A frameless battery system

Abstract

This utility model discloses a frameless battery system, comprising: a base, multiple battery boxes, and a skin; multiple battery boxes are stacked on the base to form a battery stack, with the bottommost battery box fixedly connected to the base. Each battery box has a first support fixedly connected to its outer wall. The skin covers the sides and top of the battery stack and is fixedly connected to the first support. This application achieves a balance between fully enclosed protection and lightweight structure in the battery system. The skin is directly fixed to the battery box body through distributed support points, effectively reducing the overall steel consumption of the system. The self-supporting system formed by the stacked battery boxes effectively transfers external loads, ensuring the stability of the skin structure.

Description

Technical Field

[0001] This utility model relates to the field of battery system technology, and in particular to a frameless battery system. Background Technology

[0002] Existing battery systems typically employ a frame structure, consisting of a base, a frame, multiple battery cells, and a skin. The frame is fixedly mounted on the base, the battery cells are stacked inside the frame and fixedly connected to it, and the skin covers the outside of the frame. While this structure is robust, the weight of the frame itself increases the overall weight of the battery system, hindering lightweight design.

[0003] To address the weight issue associated with traditional battery packs, frameless battery systems have emerged in the market. These systems eliminate the traditional frame structure, directly stacking and fixing the battery pack onto a base. However, this frameless design introduces new problems: on the one hand, electrical components typically need to be externally mounted on the outside of the battery pack, exposed to the external environment for extended periods, making them susceptible to corrosion from wind, sun, and other natural factors, thus affecting their lifespan; on the other hand, if the electrical components were built into the battery pack, the battery pack volume would need to be increased, which would lead to an increase in battery pack weight, contradicting the initial goal of lightweight design.

[0004] Furthermore, existing frameless battery systems also have shortcomings in terms of skin mounting. Traditional skin mounting methods are complex and inconvenient for disassembly and maintenance. Especially in applications where battery systems require frequent maintenance, existing skin structures often fail to meet the needs for rapid assembly and disassembly. Summary of the Invention

[0005] In view of this, the present invention provides a frameless battery system, which has the advantages of reducing overall weight, protecting electrical components and facilitating maintenance.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] A frameless battery system includes: a base, multiple battery boxes, and a skin; the multiple battery boxes are stacked on the base to form a battery stack, the bottommost battery box is fixedly connected to the base, and a first bracket is fixedly connected to the outer wall of each battery box; the skin covers the four sides and top surface of the battery stack and is fixedly connected to the first bracket.

[0008] Preferably, the skin includes a top skin and a circumferential skin. The circumferential skin includes a first circumferential skin layer, a second circumferential skin layer, and a third circumferential skin layer. The first circumferential skin layer, the second circumferential skin layer, and the third circumferential skin layer are overlapped sequentially from bottom to top. A top skin edging is provided around the top skin, and the top skin edging overlaps and presses against the upper end of the third circumferential skin layer.

[0009] Preferably, the first circumferential skin, the second circumferential skin, and the third circumferential skin are each composed of two front skins and two side skins. The two front skins cover the front and rear sides of the battery stack, respectively, and the two side skins cover the left and right sides of the battery stack, respectively.

[0010] Preferably, the front skin includes a front skin body, two first folded edges, and a second folded edge. The two first folded edges are respectively disposed on the left and right sides of the front skin body, and the second folded edge is disposed on the upper side of the front skin body. The lower end of the upper front skin overlaps and presses against the second folded edge of the lower front skin. The second folded edge has a plurality of perforations spaced apart, and each perforation is fitted with a rivet nut. The lower end of the front skin body has a plurality of through holes spaced apart, corresponding one-to-one with the plurality of perforations. The upper and lower adjacent front skin layers are fixedly connected by bolts connected to the rivet nuts.

[0011] Preferably, the side skin includes a side skin body, two side skin edgings, and a third folded edge. The two side skin edgings are respectively disposed on the left and right sides of the side skin body, and the third folded edge is disposed on the upper side of the side skin body. The lower end of the upper side skin overlaps and presses against the third folded edge of the lower side skin, and the side skin edgings on the same layer overlap and press against the first folded edge of the adjacent front skin and are screwed together onto the first bracket. The third folded edge has multiple perforations spaced apart, and each perforation is fitted with a rivet nut. The lower end of the side skin body has multiple through holes spaced apart, corresponding one-to-one with the multiple perforations. The upper and lower adjacent side skins are fixedly connected by bolts connected to the rivet nuts.

[0012] Preferably, the frameless battery system further includes a mounting bracket, which is fixedly connected to the upper side of the battery box at the top. The top skin edges on the front and rear sides of the top skin overlap and press against the second folded edge and are screwed together onto the mounting bracket. The top skin edges on the left and right sides of the top skin overlap and press against the third folded edge and are screwed together onto the mounting bracket.

[0013] Preferably, the first bracket is also fixedly connected to the mounting bracket, and the mounting position of the first bracket corresponds vertically to the mounting position of the first bracket on the battery box.

[0014] Preferably, each of the battery boxes has two first brackets on its front and rear outer walls, and the two first brackets are symmetrically assembled at both ends of the battery box along its length on the same side of the outer wall.

[0015] Preferably, each battery box has multiple second brackets spaced apart along its length on the outer wall of the box in both length directions. Each second bracket has bolt holes, and each front skin has multiple through holes on its main body that mate with the bolt holes on the corresponding second brackets. The front skin is fixedly connected to the second brackets by bolts screwed into the bolt holes.

[0016] Preferably, the base has bottom mounting brackets at both ends along its length. The bottom mounting brackets have bolt holes corresponding to the through holes at the lower end of the bottommost side skin body. The lower end of the bottommost side skin body is fixedly connected to the bottom mounting brackets by bolts.

[0017] Preferably, the inner surfaces of both the front skin and the side skin are provided with reinforcing ribs.

[0018] Preferably, heat dissipation holes are provided on the uppermost skin layer.

[0019] The beneficial effects of this utility model are as follows: Compared with the prior art, this application achieves a unity of fully enclosed protection and lightweight structure for the battery system. The skin is directly fixed to the battery box body through distributed support points, effectively reducing the overall steel consumption of the system. The self-supporting system formed by the stacked battery boxes effectively transfers external loads, ensuring the stability of the skin structure. The continuous support ring formed by the top mounting bracket and the battery box support enhances the edge protection of openings such as heat dissipation holes.

[0020] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the frameless battery system of this utility model;

[0022] Figure 2 This is a structural schematic diagram of the frameless battery system (with the bottom layer skin removed) of this utility model;

[0023] Figure 3 This is a schematic diagram of the frameless battery system (without the skin) of this utility model;

[0024] Figure 4 This is a structural schematic diagram of the front skin (front) of this utility model;

[0025] Figure 5 This is a structural schematic diagram of the front skin (back side) of this utility model;

[0026] Figure 6This is a structural schematic diagram of the side skin (front) of this utility model;

[0027] Figure 7 This is a structural schematic diagram of the side skin (back side) of this utility model.

[0028] Figure label:

[0029] 1. Base; 101. Bottom mounting bracket;

[0030] 2. Mounting bracket; 3. Battery box;

[0031] 4. Skin; 41. Top skin; 42. Circumferential skin; 411. Top skin edging; 421. First layer of circumferential skin; 422. Second layer of circumferential skin; 423. Third layer of circumferential skin; 401. Front skin; 402. Side skin; 4011. Front skin body; 4012. First folded edge; 4013. Second folded edge; 4014. Ventilation vent; 4021. Side skin body; 4022. Side skin edging; 4023. Third folded edge;

[0032] 5. First bracket; 6. Second bracket; 7. Reinforcing rib; 8. Rivet nut. Detailed Implementation

[0033] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. 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.

[0034] 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0035] The following is for reference. Figures 1 to 7 Describe the frameless battery system in the embodiments of this utility model.

[0036] This application discloses a frameless battery system, including: a base 1, a mounting bracket 2, multiple battery boxes 3 and a skin 4; multiple battery boxes 3 are stacked on the base 1 to form a battery stack, the bottommost battery box 3 is fixedly connected to the base 1, and a first bracket 5 is fixedly connected to the outer wall of each battery box 3. The skin 4 covers the four sides and the top surface of the battery stack and is fixedly connected to the first bracket 5.

[0037] Furthermore, each battery box 3 has two first brackets 5 on its front and rear outer walls. On the same side of the outer wall, the two first brackets 5 are symmetrically assembled at both ends of the battery box 3 along its length.

[0038] The base 1 serves as the foundation platform supporting the battery stack, providing basic support for the entire system. The battery box 3 is a standardized unit that houses the battery modules, with pre-installed connection interfaces on its outer wall along its length. The first bracket 5 is a metal connector mounted on the outer wall of the battery box 3, fixed to the box body by welding or bolts, providing distributed anchoring points for the skin 4. The skin 4 is a protective plate covering the battery stack, which can be made of galvanized steel or composite material, with the connection structure formed through an edge-folding process.

[0039] Specifically, the base 1 serves as the basic load-bearing platform, and the battery boxes 3 form a self-supporting system by stacking them one on top of the other. The bottom layer of the box is rigidly connected to the base 1 to ensure overall stability. The first brackets 5 at both ends of the length of each battery box 3 form a longitudinal support line. The skin 4 is connected to each layer of the first brackets 5 by bolts to form a continuous covering structure. When the skin 4 bears external loads, the stress is transferred to the battery box 3 body through the first brackets 5, and the load is distributed by the structural strength of the box itself.

[0040] Compared to existing technologies, traditional solutions rely on independent frames to support the skin, requiring additional columns and beams, resulting in material waste and increased weight. This solution uses pre-set support points on the battery box 3 body, allowing the skin 4 to be directly fixed to the functional components, eliminating the need for an independent frame structure. In existing technologies, the installation of the skin 4 relies on pre-set connection holes in the frame; this solution uses the self-contained connection points of the layered stacked battery boxes 3 to achieve the installation and rapid positioning of the skin 4.

[0041] Through the above technical solution, this application achieves a balance between fully enclosed protection and lightweight structure for the battery system. The skin 4 is directly fixed to the battery box 3 body via distributed support points, effectively reducing the overall steel consumption of the system. The self-supporting system formed by the stacked battery boxes 3 effectively transfers external loads, ensuring the structural stability of the skin 4.

[0042] In some embodiments, for example Figure 1 As shown, the skin 4 includes a top skin 41 and a circumferential skin 42. The circumferential skin 42 includes a first circumferential skin 421, a second circumferential skin 422, and a third circumferential skin 423. The first circumferential skin 421, the second circumferential skin 422, and the third circumferential skin 423 are layered and overlapped from bottom to top. A top skin edging 411 is provided around the top skin 41, and the top skin edging 411 overlaps and presses against the upper end of the third circumferential skin 423.

[0043] The circumferential skin 42 is a protective layer surrounding the battery stack. Layered overlapping refers to a connection method where adjacent skin layers partially overlap, for example, the lower edge of the upper skin layer covers the upper edge of the lower skin layer, secured with bolts or rivets to form a continuous protective surface. The top skin edging 411 is a folded structure extending downwards from the edge of the top skin 41, used to cover the top edge of the circumferential skin 42 to prevent rainwater infiltration.

[0044] Specifically, the circumferential skin 42 is divided into three independently installed skin layers, which are overlapped one by one from the bottom layer during installation. Each skin layer 4 has a folded edge structure at its upper edge and is pre-installed with rivet nuts 8. After the upper folded edge of the lower skin layer is covered by the lower edge of the upper skin layer 4, it is locked to the rivet nuts 8 via bolts through through holes. The top skin edging 411 extends downwards to the top of the third circumferential skin layer 423, and is fixed together with the third skin layer 4 by bolts, forming a continuous seal at the top and sides. This structure allows the skin 4 to be installed in segments in the vertical direction, avoiding installation difficulties caused by excessively large single-layer skin dimensions, while the overlapping areas between layers form a double protective barrier.

[0045] Compared to existing technologies, traditional frameless battery systems employ a monolithic or simple layered structure for their skin, requiring multiple people to work together during installation and prone to assembly errors. This solution, however, utilizes a three-layer overlapping circumferential skin 42, reducing the weight of each layer and allowing for single-person positioning and installation. The bolted connection between the top skin edge 411 and the third circumferential skin 423 replaces the supporting role of crossbeams in traditional frame structures, ensuring connection strength while reducing the number of structural components.

[0046] Through the above technical solution, this application solves the problems of complex installation and insufficient protection of the skin 4 in frameless battery systems. The layered overlapping structure reduces the installation difficulty of a single-layer skin, and the overlapping areas between layers form multiple seals, effectively preventing the intrusion of moisture and dust. The screw connection between the top skin edge 411 and the circumferential skin 42 ensures a reliable connection between the top and sides under frameless conditions, preventing the skin 4 from falling off due to vibration.

[0047] In some embodiments, for example Figure 1 As shown, the first circumferential skin 421, the second circumferential skin 422 and the third circumferential skin 423 are each composed of two front skins 401 and two side skins 402. The two front skins 401 cover the front and rear sides of the battery stack, respectively, and the two side skins 402 cover the left and right sides of the battery stack, respectively.

[0048] The front skin 401 is a flat structure covering the front and rear sides of the battery stack, which can be formed by stamping metal sheets. Its left and right edges can be fitted with folded edges to overlap with the side skin 402. The side skin 402 is a horizontal U-shaped structure covering the left and right sides of the battery stack, which can be formed by bending. Its ends are fitted with edging structures to connect with the front skin 401 and the support structure. The single-layer circumferential skin 42 adopts a split structure, which is divided into independent components: the front skin 401 and the side skin 402. Circumferential coverage is achieved through modular assembly. This design reduces the processing difficulty of individual skin components.

[0049] Specifically, the front skin 401 and the side skin 402 form independent mounting units during assembly. The front skin 401 covers the front and rear planar areas of the battery stack, and its folded edge structure can form an overlapping surface with the side skin edge 4022. The side skin 402 wraps around the left and right sides of the battery stack through a horizontal U-shaped structure, and its edge extends to the outside of the folded edge of the front skin 401. During installation, the front skin 401 and the side skin 402 can be aligned with the corresponding surfaces of the battery stack for positioning, and then fixed to the bracket in sequence with bolts. The split structure allows the skin 4 in each direction to be adjusted independently for installation, avoiding the cumulative error caused by the stacking of multiple layers of integral skin 4, while simplifying the processing complexity of a single layer skin 4.

[0050] Compared with existing technologies, traditional circumferential skins adopt an integral ring structure, which requires precise control of the skin size to match the battery stack. During installation, the entire piece needs to be fitted together and its position adjusted, resulting in positioning difficulties and low assembly efficiency. This solution decomposes the circumferential skin 42 into planar and three-dimensional components through a split design, allowing the front skin 401 and the side skin 402 to be installed independently, reducing the precision requirements for individual parts, and enabling rapid positioning and layered overlapping of the skins 4 in all directions.

[0051] Through the above technical solution, this application effectively solves the problem of complex structure when the circumferential skin 42 is layered and overlapped. The split skin 4 structure allows each layer of skin 4 to be decomposed into standardized components for mass production, and the independent assembly of the front skin 401 and the side skin 402 simplifies the operation process during installation. The modular design avoids the risk of misalignment when the overall skin 4 is stacked in multiple layers, improving assembly efficiency while ensuring the connection stability between each layer of skin 4.

[0052] In some embodiments, for example Figure 4 and Figure 5As shown, the front skin 401 includes a front skin body 4011, two first folded edges 4012, and a second folded edge 4013. The two first folded edges 4012 are respectively disposed on the left and right sides of the front skin body 4011, and the second folded edge 4013 is disposed on the upper side of the front skin body 4011. The lower end of the upper front skin 401 overlaps and presses against the second folded edge 4013 of the lower front skin 401. The second folded edge 4013 has multiple perforations spaced apart, and each perforation is fitted with a rivet nut 8. The lower end of the front skin body 4011 has multiple through holes spaced apart, corresponding one-to-one with the multiple perforations. The upper and lower adjacent front skins 401 are fixedly connected by bolts connected to the rivet nuts 8.

[0053] The front skin body 4011 refers to the flat plate structure that constitutes the main covering surface of the front skin 401, used to cover the front and rear surfaces of the battery stack. The first folded edge 4012 is used to provide a support surface for the side skins 402 to overlap. The second folded edge 4013 refers to a folded edge structure that extends horizontally outward along the upper edge of the front skin body 4011, and the perforations on its surface are used to install rivet nuts 8, forming pre-embedded connection points. The rivet nut 8 refers to a threaded connector that is pre-riveted into the perforations of the second folded edge 4013, used to form a bolt connection with the through holes of the upper front skin 401.

[0054] Specifically, the main body 4011 of the front skin is formed into a planar covering structure by stamping, and the first folded edges 4012 on its left and right sides overlap with the side skins 402. The second folded edge 4013 forms a horizontally extending bearing surface on the upper side of the main body 4011 of the front skin, and a fixed connection point is formed after installing the rivet nuts 8 in the through holes opened by the punching process. The lower edge of the upper front skin 401 is directly pressed onto the upper surface of the lower second folded edge 4013, and is positioned by corresponding positions with the lower rivet nuts 8 through through holes, and is vertically fastened with bolts. An overlapping structure is formed between the two adjacent front skins 401 to ensure the sealing of the connection area and the load transfer effect. During installation, the operator only needs to align the through holes of the upper front skin 401 with the positions of the lower rivet nuts 8 and screw in the bolts to complete the fixation, without the need for on-site welding or special positioning tools.

[0055] Through the above technical solutions, this application achieves a reliable mechanical connection between adjacent front skin layers 401, and enhances the bending stiffness of the connection area through the overlapping structure. The design of the pre-embedded rivet nuts 8 simplifies the on-site assembly process and avoids damage to the surface of the skin 4 during welding operations. The corresponding setting of the upper and lower layer through holes and perforations ensures the connection accuracy, and the bolt tightening method facilitates partial disassembly and replacement during later maintenance. The overlapping fit of the folded edge structure forms a continuous sealing surface, effectively preventing moisture and dust from entering the battery system.

[0056] In some embodiments, for example Figure 6 and Figure 7 As shown, the side skin 402 includes a side skin body 4021, two side skin edgings 4022, and a third folded edge 4023. The two side skin edgings 4022 are respectively located on the left and right sides of the side skin body 4021, and the third folded edge 4023 is located on the upper side of the side skin body 4021. The lower end of the upper side skin 402 overlaps and presses against the third folded edge 4023 of the lower side skin 402. The side skin edgings 4022 on the same layer overlap and press against the first folded edge 4012 of the adjacent front skin 401 and are screwed together onto the first bracket 5. The third folded edge 4023 has multiple perforations spaced apart, and each perforation is fitted with a rivet nut 8. The lower end of the side skin body 4021 has multiple through holes spaced apart, corresponding one-to-one with the multiple perforations. The two adjacent side skins 402 are fixedly connected by bolts connected to the rivet nuts 8.

[0057] Among them, the side skin edge 4022 is a folded structure extending outward from the left and right sides of the side skin body 4021. Specifically, it can be formed by bending an aluminum plate using a stamping process, and is used to cover the edge of the first folded edge 4012 of the front skin 401 to achieve a seal. The third folded edge 4023 is a folded edge structure extending horizontally outward from the upper side of the side skin body 4021, and is used to form an overlapping interface with the upper side skin body 4021.

[0058] Specifically, after the side skin edge 4022 overlaps with the first folded edge 4012 of the front skin 401, it is fastened to the first bracket 5 by bolts passing through both, forming a transverse sealing interface and a longitudinal support structure. After the third folded edge 4023 overlaps with the upper side skin body 4021, the lower layer pre-embedded rivet nuts 8 are precisely aligned with the upper layer through holes, and a vertical rigid connection is achieved by screwing in bolts. This structure, through the multiple overlaps of the edge and folded edge, enables the side skin 402 to form continuous support in both the transverse and longitudinal directions. At the same time, the pre-embedded rivet nuts 8 avoid damage to the skin 4 material caused by welding or riveting, simplifying the assembly process.

[0059] Through the above technical solution, this application solves the problem of unstable connection between the side skin 402 and adjacent components, realizes the sealed connection between the same layer skin 4 and the precise positioning of the upper and lower layers skin 4, and simplifies the assembly process by using pre-set threaded connection points, thereby improving the maintainability and deformation resistance of the skin 4 system.

[0060] In some embodiments, for example Figure 2As shown, the frameless battery system also includes a mounting bracket 2, which is fixedly connected to the upper side of the top battery box 3. The top skin edges 411 on the front and rear sides of the top skin 41 overlap and press against the second folded edge 4013 and are screwed together onto the mounting bracket 2. The top skin edges 411 on the left and right sides of the top skin 41 overlap and press against the third folded edge 4023 and are screwed together onto the mounting bracket 2. The mounting bracket 2 is a constraint member located at the top of the battery stack, and it is bolted to the top battery box 3 to form an upper fixing point. Furthermore, a first bracket 5 is also fixedly connected to the mounting bracket 2, and the mounting position of the first bracket 5 corresponds vertically to the mounting position of the first bracket 5 on the battery box 3.

[0061] Specifically, the base 1 and the top mounting bracket 2 form an upper and lower constraint structure. The first bracket 5 at the corresponding position of the mounting bracket 2 forms a top support ring. The top mounting bracket 2 and the first bracket 5 of the uppermost battery box 3 together form a closed support ring to prevent the top skin 41 from collapsing. The edging on the front and rear sides of the top skin 41 covers the surface of the second folded edge 4013 of the front skin 401. Bolts pass through the rivet nuts 8 of the edging and the second folded edge 4013, locking both together in the screw holes of the mounting bracket 2. The edging on the left and right sides covers the surface of the third folded edge 4023 of the side skin 402. Bolts pass through the rivet nuts 8 of the edging and the third folded edge 4023, locking both together in another set of screw holes of the mounting bracket 2. The second folded edge 4013 of the front skin 401 and the third folded edge 4023 of the side skin 402 serve as longitudinal and transverse load-bearing structures, respectively. The mounting bracket 2 achieves centralized fixation of the skins 4 in different directions, forming a continuous sealed interface.

[0062] Through the above technical solution, this application solves the problems of easy water seepage and loosening at the connection between the top skin 41 and the circumferential skin 42. The differentiated overlapping method of the top skin edge 411 and different folded edges not only maintains the original layered connection characteristics of the front skin 401 and the side skin 402, but also forms a three-dimensional fixing structure through the mounting bracket 2, which reduces the shear force borne by the bolt connection points at the joints of the skin 4, and effectively controls the compression of the sealing strip, thereby improving the waterproof performance and long-term reliability of the overall structure.

[0063] In some embodiments, for example Figure 2 and Figure 3 As shown, bottom mounting brackets 101 are provided at both ends of the base 1 along its length. The bottom mounting brackets 101 are provided with bolt holes corresponding to the through holes opened at the lower end of the bottom side skin body 4021. The lower end of the bottom side skin body 4021 is fixedly connected to the bottom mounting brackets 101 by bolts.

[0064] The bottom mounting bracket 101 refers to the metal support structure located at both ends of the base 1 along its length. It can be fixed to the base 1 by welding or bolting, providing a load-bearing interface for the lower end of the side skin 402. The bolt holes and through holes correspond to each other, meaning that the bolt holes of the bottom mounting bracket 101 and the through holes at the lower end of the side skin 402 are perfectly matched in space. This can be achieved using laser positioning or mold forming processes to ensure precise hole alignment during installation.

[0065] Specifically, the bottom mounting bracket 101 is pre-fixed to both ends of the base 1 along its length, and the bolt holes on its surface correspond one-to-one with the through holes at the lower end of the side skin 402. During installation, the lower end of the side skin 402 is fitted against the surface of the bottom mounting bracket 101, and is fixed by screwing bolts through the through holes. This connection method allows the lower end of the side skin 402 to directly bear the structural support force from the base 1, avoiding the risk of deformation of the skin 4 due to bottom suspension. At the same time, the pre-tightening force of the bolts forms a rigid connection interface, effectively limiting the displacement of the side skin 402 under vibration or impact loads.

[0066] Through the above technical solution, this application achieves a stable connection between the bottom of the side skin 402 and the base 1, effectively preventing the skin 4 from losing its protective performance due to bottom fixation failure, while enhancing the overall structural rigidity of the bottom of the battery stack, providing a more reliable protective barrier for the internal battery box 3 and electrical components.

[0067] In some embodiments, for example Figure 3 As shown, each battery box 3 has multiple second supports 6 spaced apart along its length on its outer wall in both longitudinal directions. Each second support 6 has bolt holes, and each front skin 401 has multiple through holes on its main body 4011 that mate with the bolt holes on the corresponding second supports 6. The front skin 401 is fixedly connected to the second supports 6 by bolts screwed into the bolt holes. The second supports 6 refer to the support structures spaced apart along the length of the battery box 3. Specifically, they can be implemented by welding metal stampings to the outer wall of the box, forming fixed support points in the middle area of ​​the battery box 3.

[0068] Specifically, when the front skin body 4011 covers the outer wall of the battery box 3 along its length, its through holes are aligned with the bolt holes of the second bracket 6. By inserting and tightening bolts, the front skin 401 is pressed and fixed to the surface of the second bracket 6. Multiple second brackets 6 are distributed at intervals along the length, forming continuous support points, and the force on the front skin 401 in the middle area is evenly distributed to each bracket. The bolt connection method allows for fine-tuning of the positioning during installation, ensuring the fit between the skin 4 and the bracket.

[0069] Compared to existing technologies, traditional frameless battery systems only have fixing points at both ends of the battery box 3, resulting in a lack of support in the middle of the front skin 401, which can cause vibration or deformation. This solution adds multiple second supports 6 in the middle area to form a multi-point fixing structure, so that the skin 4 is supported along its entire length, avoiding installation instability caused by large spans.

[0070] Through the above technical solution, this application effectively solves the problem of loose installation of the front skin 401 in the middle area of ​​the battery box 3 due to lack of support, and enhances the connection strength between the skin 4 and the battery box 3. The multiple brackets are arranged at intervals to ensure uniform stress on the skin 4, and the bolt fixing method ensures installation accuracy and maintainability, and the overall structural stability is significantly improved.

[0071] In some embodiments, for example Figure 5 and Figure 6 As shown, reinforcing ribs 7 are provided on the inner surfaces of both the front skin 401 and the side skin 402.

[0072] The reinforcing rib 7 refers to a raised structure extending along the surface of the skin 4, which can be achieved by stamping or welding. Its cross-sectional shape can be trapezoidal, rectangular, or wavy. This feature increases the moment of inertia of the skin 4's cross-section, improving its bending resistance and thus forming a self-supporting structure within the skin 4. The inner side refers to the side of the skin 4 facing the battery stack. Specifically, this can be achieved by providing a reinforcing rib 7 integrally formed with the main body of the skin 4 on its inner side, avoiding interference from external structures. This feature allows the skin 4 to achieve increased rigidity through its own structure without adding an external frame.

[0073] Specifically, the reinforcing ribs 7 are continuously arranged along the width of the skin 4, forming a parallel linear distribution. When external loads are applied to the surface of the skin 4, the reinforcing ribs 7 suppress local depressions or warping deformation of the skin 4 by dispersing stress distribution. Under vibration conditions, the stiffness-enhancing effect of the reinforcing ribs 7 can reduce stress concentration at the connection between the skin 4 and the support. At the same time, the reinforcing ribs 7 remain flush with the inner surface of the skin 4, avoiding encroachment on the installation space of the battery box 3 and maintaining the compact layout of the battery stack.

[0074] In some specific embodiments, the arrangement density of the reinforcing ribs 7 can be adjusted according to the skin size. For example, dense ribs with smaller spacing can be provided in the central area of ​​the skin 4, while sparse ribs with larger spacing can be provided in the edge area. The height of the reinforcing ribs 7 can gradually change with the thickness of the skin 4. For example, taller reinforcing ribs 7 can be used in areas with greater stress, while the height can be gradually reduced in transition areas.

[0075] Through the above technical solutions, this application achieves a significant improvement in the structural rigidity of the skin 4, ensuring the battery system's ability to resist external impacts during transportation and use. The arrangement of the reinforcing ribs 7 enables the skin 4 to maintain its lightweight characteristics while effectively suppressing deformation caused by temperature changes or mechanical vibrations, ensuring the stability of the connection structure between the battery boxes 3. This design also avoids the increased assembly complexity caused by adding an external support frame, making the skin 4 installation process compatible with conventional processes.

[0076] In some embodiments, for example Figure 1 As shown, heat dissipation holes 4014 are provided on the uppermost front skin 401.

[0077] Among them, the heat dissipation hole 4014 is a through hole opened on the surface of the front skin 401. Its position should correspond to the heat accumulation area inside the battery system. The hole diameter can be adjusted according to the heat dissipation requirements, such as using a circular through hole or a long strip slot. The edge of the hole can be provided with a flange structure to enhance local strength.

[0078] Specifically, the heat generated during battery system operation accumulates in the upper layers through natural convection, and the heat dissipation holes 4014 in the uppermost skin 401 form a directional heat dissipation channel. Hot air rises vertically under buoyancy and is directly discharged to the external environment through the heat dissipation holes 4014, avoiding stagnation within the enclosed space of the skin 4. This design specifically selects the end of the heat flow path as the location of the heat dissipation opening, optimizing heat dissipation efficiency using thermodynamic principles while maintaining the overall protective performance of the skin 4. The number and distribution of the heat dissipation holes 4014 can be matched according to the battery module layout, for example, increasing the hole density in areas with densely packed battery cells.

[0079] Through the above technical solution, this application effectively solves the problem of insufficient heat dissipation inside the battery system caused by the closed skin 4. By optimizing the arrangement of the heat dissipation holes 4014, the heat exchange efficiency is significantly improved, and the battery operating temperature is kept stable without the need to add auxiliary heat dissipation equipment, while ensuring the complete protection function of the skin 4 for the internal electrical components.

[0080] Other configurations and operations of the frameless battery system according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here.

[0081] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. 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.

[0082] Although embodiments of the present invention have been shown and described, those skilled in the art will understand 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 claims and their equivalents.

Claims

1. A frameless battery system, characterized in that, include: Base, multiple battery compartments, and skin; Multiple battery boxes are stacked on the base to form a battery stack. The bottommost battery box is fixedly connected to the base. A first bracket is fixedly connected to the outer wall of each battery box. The skin covers the four sides and top surface of the battery stack and is fixedly connected to the first bracket.

2. The frameless battery system of claim 1, wherein, The skin includes a top skin and a circumferential skin. The circumferential skin includes a first circumferential skin, a second circumferential skin, and a third circumferential skin. The first circumferential skin, the second circumferential skin, and the third circumferential skin are overlapped sequentially from bottom to top. The top skin is provided with a top skin edging around its perimeter, and the top skin edging overlaps and presses against the upper end of the third circumferential skin.

3. The frameless battery system of claim 2, wherein, The first circumferential skin, the second circumferential skin, and the third circumferential skin are each composed of two front skins and two side skins. The two front skins cover the front and rear sides of the battery stack, respectively, and the two side skins cover the left and right sides of the battery stack, respectively.

4. The frameless battery system of claim 3, wherein, The front skin includes a front skin body, two first folded edges, and a second folded edge. The two first folded edges are respectively located on the left and right sides of the front skin body, and the second folded edge is located on the upper side of the front skin body. The lower end of the upper front skin overlaps and presses against the second folded edge of the lower front skin. The second folded edge has multiple perforations spaced apart, and each perforation is fitted with a rivet nut. The lower end of the front skin body has multiple through holes spaced apart, corresponding one-to-one with the multiple perforations. The upper and lower adjacent front skin layers are fixedly connected by bolts connected to the rivet nuts.

5. The frameless battery system of claim 4, wherein, The side skin includes a side skin body, two side skin edgings, and a third folded edge. The two side skin edgings are respectively located on the left and right sides of the side skin body, and the third folded edge is located on the upper side of the side skin body. The lower end of the upper side skin overlaps and presses against the third folded edge of the lower side skin. The side skin edgings on the same layer overlap and press against the first folded edge of the adjacent front skin and are screwed together onto the first bracket. The third folded edge has multiple perforations spaced apart, and each perforation is fitted with a rivet nut. The lower end of the side skin body has multiple through holes spaced apart, corresponding one-to-one with the multiple perforations. The upper and lower adjacent side skin layers are fixedly connected by bolts connected to the rivet nuts.

6. The frameless battery system of claim 5, wherein, It also includes a mounting bracket, which is fixedly connected to the upper side of the battery box at the top. The top skin edging on the front and rear sides of the top skin overlaps and presses against the second folded edge and is screwed together onto the mounting bracket. The top skin edging on the left and right sides of the top skin overlaps and presses against the third folded edge and is screwed together onto the mounting bracket.

7. The frameless battery system of claim 6, wherein, The first bracket is also fixedly connected to the mounting bracket, and the mounting position of the first bracket corresponds vertically to the mounting position of the first bracket on the battery box.

8. The frameless battery system of claim 1, wherein, Two of the first brackets are provided on the outer wall of the front and rear sides of each battery box. On the outer wall of the same side, the two first brackets are symmetrically assembled at both ends of the battery box in the length direction.

9. The frameless battery system of claim 4, wherein, On the outer wall of each battery box in both length directions, there are multiple second brackets spaced apart along the length direction. Each second bracket is provided with bolt holes. On the main body of each front skin, there are multiple through holes that mate with the bolt holes on the corresponding second brackets. The front skin is fixedly connected to the second bracket by bolts screwed into the bolt holes.

10. The frameless battery system of claim 5, wherein, Bottom mounting brackets are provided at both ends of the base along its length. The bottom mounting brackets are provided with bolt holes corresponding to the through holes opened at the lower end of the bottommost side skin body. The lower end of the bottommost side skin body is fixedly connected to the bottom mounting brackets by bolts.

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