Multifunctional integrated battery pack

Abstract

The utility model discloses a kind of multifunctional integrated battery pack, including battery pack assembly upper cover body, battery pack assembly upper cover body is as plate structure, first seat crossbeam and second seat crossbeam are spaced apart and are welded on its upper surface along transverse direction, make three functional integration structure, battery pack assembly upper cover body can directly as a part of vehicle body front floor and participate in bearing, effectively simplify vehicle body structure level, realize the space fusion of battery pack and vehicle body key bearing component, substantially improve the utilization efficiency of vehicle body interior space, provide more flexible space condition for the layout of other components of whole vehicle, battery pack and vehicle body structure function coupling, topological optimization and vehicle, the battery pack and vehicle body high integration structure can better protect the internal components of battery pack, can improve passenger compartment space utilization, reduce the weight of whole vehicle, reduce production manufacturing cost.

Description

Technical Field

[0001] This utility model relates to the field of new energy electric vehicle technology, specifically a multi-functional integrated battery pack. Background Technology

[0002] The structural designs of new energy vehicle battery packs include the common chassis-integrated type and the under-floor mounting type. In the former, the battery cells are directly integrated into the battery pack, and the mechanical strength of the battery pack depends entirely on the shell design and the cell support structure. This makes it more prone to deformation in severe collisions, affecting safety, and replacing the entire pack is costly. In the latter, the battery pack is installed at the lowest point of the chassis. Traditional under-floor battery pack designs are limited by the vehicle structure and cannot maximize space utilization. Areas such as under the rear seats and in the front compartment are not fully utilized. In addition, due to the lack of integration between the body and the battery pack, the weight of the battery pack will increase, affecting the overall vehicle range. Therefore, we need to propose a multi-functional integrated battery pack. Utility Model Content

[0003] The purpose of this utility model is to provide a multifunctional integrated battery pack. By setting a plate-shaped battery pack assembly cover body and welding the first and second seat crossbeams laterally spaced on it to form an integrated structure, it achieves the effects of simplifying the vehicle body layers, integrating the battery pack with the vehicle body space, protecting the battery components, improving the utilization rate of the passenger compartment, and reducing costs by making it lightweight, thereby solving the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A multifunctional integrated battery pack includes: a battery pack assembly top cover body, a first seat crossbeam, a second seat crossbeam, a battery pack assembly lower housing, battery pack assembly mounting lugs, sealing components, and a power system bottom cover plate; the battery pack assembly top cover body is a plate-shaped structure, the first seat crossbeam and the second seat crossbeam are welded to the upper surface of the battery pack assembly top cover body at transverse intervals, the battery pack assembly lower housing is a box structure with an open top, the sealing components are annularly bonded to the edge of the lower surface of the battery pack assembly top cover body, and the battery pack assembly top cover body closes to the opening of the battery pack assembly lower housing.

[0005] Preferably, the bottom cover of the power system is bolted to the bottom of the lower housing of the battery pack assembly and is flush with the outer side of the lower housing of the battery pack assembly.

[0006] Preferably, the battery pack assembly cover body integrates the first seat crossbeam and the second seat crossbeam into a single structure.

[0007] Preferably, the sealing member is a strip made of silicone foam, and its width is adapted to the edge thickness of the battery pack assembly cover.

[0008] Preferably, at least four mounting lugs are provided for the battery pack assembly, and the mounting lugs are block-shaped structures pre-cast around the lower housing of the battery pack assembly.

[0009] Preferably, each of the battery pack assembly mounting lugs has a positioning hole at its center, and the positioning hole wall has a guide chamfer.

[0010] Preferably, the diameter of the positioning hole is consistent with the diameter of the preset fixing hole in the vehicle chassis.

[0011] Preferably, the bottom cover plate of the power system is a metal sheet with several longitudinally extending reinforcing ribs stamped on its surface.

[0012] Compared with the prior art, the beneficial effects of this utility model are: In this invention, the battery pack assembly cover is a plate-like structure, with the first and second seat crossbeams welded to its upper surface at transverse intervals, forming a functionally integrated structure. This design eliminates the need for separate connecting transition components between the battery pack and the vehicle body, allowing the battery pack assembly cover to directly serve as part of the front floor of the vehicle, effectively simplifying the vehicle structure hierarchy. Compared to the traditional method of dispersing the battery pack and seat crossbeams, this solution achieves spatial integration between the battery pack and key load-bearing components of the vehicle body, significantly improving the utilization efficiency of the vehicle's internal space and providing more flexible spatial conditions for the layout of other vehicle components. The battery pack and vehicle body structure are functionally coupled and topologically optimized. This highly integrated structure of the battery pack and vehicle body can better protect the internal components of the battery pack, improve the utilization rate of the passenger compartment space, reduce the overall vehicle weight, and lower manufacturing costs. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the topology optimization structure of the battery pack housing of this utility model.

[0014] In the diagram: 1. Battery pack assembly top cover; 2. First seat crossbeam; 3. Second seat crossbeam; 4. Battery pack assembly lower housing; 5. Battery pack assembly mounting lugs; 6. Sealing components; 7. Power system bottom protection plate; 8. Positioning holes. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] Please see Figure 1-2 This utility model provides a technical solution: A multifunctional integrated battery pack includes: a battery pack assembly upper cover body 1, a first seat crossbeam 2, a second seat crossbeam 3, a battery pack assembly lower housing 4, battery pack assembly mounting lugs 5, sealing components 6, and a power system bottom protection plate 7. The battery pack assembly upper cover body 1 is a plate-like structure made of high-strength steel with a thickness of 1.0mm. Reinforcing beams are provided on the inner side of the upper cover to balance floor load-bearing capacity and lightweight requirements. The first seat crossbeam 2 and the second seat crossbeam 3 are both U-shaped cross-section metal beams, welded laterally at intervals to the upper surface of the battery pack assembly upper cover body 1. The spacing between adjacent crossbeams is set at 600-800mm to accommodate the seat installation dimensions of mainstream vehicle models. The battery pack assembly lower housing 4 is a box structure with an open top, made of roll-formed steel and high-frequency welded. The battery pack assembly is formed by spraying an anti-rust coating with a thickness of 8-12μm on the inner wall. The sealing component 6 is annularly bonded to the lower edge of the battery pack assembly cover body 1. Epoxy resin adhesive is applied to the bonding surface with a thickness of 0.5-1mm. The battery pack assembly cover body 1 covers the opening of the battery pack assembly lower box 4. By setting a high-strength plate-shaped battery pack assembly cover body 1, a U-shaped crossbeam, and an anti-rust box-shaped battery pack assembly lower box 4, combined with the annularly bonded sealing component 6, the structure is guaranteed, the seat installation is compatible, the box is prevented from rusting, and the upper and lower boxes are initially sealed. At the same time, the combination of the aluminum alloy cover and the U-shaped crossbeam can make the stress transmission more uniform and avoid structural damage caused by local stress concentration.

[0017] The power system bottom guard plate 7 is connected to the bottom of the battery pack assembly lower housing 4 using M8-M10 hex bolts. The bolt tightening torque is controlled at 25-30 N·m. The power system bottom guard plate 7 is flush with the outer side of the battery pack assembly lower housing 4, and the joint between the two is filled with sealant with a width of 5-8 mm. By setting specific bolts, controlling the tightening torque, and filling the bottom guard plate 7 with sealant, the power system bottom guard plate is securely installed, preventing loosening and abnormal noise during vehicle operation, and further improving the sealing of the bottom of the battery pack. The flush outer side design also reduces air resistance during vehicle operation and improves the aerodynamic performance of the entire vehicle.

[0018] The battery pack assembly cover body 1 integrates the first seat crossbeam 2 and the second seat crossbeam 3 into a single structure. After welding, the three parts undergo overall aging treatment to eliminate welding internal stress. The flatness error of the integrated structure is controlled within 0.3mm / m. By setting up an integrated structure with aging treatment and strict flatness control, the overall rigidity of the structure is enhanced, the transmission of body vibration is reduced, and the installation accuracy of subsequent components is guaranteed. The integrated design also eliminates the need for additional connecting parts between the seat crossbeam and the body in the traditional structure, simplifying the production process.

[0019] The sealing component 6 is a strip of silicone foam with a Shore hardness of 50-60HA. Its width is adapted to the edge thickness of the battery pack assembly cover body 1, with the fitting gap controlled at 0.1-0.2mm. The length of the sealing component 6 is customized according to the perimeter of the edge of the battery pack assembly cover body 1. The joint adopts a beveled overlap with an overlap length of 20-30mm. By setting a specific hardness, fitting width, and customized length and using a beveled overlap, the silicone foam sealing component 6 achieves the effects of ensuring sealing compression, avoiding sealing failure, and achieving a ring-shaped seal without dead corners. The silicone foam material also has good high and low temperature resistance and can adapt to the complex operating environment of vehicles.

[0020] At least four battery pack assembly mounting lugs 5 are provided, and the battery pack assembly mounting lugs 5 are block structures, made of ductile iron and cast in shape. They are pre-cast around the lower housing 4 of the battery pack assembly. The connecting surfaces of the battery pack assembly mounting lugs 5 and the lower housing 4 are polished, and the surface roughness is controlled below Ra12.5μm. By setting block-shaped battery pack assembly mounting lugs 5 made of ductile iron, cast in shape and polished, the load-bearing capacity of the lugs is improved, the connection strength with the lower housing 4 is ensured, and structural interference during assembly is reduced. The pre-casting process makes the lugs and the lower housing more tightly connected, avoiding connection defects that may occur during later welding.

[0021] Each battery pack assembly mounting lug 5 has a positioning hole 8 at its center. The positioning hole 8 has a diameter tolerance grade of H8 and a guide chamfer on its wall. The chamfer angle is 30°-45° and the chamfer length is 2-3mm. By setting the positioning hole 8 with a specific tolerance grade, diameter, and guide chamfer with a specific angle and length, the matching accuracy with the mounting holes on the vehicle chassis is guaranteed, and the effect of quick alignment and reduced assembly difficulty is achieved. The H8 tolerance grade ensures a good fit between the bolt and the hole, avoiding assembly difficulties caused by hole diameter deviation.

[0022] The diameter of positioning hole 8 is consistent with the diameter of the pre-set fixing hole on the chassis, and the clearance between the two is controlled at 0.02-0.05mm. The depth of positioning hole 8 is 15-20mm, which meets the requirements for screwing in the full thread section of the bolt. By setting positioning hole 8 with the same diameter as the fixing hole on the chassis, a specific clearance, and sufficient depth, the stability of the bolt connection, the misalignment of the assembly, and the connection strength are ensured. Screwing in the full thread section makes the bolt more evenly stressed, which further improves the reliability of the connection between the battery pack and the vehicle body.

[0023] The power system bottom cover plate 7 is made of metal sheet, using Q235 cold-rolled steel plate with a thickness of 1.2mm. Its surface is stamped with several longitudinally extending concave and convex reinforcing ribs. The cross-section of the reinforcing ribs is trapezoidal, with a rib height of 5-8mm and a rib spacing of 30-50mm. By setting the power system bottom cover plate 7 with specific material, thickness, and concave and convex reinforcing ribs with trapezoidal cross-section, specific rib height and spacing, the bottom cover plate's impact and deformation resistance are improved, its service life is extended, and the internal components of the battery pack are protected. The Q235 cold-rolled steel plate material has both good strength and processing performance, making it easy to mass-produce.

[0024] Working principle: During assembly, the core electrical components such as the cell modules and management modules are first precisely installed into the lower housing 4 of the battery pack assembly, and the inner wall structure of the lower housing completes the initial positioning. Then, the upper cover body 1 of the battery pack assembly, which is prefabricated with the first seat beam 2 and the second seat beam 3, is closed onto the opening of the lower housing 4 of the battery pack assembly. The annular sealing component 6 is compressed and fills the gap of the mating surface, forming an initial sealing barrier. Next, the positioning holes 8 of the battery pack assembly mounting lugs 5 are aligned with the fixing holes of the vehicle chassis, and the guide chamfer guides the bolts to pass smoothly. The bolts are tightened with a specific torque to achieve a rigid connection between the battery pack and the vehicle body. Finally, the power system bottom guard plate 7 is fixed to the bottom of the lower housing 4 of the battery pack assembly with bolts, and the sealant at the joint further strengthens the protection. During vehicle operation, the integrated top cover and seat beam jointly bear the vehicle body load and disperse bumps and impact stress; the sealing component 6 prevents water vapor and dust from entering; the reinforcing rib structure of the power system bottom guard plate 7 resists the impact of road stones and other debris. The coordinated action of each component achieves the safe and stable operation of the battery pack and the efficient coupling of vehicle body functions.

[0025] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multifunctional integrated battery pack, characterized in that, include: Battery pack assembly top cover body (1), first seat crossbeam (2), second seat crossbeam (3), battery pack assembly lower box (4), battery pack assembly mounting lugs (5), sealing components (6) and power system bottom protection plate (7); The battery pack assembly upper cover body (1) is a plate structure. The first seat crossbeam (2) and the second seat crossbeam (3) are welded to the upper surface of the battery pack assembly upper cover body (1) at a transverse interval. The battery pack assembly lower box (4) is a box structure with an open top. The sealing member (6) is annularly bonded to the edge of the lower surface of the battery pack assembly upper cover body (1). The battery pack assembly upper cover body (1) covers the opening of the battery pack assembly lower box (4).

2. The multifunctional integrated battery pack according to claim 1, characterized in that: The power system bottom cover plate (7) is bolted to the bottom of the lower housing (4) of the battery pack assembly and is flush with the outer side of the lower housing (4) of the battery pack assembly.

3. The multifunctional integrated battery pack according to claim 1, characterized in that: The battery pack assembly cover body (1) integrates the first seat crossbeam (2) and the second seat crossbeam (3) into a single structure.

4. A multifunctional integrated battery pack according to claim 1, characterized in that: The sealing component (6) is a strip made of silicone foam, and its width is adapted to the edge thickness of the battery pack assembly cover body (1).

5. A multifunctional integrated battery pack according to claim 1, characterized in that: At least four mounting lugs (5) are provided for the battery pack assembly, and the mounting lugs (5) are block structures and precast around the lower housing (4) of the battery pack assembly.

6. A multifunctional integrated battery pack according to claim 5, characterized in that: Each of the battery pack assembly mounting lugs (5) has a positioning hole (8) at its center, and the positioning hole (8) has a guide chamfer on its wall.

7. A multifunctional integrated battery pack according to claim 6, characterized in that: The diameter of the positioning hole (8) is consistent with the diameter of the preset fixing hole on the vehicle chassis.

8. A multifunctional integrated battery pack according to claim 1, characterized in that: The bottom cover plate (7) of the power system is a metal plate with several longitudinally extending convex and concave reinforcing ribs stamped on its surface.

Images