A battery pack housing load-bearing beam frame, a battery pack housing, a battery pack, and an electric passenger vehicle.

Abstract

This utility model relates to a battery pack housing support beam frame, a battery pack housing, a battery pack, and an electric passenger vehicle. The support beam frame serves as a carrier supporting the weight of the battery pack modules, constraining their movement and improving the battery pack's rigidity. This utility model optimizes the structure of the second longitudinal beam and the lifting lugs mounted on it. By incorporating recessed grooves and inclined reinforcing plates on the second longitudinal beam, and integrating multiple individual lifting lugs into a single integrated lug, this not only increases the contact and connection between the support beam and the housing body but also enhances the rigidity and force transmission path of the second longitudinal beam and the lifting lugs themselves, solving the problems of insufficient rigidity and stress concentration. The battery pack housing support beam frame described in this utility model exhibits good structural load-bearing and bending resistance, can be used on a platform, reducing the cost of repetitive development, and has a low structural design complexity, making it easy to process and mass-produce.

Description

Technical Field

[0001] This utility model relates to the field of power battery packs, specifically to a battery pack housing load-bearing beam frame, a battery pack housing, a battery pack, and an electric passenger vehicle. Background Technology

[0002] New energy vehicle power battery packs typically consist of subsystems such as a housing, beam frame, module system, thermal management system, and electrical system. The power battery pack is mounted on the vehicle's main beam via lifting lugs. Given sufficient vehicle body rigidity, the rigidity of the housing and beam frame becomes particularly crucial. The stamped housing is composed of stamped housing parts, beam frame, lifting lugs, bolts, and other components. The housing and beam frame provide a stable and reliable spatial arrangement and safety protection for the battery module system, electrical system, and thermal management system.

[0003] Typically, the weight of a power battery pack is concentrated in the modules, which are bolted to the casing. Since the casing itself is insufficient to support the weight of the modules, a load-bearing beam frame is usually added inside the casing to improve the overall rigidity and strength, ensuring good load-bearing capacity and excellent force transmission between the modules and the casing. Existing load-bearing beam frames lack torsional stiffness, leading to stress concentration at the module mounting points. Achieving a beam frame with good mechanical properties, high load-bearing capacity, light weight, and manufacturing feasibility within the limited space of the casing design is a major challenge in battery pack design. Utility Model Content

[0004] In order to overcome the shortcomings of the existing technology, the purpose of this utility model is to provide a battery pack housing load-bearing beam frame, a battery pack housing, a battery pack, and an electric passenger vehicle.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A battery pack housing support beam frame includes: a crossbeam portion and a left longitudinal beam and a right longitudinal beam respectively disposed on the left and right sides of the crossbeam portion; the crossbeam portion includes a first crossbeam, a second crossbeam, a middle crossbeam and a third crossbeam arranged in parallel and spaced apart in sequence; the left longitudinal beam and the right longitudinal beam each include a first longitudinal beam and a second longitudinal beam connected in sequence; a middle longitudinal beam connects the middle crossbeam and the third crossbeam; and multiple lifting lugs are provided on the outer periphery of the support beam frame.

[0007] Furthermore, the two ends of the first crossbeam are respectively connected to the ends of the first longitudinal beam on the left and right sides of the longitudinal beam; the two ends of the second crossbeam are respectively connected to the connection points of the first and second longitudinal beams on the left and right sides of the longitudinal beam; the two ends of the middle crossbeam are respectively connected to the ends of the second longitudinal beam on the left and right sides of the longitudinal beam; the two ends of the third crossbeam are respectively connected to the ends of the second longitudinal beam on the left and right sides of the longitudinal beam; the middle longitudinal beam and the second longitudinal beam are arranged parallel to each other at intervals; the two ends of the middle longitudinal beam are respectively perpendicularly connected to the middle crossbeam and the third crossbeam.

[0008] Furthermore, the groove is provided with multiple arc spot welded connection parts; the arc spot welded connection parts are used to connect the load-bearing beam frame and the battery pack box.

[0009] Furthermore, an inclined reinforcing plate is provided on the second longitudinal beam, and the reinforcing plate is connected to the second longitudinal beam and the power battery pack housing respectively.

[0010] Furthermore, the lifting lug is provided with a connecting hole; the lifting lug includes a plurality of connecting parts connected in sequence.

[0011] Furthermore, the lifting lug is connected to the edge of the load-bearing beam frame. The lifting lug located on the outside of the second longitudinal beam is integrally formed from multiple stamped parts.

[0012] This utility model also includes a battery pack housing, which includes the aforementioned load-bearing beam frame and a housing body installed below the load-bearing beam frame; both the load-bearing beam frame and the housing body are stamped parts.

[0013] This utility model also includes a power battery pack, which includes a battery module, a thermal management system, and an electrical system. The power battery pack also includes the power battery pack housing. The battery module, thermal management system, and electrical system are all disposed in the power battery pack housing and are mounted on the load-bearing beam frame by fasteners.

[0014] This utility model also includes an electric passenger vehicle, which includes: a vehicle body and a power battery pack; the power battery pack adopts the aforementioned power battery pack; the power battery pack is connected to the vehicle body via a lifting lug.

[0015] Compared with the prior art, the advantages of this utility model are:

[0016] (1) The battery box internal load-bearing beam frame described in this utility model serves as a carrier for bearing the weight of the battery pack module, constraining the movement of the battery module and improving the rigidity of the battery pack. This utility model optimizes the structure of the second longitudinal beam and the lifting lugs set on the second longitudinal beam. By setting a recessed groove and an inclined reinforcing plate on the second longitudinal beam, and designing the lifting lugs on the second longitudinal beam from multiple individual lifting lugs into a single integrated lifting lug, this design not only increases the contact and connection between the load-bearing beam and the box body, but also increases the rigidity and force transmission path of the second longitudinal beam and the lifting lugs themselves, solving the problems of insufficient rigidity and stress concentration. The battery box internal load-bearing beam frame described in this utility model has good structural load-bearing and bending resistance, can be used on a platform, which helps to reduce the cost of repeated development, and its structural design has low complexity. By optimizing the processing technology, it is easy to process and mass-produce.

[0017] (2) The load-bearing beam frame inside the battery box described in this utility model improves the rigidity and strength performance of the battery pack within a limited design space. The overall pack mode frequency is increased from 42.5Hz to 44.7Hz, and the stiffness is increased by 5.18%. The stress is reduced from 285.8MPa to 183.3MPa, a reduction of 35.9%, effectively solving the problem of stress concentration. The load-bearing beam frame inside the battery box described in this utility model has good mechanical properties, good load-bearing capacity and deformation resistance, and the structural design of the load-bearing beam frame is low in complexity, highly versatile, and has good manufacturing feasibility. Attached Figure Description

[0018] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a structural schematic diagram of the load-bearing beam frame in Embodiment 1;

[0020] Figure 2 This is a partially enlarged view of the load-bearing beam frame in Example 1;

[0021] Figure 3 This is a structural schematic of the load-bearing beam frame in Embodiment 2. Figure 1 ;

[0022] Figure 4 This is a partially enlarged view of the load-bearing beam frame in Example 2;

[0023] Figure 5 This is a structural schematic of the load-bearing beam frame in Embodiment 2. Figure 2 ;

[0024] Figure 6 This is an assembly diagram of the load-bearing beam frame, battery module assembly, and housing assembly in Embodiment 2;

[0025] Figure 7 This is a schematic diagram of the first-order mode shape of the battery pack system of the load-bearing beam frame in Embodiment 1;

[0026] Figure 8 This is a schematic diagram of the first-order mode shape of the battery pack system of the load-bearing beam frame in Embodiment 2;

[0027] Figure 9 This is a schematic diagram showing the maximum stress result of the load-bearing beam frame in the deep pit condition in Example 1;

[0028] Figure 10 This is a schematic diagram showing the maximum stress result of the load-bearing beam frame in the deep pit condition in Example 2.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. First crossbeam, 2. First longitudinal beam, 3. Second longitudinal beam, 4. Lifting lug, 5. Second crossbeam, 6. Middle crossbeam, 7. Third longitudinal beam, 8. Third crossbeam, 9. Groove, 10. Reinforcing plate, 11. Battery module, 12. Load-bearing beam frame, 13. Box body. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0032] Example 1

[0033] like Figures 1 to 2 The load-bearing beam frame 12 shown includes a crossbeam section and a left longitudinal beam and a right longitudinal beam respectively disposed on the left and right sides of the crossbeam section. The crossbeam section includes a first crossbeam 1, a second crossbeam 5, a middle crossbeam 6, and a third crossbeam 8 arranged in parallel at intervals. The left and right longitudinal beams each include a first longitudinal beam 2 and a second longitudinal beam 3 connected in sequence. A middle longitudinal beam 7 connects the middle crossbeam 6 and the third crossbeam 8. The beams are cross-connected by gas shielded welding, resistance welding, and arc spot welding to form a grid-like frame structure.

[0034] like Figure 1 and Figure 2 As shown, the two ends of the first crossbeam 1 are connected to the ends of the first longitudinal beam 2 on the same side of the left and right longitudinal beams, respectively. The two ends of the second crossbeam 5 are connected to the connection points of the first longitudinal beam 2 and the second longitudinal beam 3 on the left and right longitudinal beams, respectively. The two ends of the middle crossbeam 6 are connected to the ends of the second longitudinal beam 3 on the same side of the left and right longitudinal beams, respectively; the two ends of the third crossbeam 8 are connected to the ends of the second longitudinal beam 3 on the same side of the left and right longitudinal beams, respectively. The middle longitudinal beam 7 is arranged parallel to the second longitudinal beam 3 at intervals. The two ends of the middle longitudinal beam 7 are perpendicularly connected to the middle crossbeam 6 and the third crossbeam 8, respectively.

[0035] Example 2

[0036] Based on the structural design of the load-bearing beam frame 12 described in Embodiment 1, Embodiment 2 improves upon the second longitudinal beam 3. In Embodiment 1, multiple lifting lugs are provided on the outer side of the second longitudinal beam 3. For example... Figures 3-5 As shown in the second embodiment, multiple lifting lugs on the second longitudinal beam 3 are integrated into a single lifting lug 4.

[0037] like Figure 4 As shown, the second longitudinal beam 3 is provided with multiple grooves 9, which are arranged vertically, that is, recessed downwards in a direction perpendicular to the horizontal plane. Multiple arc-welded connection parts are provided on the grooves 9; these arc-welded connection parts are used to connect the load-bearing beam frame 12 and the box body 13. Compared with Embodiment 1, Embodiment 2, by providing grooves 9 with arc-welded connections, increases the connection area between the load-bearing beam frame 12 and the box body 13, thereby increasing the force transmission path and improving the overall rigidity.

[0038] In Example 1, as Figure 1 and Figure 3 As shown, the supporting beam frame 12 is provided with multiple lifting lugs 4, which are made of multiple stamped parts. In embodiment two, the lifting lugs have been improved. Figures 3-5 As shown, the lifting lug 4 on the second longitudinal beam 3 is made into a single stamped part from multiple stamped parts in Embodiment 1.

[0039] As a further improvement to the above technical solution, an obliquely placed reinforcing plate 10 is provided between the box body 13 and the second longitudinal beam 3. The reinforcing plate 10 is connected to the box body 13 and the second longitudinal beam 3 respectively, and the connection method is spot welding or gas shielded welding. The second longitudinal beam 3 is a bent component, including a horizontally arranged horizontal plate and a vertically arranged vertical plate above the outer end of the horizontal plate. The reinforcing plate 10 is obliquely connected between the outer end of the horizontal plate and the upper end of the vertical plate.

[0040] To address the issue of excessive intrusion into battery cells during side impacts or other collisions, leading to fires and explosions, and to resolve the problems of weak beam frame stiffness and stress concentration, Embodiment Two, based on the load-bearing beam frame described in Embodiment One, improves the structure of the second longitudinal beam 3 and the lifting lugs 4 on the second longitudinal beam 3, thereby increasing the stiffness of the load-bearing beam frame. By making the lifting lugs 4 on the second longitudinal beam 3 from multiple stamped parts into a single stamped part, not only is the number of molds reduced, but the lateral and transverse stiffness of the load-bearing beam frame is also increased. When the battery pack is impacted, the deformation of the lifting lugs 4 in Embodiment Two is smaller while absorbing the same amount of energy, thus protecting the battery cells. In addition, by providing a concave groove 9 on the second longitudinal beam 3 and an obliquely placed reinforcing plate 10 at the connection between the second longitudinal beam 3 and the lifting lugs 4, the reinforcing plate 10 is connected to the battery box body to increase the force transmission path, allowing the battery box body to absorb more energy, reducing direct impact on the battery cells, and protecting the battery cells.

[0041] As a further improvement to the above technical solution, this utility model also relates to a power battery pack housing, such as... Figure 6 As shown, the power battery pack housing includes: a load-bearing beam frame 12, a main body 13, and lifting lugs 4. Both the load-bearing beam frame 12 and the main body 13 are stamped parts. Multiple lifting lugs are provided on the outer periphery of the load-bearing beam frame 12. In Embodiment 2, the multiple lifting lugs located on the outer side of the second longitudinal beam 3 are integrated into a single stamped part. In Embodiment 1, the multiple lifting lugs on the outer side of the second longitudinal beam 3 are spaced apart, with a certain interval between adjacent lugs. In Embodiment 2, the multiple lifting lugs 4 are integrally formed from multiple stamped parts, including multiple connecting portions connected in sequence.

[0042] Specifically, the box body 13 is located below the load-bearing beam frame 12, and the box body 13 matches and is connected to the load-bearing beam frame 12 in shape; multiple lifting lugs 4 are respectively arranged on the outer edge of the box body 13. The lifting lugs 4 are connected to the edge of the load-bearing beam frame 12, specifically by welding, which can be electric arc spot welding or gas shielded arc welding. Specifically, the box body 13 and the load-bearing beam frame 12 are connected by welding, which can be resistance welding or electric arc spot welding. The box body 13 is square and adapted to the load-bearing beam frame 12. The lifting lugs 4 can be plates with two connecting holes, or they can be bent plates with connecting holes on the horizontal part of the upper part of the bent plates.

[0043] As a further improvement to the above technical solution, this utility model also provides a battery pack, such as... Figure 5As shown, the battery pack includes: a housing, a battery module 11, a thermal management system, and an electrical system. The battery module 11, thermal management system, and electrical system are all housed within the housing. Specifically, the battery module, thermal management system, and electrical system are mounted on a load-bearing beam frame 12 within the housing using fasteners, such as bolts.

[0044] As a further improvement to the above technical solution, this utility model also provides an electric passenger vehicle, which includes a vehicle body and a battery pack. The battery pack is connected to the vehicle body via multiple lifting lugs 4. Specifically, the electric passenger vehicle is an electric car. The lifting lugs 4 are connected to the vehicle body via fasteners, which can be bolts.

[0045] To verify the performance of the load-bearing beam frame 12 described in this utility model, simulation tests were conducted.

[0046] Depend on Figure 7 and Figure 8 As can be seen, compared with the load-bearing beam frame 12 in Embodiment 1, the first-order mode shape of the battery pack in Embodiment 2 has shifted from the middle of the battery pack to the front of the battery pack, indicating that the overall stiffness of the middle position of the battery pack has been enhanced. The overall mode has increased from 42.5Hz in the prior art to 44.7Hz, and the stiffness has increased by 5.18%. The load-bearing beam frame 12 structure described in this utility model improves the stiffness and strength performance of the battery pack within a limited design space, thereby enhancing the safety and stability of the battery pack.

[0047] Depend on Figure 9 and Figure 10 It can be seen that, compared with the load-bearing beam frame 12 in Example 1, the maximum stress in the single-sided deep pit condition in Example 2 is reduced from 285.8MPa to 183.3MPa, a reduction of 35.9%, and the stress at the same location is reduced from 285.8MPa to 31.3MPa, a reduction of 89%, thus effectively solving the problem of stress concentration.

[0048] The above-described embodiments are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made by those skilled in the art to the technical solutions of the present utility model without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A battery pack housing load-bearing beam frame, characterized in that, The load-bearing beam frame (12) includes: a crossbeam portion and a left longitudinal beam and a right longitudinal beam respectively disposed on the left and right sides of the crossbeam portion; the crossbeam portion includes a first crossbeam (1), a second crossbeam (5), a middle crossbeam (6) and a third crossbeam (8) arranged in parallel intervals; the left longitudinal beam and the right longitudinal beam each include a first longitudinal beam (2) and a second longitudinal beam (3) connected in sequence; a middle longitudinal beam (7) connects the middle crossbeam (6) and the third crossbeam (8); a plurality of lifting lugs (4) are provided on the outer periphery of the load-bearing beam frame (12); a plurality of grooves (9) are provided on the top of the second longitudinal beam (3).

2. The battery pack housing load-bearing beam frame according to claim 1, characterized in that, The two ends of the first crossbeam (1) are respectively connected to the ends of the first longitudinal beam (2) on the left and right sides of the longitudinal beam; the two ends of the second crossbeam (5) are respectively connected to the connection between the first longitudinal beam (2) and the second longitudinal beam (3) on the left and right sides of the longitudinal beam; the two ends of the middle crossbeam (6) are respectively connected to the ends of the second longitudinal beam (3) on the left and right sides of the longitudinal beam; the two ends of the third crossbeam (8) are respectively connected to the ends of the second longitudinal beam (3) on the left and right sides of the longitudinal beam; the middle longitudinal beam (7) and the second longitudinal beam (3) are arranged parallel to each other at intervals; the two ends of the middle longitudinal beam (7) are respectively perpendicularly connected to the middle crossbeam (6) and the third crossbeam (8).

3. The battery pack housing load-bearing beam frame according to claim 1, characterized in that, The groove (9) is provided with multiple arc spot welding connection parts; the arc spot welding connection parts are used to connect the load-bearing beam frame (12) and the power battery pack box.

4. The battery pack housing load-bearing beam frame according to claim 1, characterized in that, An inclined reinforcing plate (10) is provided on the second longitudinal beam (3), and the reinforcing plate (10) is connected to the second longitudinal beam (3) and the power battery pack box respectively.

5. The battery pack housing load-bearing beam frame according to claim 2, characterized in that, The beams in the load-bearing beam frame (12) are intersected and connected.

6. The battery pack housing load-bearing beam frame according to claim 1, characterized in that, The lifting lug (4) has a connecting hole; the lifting lug includes a plurality of connecting parts connected in sequence.

7. The battery pack housing load-bearing beam frame according to claim 1, characterized in that, The lifting lug (4) is connected to the edge of the load-bearing beam frame (12), and the lifting lug located on the outside of the second longitudinal beam (3) is integrally formed by multiple stamping parts.

8. A battery pack housing, characterized in that, The battery pack housing includes a load-bearing beam frame (12) as described in any one of claims 1 to 7 and a housing body (13) installed below the load-bearing beam frame (12); both the load-bearing beam frame (12) and the housing body (13) are stamped parts.

9. A battery pack comprising: The battery pack includes a battery module (11), a thermal management system, and an electrical system, characterized in that the battery pack further includes a battery pack housing as described in claim 8; the battery module (11), the thermal management system, and the electrical system are all disposed within the battery pack housing, and the battery module, the thermal management system, and the electrical system are mounted on the load-bearing beam frame (12) by fasteners.

10. An electric passenger vehicle, the electric passenger vehicle comprising: A vehicle body and a battery pack; characterized in that the battery pack is the battery pack according to claim 8; the battery pack is connected to the vehicle body via a lifting lug.

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