Battery box frame, battery box and battery pack
By adopting a sheet metal structure and longitudinal reinforcing ribs, the problem of excessive weight of the injection-molded battery box frame was solved, achieving lightweighting and improved structural strength of the battery box frame.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CALB GROUP CO LTD
- Filing Date
- 2025-06-04
- Publication Date
- 2026-06-30
Smart Images

Figure CN224437811U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to electrochemical battery frames other than fuel cells, and in particular to a battery box frame, a battery box, and a battery pack. Background Technology
[0002] The basic components of a battery box include a frame, cooling plate, and cover. The frame typically consists of two longitudinal side beams spaced apart on the left and right sides, extending in the front-to-back direction. A front side beam connects the front ends of the two side beams, and a rear side beam connects their rear ends. For mounting the battery pack, mounting ribs are also provided on the outer sides of the two side beams. The strength of the frame is a crucial indicator of battery pack safety. This is especially true for vehicle battery packs, as the two side beams are often located on the left and right sides of the vehicle during use and need to possess impact-resistant characteristics; therefore, their strength and rigidity requirements are particularly stringent.
[0003] In existing technologies, battery box frames are manufactured using processes such as metal casting and metal injection molding, with the mounting ribs and longitudinal beams integrally formed. To ensure the structural strength of the battery box frame, a certain thickness is required, which results in excessive weight of the battery box and, to some extent, reduces the mass energy density of the battery pack. Utility Model Content
[0004] One of the objectives of this utility model is to provide a battery box frame to solve the problem of excessive weight caused by the injection molding method used in the manufacturing of existing battery box frames.
[0005] Meanwhile, the purpose of this utility model is also to provide a battery box and a battery pack using the above-mentioned battery box frame.
[0006] To solve the above problems, the battery box frame of this utility model adopts the following technical solution:
[0007] The battery box frame includes two longitudinal side beams arranged at left and right intervals, a front side beam connecting the front ends of the two longitudinal side beams, and a rear side beam connecting the rear ends of the two longitudinal side beams. Hanging ribs for mounting the battery pack are provided on the outer side of the longitudinal side beams. The longitudinal side beams, the front side beams, and the rear side beams are all sheet metal parts. The longitudinal side beams have an inner cavity extending along their length direction. A longitudinal reinforcing rib extending in the front-back direction is fixed in the inner cavity. The longitudinal reinforcing rib contacts the left inner wall and the right inner wall of the inner cavity, respectively, and its projection in the left-right direction at least partially coincides with the projection of the hanging rib on the longitudinal side beam in the left-right direction.
[0008] The beneficial effects of this utility model's battery box frame: This utility model's battery box frame is a pioneering invention. Specifically, this utility model's battery box frame completely abandons the battery box frame manufactured by injection molding in the prior art. Instead, the longitudinal beams, front beams, and rear beams of the battery box frame are all made of sheet metal, achieving a lightweight effect. At the same time, the longitudinal beams are strengthened by setting longitudinal reinforcing ribs on them. In addition, by ensuring that the projection of the longitudinal reinforcing ribs in the left-right direction at least partially coincides with the projection of the mounting ribs on the longitudinal beams in the left-right direction, the longitudinal reinforcing ribs and mounting ribs support each other in the left-right direction, i.e., the direction in which collision may occur. With this structural design, the battery box frame is lightweight while ensuring its structural strength.
[0009] The battery box of this utility model adopts the following technical solution:
[0010] A battery box includes a battery box frame and a cold plate disposed within the battery box frame. The battery box frame includes two longitudinal side beams arranged at left and right intervals, a front side beam connecting the front ends of the two longitudinal side beams, and a rear side beam connecting the rear ends of the two longitudinal side beams. Hanging ribs for mounting battery packs are provided on the outer side of the longitudinal side beams. The longitudinal side beams, the front side beam, and the rear side beam are all sheet metal parts. The longitudinal side beams have an inner cavity extending along their length direction. A longitudinal reinforcing rib extending in the front-back direction is fixed in the inner cavity. The longitudinal reinforcing rib contacts the left inner wall and the right inner wall of the inner cavity, respectively, and its projection in the left-right direction at least partially coincides with the projection of the hanging rib on the longitudinal side beam in the left-right direction.
[0011] The beneficial effects of this utility model's battery box: This utility model's battery box is an improved invention. Specifically, the battery box of this utility model improves its battery box frame. The battery box frame completely abandons the injection molding method used in the prior art, instead using sheet metal structures for the longitudinal beams, front beams, and rear beams of the battery box frame, achieving a lightweight effect. Simultaneously, longitudinal reinforcing ribs are provided on the longitudinal beams to strengthen them. Furthermore, by ensuring that the projection of the longitudinal reinforcing ribs in the left-right direction at least partially overlaps with the projection of the mounting ribs on the corresponding longitudinal beams in the left-right direction, the longitudinal reinforcing ribs and mounting ribs support each other in the left-right direction, i.e., the direction in which collision may occur. This structural design achieves lightweighting of the battery box frame while ensuring its structural strength.
[0012] The battery pack of this utility model adopts the following technical solution:
[0013] A battery pack includes a battery box and battery cells. The battery box includes a battery box frame and a cold plate disposed in the battery box frame. The battery box frame includes two longitudinal side beams arranged at left and right intervals, a front side beam connecting the front ends of the two longitudinal side beams, and a rear side beam connecting the rear ends of the two longitudinal side beams. Hanging ribs for mounting the battery pack are provided on the outer side of the longitudinal side beams. The longitudinal side beams, the front side beam, and the rear side beam are all sheet metal parts. The longitudinal side beams have an inner cavity extending along their length direction. A longitudinal reinforcing rib extending in the front-back direction is fixed in the inner cavity. The longitudinal reinforcing rib contacts the left inner wall and the right inner wall of the inner cavity, respectively, and its projection in the left-right direction at least partially coincides with the projection of the hanging rib on the longitudinal side beam in the left-right direction.
[0014] The beneficial effects of this battery pack: This battery pack is an improved invention. Specifically, the battery pack of this invention improves the battery box frame. The battery box frame completely abandons the injection molding method used in the prior art, and instead, the longitudinal beams, front beams, and rear beams of the battery box frame are all made of sheet metal, achieving a lightweight effect. Simultaneously, longitudinal reinforcing ribs are provided on the longitudinal beams to strengthen them. Furthermore, by ensuring that the projection of the longitudinal reinforcing ribs in the left-right direction at least partially overlaps with the projection of the mounting ribs on the corresponding longitudinal beams in the left-right direction, the longitudinal reinforcing ribs and mounting ribs support each other in the left-right direction, i.e., the direction in which collision may occur. This structural design achieves lightweighting of the battery box frame while ensuring its structural strength. Attached Figure Description
[0015] Figure 1 This is a perspective view of one embodiment of the battery box frame;
[0016] Figure 2 yes Figure 1 The main view of the battery box frame;
[0017] Figure 3 yes Figure 2 AA section view;
[0018] Figure 4 yes Figure 3 A magnified view of a portion at point A;
[0019] Figure 5 This is a schematic diagram of the cross-sectional shape of the longitudinal beam in one embodiment of the battery box frame;
[0020] Figure 6 This is a schematic diagram of the cross-sectional shape of the longitudinal beam and longitudinal stiffener in one embodiment of the battery box frame;
[0021] Figure 7This is a schematic diagram of the cross-sectional shape of the longitudinal beam and longitudinal stiffener in one embodiment of the battery box frame;
[0022] Figure 8 This is a schematic diagram of the cross-sectional shape of the longitudinal beam and longitudinal stiffener in one embodiment of the battery box frame;
[0023] Figure 9 This is a schematic diagram of one embodiment of the battery box frame;
[0024] Figure 10 yes Figure 1 Three-dimensional view of the front and rear side beams and longitudinal side beams;
[0025] Figure 11 yes Figure 1 Top view of the front and rear side beams and longitudinal side beams;
[0026] Figure 12 yes Figure 11 A magnified view of a section at point C.
[0027] In the diagram: 1. Longitudinal side beam; 101. Inner cavity; 102. Weight reduction hole; 2. Front side beam; 3. Rear side beam; 4. Hanging reinforcement; 401. Connecting hole; 5. Longitudinal reinforcing rib; 501. Connecting part; 502. Transition part; 6. Cut; 7. Continuous weld. Detailed Implementation
[0028] The features and performance of this utility model will be further described in detail below with reference to specific embodiments.
[0029] The battery box frame is a key structural component of the power battery pack for new energy vehicles, primarily used to fix the battery modules, provide mechanical support, and protect the battery system from external impacts. During use, the battery box frame acts as the skeleton of the battery box, bearing the weight of the battery modules and other components of the box, resisting external forces such as collisions and compression, and preventing battery damage leading to thermal runaway. In existing technologies, the battery box frame is formed by injection molding. To ensure a certain structural strength, each part needs a large cross-sectional area, resulting in a relatively heavy battery box frame, which to some extent reduces the mass energy density of the battery pack. This invention addresses this issue by using sheet metal as the main material for the side beams of the battery box frame, and by reinforcing certain locations to ensure the overall structural strength of the battery box frame. Overall, while maintaining structural strength, this invention reduces the weight of the battery box frame compared to injection-molded frames. Based on the above inventive concept, this invention proposes technical solutions for the battery box frame, battery box, and battery pack.
[0030] The specific implementation of the battery box frame of this utility model is as follows:
[0031] The battery box frame of this utility model includes two longitudinal side beams 1 arranged at intervals on the left and right. The longitudinal side beam 1 refers to the side beam extending longitudinally along the electrical equipment during use. For example, when the electrical equipment is an electric vehicle, the longitudinal side beam 1 is a beam extending in the front-to-back direction (in this embodiment, front-to-back and left-to-right are relative terms). The front ends of the two longitudinal side beams 1 are connected by a front side beam 2, and the rear ends of the two longitudinal side beams 1 are connected by a rear side beam 3. The front side beam 2, the two longitudinal side beams 1, and the rear beam 3 together form a battery housing space for accommodating the battery. Typically, both longitudinal side beams 1 are straight beams. However, this is not absolute. When the space required by the electrical equipment dictates that the longitudinal side beams 1 have other shapes, their shapes can be designed according to actual needs. For example, they can be curved beams with a certain curvature, or other irregularly shaped beams. As for the shapes of the front side beam 2 and the rear beam 3, they are often related to the space conditions of the installation scenario, and are generally curved beams or other irregularly shaped beams. In summary, the shapes of the longitudinal beam 1, the front beam 2, and the rear beam 3 can be designed by those skilled in the art as needed.
[0032] The battery pack needs to be mounted on a corresponding fixed component during use, such as... Figure 1 , Figure 2 The battery box frame in the illustrated embodiment is for a battery pack used in an electric vehicle. The battery pack needs to be mounted on the vehicle frame during use. To meet the mounting requirements, a mounting rib 4 is provided on the outer side of the longitudinal beam 1 for mounting the battery pack. The mounting rib 4 has a connecting hole 401 for connecting to a corresponding connecting device. Regarding the mounting rib 4, as... Figure 4 As shown, its cross-sectional shape can be rectangular or "U"-shaped, and it is fixedly connected to the corresponding longitudinal beam by welding, riveting, or a combination of welding and riveting. In order for the load-bearing rib 4 to have the expected weight, the load-bearing rib 4 is also made of sheet metal.
[0033] To reduce weight, the longitudinal beam 1, front beam 2, and rear beam 3 of the battery pack frame of this utility model are all sheet metal parts. To ensure that the longitudinal beam 1 has a certain structural strength, a longitudinal reinforcing rib 5 is also fixed on the longitudinal beam 1. The longitudinal reinforcing rib 5 extends in the front-back direction, and its projection in the left-right direction at least partially overlaps with the projection of the hanging rib 4 on the longitudinal beam in the left-right direction. In order to enable the longitudinal reinforcing rib 5 and the hanging rib 4 to form a structure that directly supports each other, the left and right sides of the longitudinal reinforcing rib 5 respectively contact and cooperate with the longitudinal beam on which it is located.
[0034] By using sheet metal for the longitudinal side beam 1, front side beam 2, and rear side beam 3, the weight is significantly reduced compared to injection-molded longitudinal side beam 1, front side beam 2, and rear side beam 3. Furthermore, by ensuring that the projection of the longitudinal reinforcing rib 5 in the left-right direction at least partially overlaps with the projection of the mounting rib 4 on its corresponding longitudinal side beam in the left-right direction, the longitudinal reinforcing rib 5 and the mounting rib 4 form a mutually supporting structure in the left-right direction, thus ensuring that the structural strength meets requirements. For example, if the longitudinal reinforcing rib 5 and the mounting rib 4 are aligned vertically and their left and right sides contact the inner wall of the longitudinal side beam, they exhibit good compression force transmission in side-pillar impact tests. The entire battery pack structure remains relatively stable during the impact, without any damage to the internal components due to structural deformation. Specifically, taking a certain type of battery pack as an example, compared to the battery box frame formed by injection molding, the battery box frame of this invention is 20-30% lighter, and no damage to the internal components of the battery pack occurs due to structural deformation in side-pillar impact tests.
[0035] The main purpose of making the longitudinal side beam 1, front side beam 2, and rear side beam 3 all sheet metal parts is to reduce weight while maintaining sufficient strength for the battery box frame. Since sheet metal parts have a hollow structure, they naturally have a weight advantage compared to solid injection-molded parts. Therefore, ensuring the strength of these components is the primary consideration. Taking the longitudinal side beam 1 as an example, when using a single sheet of material with fixed length, width, and thickness to manufacture the longitudinal side beam 1, reinforcing ribs can be processed on it using methods such as stamping to increase its bending resistance, or it can be bent into a closed cylindrical structure to increase its bending resistance, or it can be bent into a U-shaped cross-section with folded edges (such as...). Figure 5 As shown), shapes such as C-shaped flanges are used to increase bending resistance. Those skilled in the art should understand that all of the above methods are feasible to achieve the goal of improving bending resistance. In this case, the inner cavity of the longitudinal beam is a semi-open structure, and the inner wall of the flange forms the left or right inner wall of the cavity. However, as a preferred embodiment, to facilitate processing, the arrangement of the longitudinal stiffeners 5, and to maintain surface flatness, the longitudinal beam 1 is designed as a structure with an inner cavity. In other words, the longitudinal beam 1 has an inner cavity 101 extending along its length, and the longitudinal stiffeners 5 are disposed in the inner cavity 101. For example, in... Figures 1-4 as well as Figures 6-8 In the embodiment shown, the longitudinal beam 1 is designed with a rectangular cross-section, combined with Figures 3-4As shown, as a further optimization, weight-reduction holes 102 are also provided on the longitudinal beam 1. Of course, those skilled in the art should understand that the weight-reduction holes 102 are provided to achieve a better weight-reduction effect. However, compared with the injection-molded battery box frame, even without the weight-reduction holes 102, the battery box frame of this utility model still has certain advantages in terms of lightweighting. That is, the weight-reduction holes 102 are not necessary for this utility model to solve the technical problem.
[0036] like Figure 6-8 As shown, during the sheet metal forming process, the longitudinal beam will form a rounded corner structure at its bending position. In order to avoid the longitudinal stiffeners affecting the formation of the rounded corner structure, the arrangement of the longitudinal stiffeners should meet the following conditions: Let the distance from the end of the cross section of the longitudinal stiffener in the vertical direction to 1 / 2 height of the longitudinal beam be e, and the height of the longitudinal beam be A, then 0 < e ≤ A / 2 - 2.5, in mm.
[0037] Although only the structure and principle of the longitudinal beam 1 have been described above, those skilled in the art should understand that the above structure and principle are also applicable to the front beam 2 and the rear beam 3. Therefore, the relevant content of the front beam 2 and the rear beam 3 will not be elaborated here. In some embodiments, the front beam 2, the longitudinal beam 1, and the rear beam 3 can also be set as an integral structure (e.g., Figure 1 , Figure 2 , Figure 10 , Figure 11 (As shown).
[0038] When the cross-section of the longitudinal beam 1 is rectangular, the inner cavity 101 of the longitudinal beam 1 naturally has a left inner wall and a right inner wall that are opposite to each other. At this time, the cross-section of the longitudinal stiffener 5 includes a connecting portion 501 fixed to the left or right inner wall of the inner cavity and a transition portion 502 connected to the connecting portion 501. The connecting portion 501 is fixedly connected to the inner wall of the corresponding longitudinal beam 1. By connecting the connecting portion 501 to the left and right inner walls of the inner cavity, the longitudinal stiffener 5 and the longitudinal beam to which it is located can form an integral structure, which helps to improve the overall strength. In order to achieve the effect of improving the overall strength, only the connecting portion connected to the left inner wall, only the connecting portion connected to the right inner wall, or both the left and right inner walls can be provided on the longitudinal stiffener 5. The number of connecting portions connected to the left inner wall can be multiple and distributed in the vertical direction. Similarly, the number of connecting portions connected to the right inner wall can also be multiple and distributed in the vertical direction.
[0039] The connection between the connecting part 501 and the longitudinal edge beam 1 can be achieved by welding, riveting, or bonding, or a combination of at least two of these methods. In a preferred embodiment, the connecting part 501 and the longitudinal edge beam 1 are connected longitudinally in segments to form a weld group. The welding process can be plug welding or laser welding. The weld group includes two or more longitudinally distributed welds, with the distance between adjacent welds ranging from 10mm to 300mm, specifically, for example, 10mm, 20mm, 30mm, 50mm, 100mm, 150mm, 180mm, 220mm, 270mm, 300mm, etc.; the length of the weld is 3mm to 25mm, for example, 3mm, 5mm, 9mm, 10mm, 15mm, 25mm, etc.; and the width of the weld is 2mm to 20mm, for example, 2mm, 25mm, 10mm, 14mm, 18mm, 20mm, etc. Of course, in another embodiment, laser welding can be used. The connecting part and the longitudinal beam can also be welded together to form a continuous weld at the weld. The length of the continuous weld is 10mm-3000mm, for example, it can be 10mm, 50mm, 80mm, 100mm, 300mm, 500mm, 1000mm, 1200mm, 1600mm, 2000mm, 2500mm, 2800mm, 3000mm, etc.; the weld width is 2mm-20mm. When designing the weld, it can be set as a horizontal weld, or it can be set as an inclined weld in the vertical direction, or both inclined welds and horizontal welds can be used at the same time. For example, horizontal welds and inclined welds intersect to form a fishbone-like structure, or horizontal welds and inclined welds can be arranged at intervals along the longitudinal direction.
[0040] As mentioned earlier, the main function of the longitudinal stiffener 5 is to strengthen the longitudinal beam 1 and form the aforementioned "mutually compatible" structure with the hanging stiffener 4. Therefore, provided that the above functions can be achieved, the stiffener 5 can be a sheet metal stiffener with any cross-sectional shape. For example, it can be just a sloping plate with connecting parts at the upper and lower edges (such as...). Figure 6 As shown), it can also be a waveform, with connecting parts at the upper and lower edges (such as...). Figure 7 As shown), or a U-shape, with connecting parts at the top and bottom edges (such as...). Figure 8 As shown), the connection parts at the upper and lower edges are formed by folding. When the cross-sectional shape of the longitudinal stiffener 1 is wave-shaped, the peaks of the waves can form connection parts, connecting with the corresponding positions of the longitudinal beams; when the cross-sectional shape of the longitudinal stiffener 1 is U-shaped, the bottom of the U-shape can also form connection parts, connecting with the corresponding positions of the longitudinal beams 1.
[0041] exist Figure 1-4 In the illustrated embodiment, the cross-section of the longitudinal stiffener is rectangular, and the left and right side walls of the rectangle form the connecting portion. Here, the longitudinal stiffener 5 can be rolled out by sheet metal or a finished square steel pipe can be used. In the up and down directions, the midpoints of the longitudinal stiffener 5 and the mounting stiffener 4 are arranged at the same height.
[0042] When the front side beam 2, the longitudinal side beam 1, and the rear side beam 3 are of an integral structure, arc transition portions are respectively provided at both ends of the longitudinal side beam 1. The arc transition portions are for realizing the transition between different side beams. As Figures 11-12 shown, at this time, it should be ensured that the longitudinal stiffener 1 has a set distance B from the adjacent arc transition position to avoid interference with the arc transition position.
[0043] Specifically, Figure 9 shows a typical structure of the battery box frame of the present invention. In Figure 9 the illustrated embodiment, the battery box frame adopts a three-section structure, where the front side beam and the rear side beam respectively form the front and rear sections, and the longitudinal side beam 1 forms the middle section. The front and rear side beams are welded by facing the ends of the corresponding longitudinal side beams.
[0044] In Figure 10 the illustrated embodiment, the front side beam, the rear side beam, and the longitudinal side beam are of an integral structure. At this time, attention should be paid to controlling the end positions of the longitudinal stiffeners provided in the portion corresponding to the longitudinal side beam to avoid interference with the adjacent bending sections (such as Figure 10 shown at C). The two ends of the sheet metal part are overlapped and welded together.
[0045] In Figures 9-10 the illustrated embodiments, the longitudinal side beam can adopt Figure 4 , Figure 6 , Figure 7 , <00001
[0048] Specific embodiments of the battery pack of this utility model:
[0049] The battery pack of this utility model includes a battery box and battery cells. The battery box is the battery box of this utility model. The structure and installation structure of the battery cells are existing technologies and will not be described in detail here.
[0050] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. The patent protection scope of the present utility model shall be determined by the claims. Similarly, any equivalent structural changes made based on the description and drawings of the present utility model shall also be included within the protection scope of the present utility model.
Claims
1. A battery case frame, characterized by, It includes two longitudinal side beams arranged at left and right intervals, a front side beam connecting the front ends of the two longitudinal side beams, and a rear side beam connecting the rear ends of the two longitudinal side beams. Hanging ribs for mounting battery packs are provided on the outer side of the longitudinal side beams. The longitudinal side beams, the front side beams, and the rear side beams are all sheet metal parts. The longitudinal side beams have an inner cavity extending along their length direction. A longitudinal reinforcing rib extending in the front-back direction is fixed in the inner cavity. The longitudinal reinforcing rib contacts the left inner wall and the right inner wall of the inner cavity, respectively, and its projection in the left-right direction at least partially coincides with the projection of the hanging rib on the longitudinal side beam in the left-right direction.
2. The battery case frame according to claim 1, characterized by The cross-section of the longitudinal stiffener includes a connecting portion fixed to the left or right inner wall of the cavity and a transition portion connected to the connecting portion. The connecting portion is fixedly connected to the inner wall of the corresponding longitudinal side beam.
3. The battery case frame according to claim 2, characterized by The connecting part is welded to the longitudinal edge beam in sections to form a weld group. The weld group includes two or more welds distributed longitudinally. The distance between adjacent welds is 10mm-300mm, and the length of the weld is 3mm-25mm.
4. The battery box frame according to claim 3, characterized in that, The weld is either a horizontal weld or an inclined weld; or part of the weld is a horizontal weld and part is an inclined weld.
5. The battery box frame according to claim 2, characterized in that, The connecting part is welded to the longitudinal edge beam and a continuous weld is formed at the weld. The length of the continuous weld is 10mm-3000mm, and the continuous weld is either a horizontal weld or an inclined weld.
6. The battery box frame according to claim 1, characterized in that, The distance from the end of the cross section of the longitudinal stiffener in the vertical direction to half the height of the longitudinal edge beam is e, and the height of the longitudinal edge beam is A, where 0 < e ≤ A / 2 - 2.5, and the unit is mm.
7. The battery box frame according to any one of claims 2-5, characterized in that, The longitudinal reinforcing rib is a sheet metal part with a waveform cross-section, and the connecting part is formed by the peak position of the waveform.
8. The battery box frame according to any one of claims 1-6, characterized in that, The front beam, longitudinal beam, and rear beam are an integral structure. At both ends of the longitudinal beam, there are arc transition sections. The longitudinal stiffeners are spaced at a set distance from the adjacent arc transition positions to avoid interference with the arc transition positions.
9. The battery box frame according to any one of claims 2-5, characterized in that, The longitudinal stiffener has a rectangular cross-section, and the left and right side walls of the rectangle constitute the connecting portion.
10. A battery box, comprising a frame and a cold plate disposed therein, characterized in that, The frame is the battery box frame as described in any one of claims 1-9.
11. A battery pack, comprising a battery case and battery cells, characterized in that, The battery box is the battery box as described in claim 10.