerances of the battery pack 20 during installation, which is more conducive to the assembly operation of the battery pack 20.

[0047] Compared with the bottom protector plate in the related technology where the foam layer is located between the upper and lower fiber resin layers, in the embodiment of this utility model, the foam layer 4 is not located between the upper fiber resin layer 1 and the lower fiber resin layer 3, but is located on the upper fiber resin layer 1 adjacent to the battery pack 20. Therefore, during the manufacturing process of the bottom protector plate 10, such as during the injection molding process, the foam layer 4 will not be damaged or affected, thus improving the quality of the foam layer 4 and ensuring the isolation and buffering energy absorption performance of the foam layer 4.

[0048] In addition, the foam layer 4 is relatively lightweight and has a smaller impact on the overall weight of the underbody protection plate 10, which is more conducive to achieving vehicle weight reduction.

[0049] Optionally, the foam layer 4 is made of PU or MPP material.

[0050] In some embodiments, the foam layer 4 is bonded to the upper fiber resin layer 1 or formed on the upper fiber resin layer 1 by a foaming process.

[0051] The foam layer 4 and the upper fiber resin layer 1 can be connected by adhesive bonding. They can be partially or completely bonded, offering high flexibility and suitability for complex-shaped bottom panels 10. Furthermore, replacing the foam layer 4 when damaged is easier. Alternatively, the foam layer 4 can be molded onto the upper fiber resin layer 1 using a foaming process, making them an integral part of each other. Compared to adhesive bonding, this eliminates the adhesive layer, thereby reducing the weight of the bottom panel 10.

[0052] In some embodiments, the thickness of the foam layer 4 is 2 mm to 10 mm.

[0053] By limiting the thickness of the foam layer 4 to 2mm to 10mm, the foam layer 4 can play a good role in buffering and absorbing energy when the battery pack 20 is impacted. At the same time, the thickness of the foam layer 4 has little impact on the overall thickness of the bottom guard plate 10, so that the bottom guard plate 10 can match the installation space at the bottom of the battery pack 20.

[0054] Optionally, the thickness of the foam layer 4 is 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm or 10mm.

[0055] In some embodiments, the thickness of the metal plate 2 is 0.4 mm to 2 mm.

[0056] By limiting the thickness of the metal plate 2 to 0.4mm to 2mm, the strength and rigidity requirements of the underbody protection plate 10 can be met, ensuring the protective function of the underbody protection plate 10 for the battery pack 20. At the same time, the overall thickness of the underbody protection plate 10 can be controlled, which is conducive to achieving vehicle lightweighting and controlling material costs.

[0057] It is understandable that, based on different requirements for parameters such as weight, protection level, and cost of the bottom protective plate 10, those skilled in the art can make adaptive adjustments to the thickness of the foam layer 4, the upper fiber resin layer 1, the metal plate 2, and the lower fiber resin layer 3.

[0058] In some embodiments, the upper fiber resin layer 1, the metal plate 2, and the lower fiber resin layer 3 are integrally formed using a resin transfer molding process.

[0059] The upper fiber resin layer 1, the metal plate 2, and the lower fiber resin layer 3 are integrally molded using a resin transfer molding process, which is more conducive to the mass production of the bottom guard plate 10 and improves the production efficiency of the bottom guard plate 10.

[0060] Optionally, the resin transfer molding process is high pressure resin transfer molding (HP-RTM).

[0061] The battery pack assembly of this utility model embodiment includes a battery plate and a bottom protective plate 10 of any of the above embodiments, wherein the upper fiber resin layer 1 is closer to the battery pack 20 than the lower fiber resin layer 3.

[0062] The battery pack assembly of this embodiment protects the battery pack 20 through the bottom protective plate 10 disposed at the bottom of the battery pack 20. Since the lower fiber resin layer 3 has a stronger ability to absorb impact energy than the upper fiber resin layer 1, when the battery pack 20 is impacted, the lower fiber resin layer 3 can absorb most of the impact energy and dissipate it, reducing the probability of the lower fiber resin layer 3 being punctured due to a large impact force. This, in turn, reduces the probability of the metal plate 2 being exposed and corroding, thus providing better protection for the battery pack 20.

[0063] The vehicle of this utility model embodiment includes the battery pack assembly described in the above embodiment.

[0064] In this embodiment of the vehicle, the battery pack assembly is located on the chassis of the vehicle. When the battery pack 20 is impacted, the lower fiber resin layer 3 of the underbody protection plate 10 can absorb most of the impact energy, reducing the probability that the lower fiber resin layer 3 will be punctured due to the large impact force, thereby reducing the probability that the metal plate 2 will be exposed and corroded, so as to better protect the battery pack 20.

[0065] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model 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, and therefore should not be construed as a limitation of this utility model.

[0066] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

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

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

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

[0070] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A battery pack bottom protection plate (10), characterized in that, The material includes an upper fiber resin layer (1), a metal plate (2), and a lower fiber resin layer (3). The metal plate (2) is disposed between the upper fiber resin layer (1) and the lower fiber resin layer (3) and is covered by the upper fiber resin layer (1) and the lower fiber resin layer (3). The resin content in the lower fiber resin layer (3) is not less than the resin content in the upper fiber resin layer (1). The elongation at break of the resin in both the upper fiber resin layer (1) and the lower fiber resin layer (3) is greater than or equal to 50%. The thickness of the lower fiber resin layer (3) is greater than or equal to the thickness of the upper fiber resin layer (1).

2. The battery pack bottom protective plate (10) according to claim 1, characterized in that, The elongation at break of the resin is 80%~200%.

3. The battery pack bottom protective plate (10) according to claim 1 or 2, characterized in that, The thickness of the upper fiber resin layer (1) is 0.1 mm to 1 mm.

4. The battery pack bottom protective plate (10) according to claim 1 or 2, characterized in that, The thickness of the lower fiber resin layer (3) is 0.1 mm to 10 mm.

5. The battery pack bottom protective plate (10) according to claim 1, characterized in that, The battery pack bottom cover plate (10) also includes a foam layer (4), which is located on the side of the upper fiber resin layer (1) away from the metal plate (2) and is connected to the upper fiber resin layer (1).

6. The battery pack bottom protective plate (10) according to claim 5, characterized in that, The foam layer (4) is bonded to the upper fiber resin layer (1) or formed on the upper fiber resin layer (1) by a foaming process.

7. The battery pack bottom protective plate (10) according to claim 5, characterized in that, The thickness of the foam layer (4) is 2mm to 10mm.

8. The battery pack bottom protective plate (10) according to claim 1, characterized in that, The thickness of the metal plate (2) is 0.4mm to 2mm.

9. The battery pack bottom protective plate (10) according to claim 1, characterized in that, The upper fiber resin layer (1), the metal plate (2), and the lower fiber resin layer (3) are integrally formed using a resin transfer molding process.

10. A battery pack assembly, characterized in that, Includes a battery pack (20) and a bottom cover plate (10), wherein the bottom cover plate (10) is the bottom cover plate (10) according to any one of claims 1-9, and the upper fiber resin layer (1) is closer to the battery pack (20) than the lower fiber resin layer (3).

11. A vehicle, characterized in that, Includes a battery pack assembly, wherein the battery pack assembly is the battery pack assembly of claim 10.

Images