Battery pack upper cover, battery pack shell, battery pack and electric device

Abstract

The application provides a battery pack upper cover, a battery pack shell, a battery pack and an electric equipment. It relates to the technical field of batteries. The battery pack upper cover comprises a first cover body and a second cover body. The second cover body is connected to one side of the first cover body in the extension direction of the upper cover through a tailor-welded blanking process. The thickness of the second cover body and the thickness of the first cover body are not equal. The tailor-welded blanking process is used to connect the first cover body and the second cover body, which not only saves materials but also improves the connection strength. By setting the thickness of the first cover body and the thickness of the second cover body as not equal, additional strength and rigidity can be provided where needed on the upper cover, and material use is reduced where not needed. In this way, on the basis of ensuring the strength and rigidity of the upper cover, the cost of the upper cover is reduced, and the use performance of the upper cover is improved.

Description

Technical Field

[0001] This application relates to the field of battery technology, and in particular to a battery pack cover, a battery pack housing, a battery pack, and an electrical device. Background Technology

[0002] A battery pack consists of multiple battery cells connected in series, parallel, or a combination of both. It also integrates a battery management system and a thermal management system. A battery pack is an energy storage unit.

[0003] In related technologies, the battery pack includes a distribution box, a top cover, battery cell modules, a cold plate, foam, and a tray. The top cover is a one-piece stamped part.

[0004] However, existing top covers suffer from a mismatch between high performance and low cost. Utility Model Content

[0005] This application provides a battery pack cover, a battery pack housing, a battery pack, and an electrical device. The battery pack cover provided in this application reduces the cost of the cover and improves its performance while ensuring the strength and rigidity of the cover.

[0006] In a first aspect, embodiments of this application provide a battery pack cover, comprising:

[0007] First cover;

[0008] The second cover, along the extension direction of the upper cover, is connected to one side of the first cover by a welding and stamping process; the thickness of the second cover is not equal to the thickness of the first cover.

[0009] In some embodiments of this application, there are two second covers, and the first cover is disposed between the two second covers along a first direction extending from the top cover.

[0010] In some embodiments of this application, the thickness of the second cover is greater than the thickness of the first cover.

[0011] In some embodiments of this application, the second cover has a bent portion.

[0012] The second cover protrudes outward toward the battery cells of the battery pack to form a bend.

[0013] In some embodiments of this application, along a first direction extending from the top cover, the second cover further includes a first connecting portion and a second connecting portion; the first connecting portion, the bent portion, and the second connecting portion are connected in sequence.

[0014] The first connecting part is provided with a lifting lug at the end opposite to the bending part; the first connecting part is used to connect with the tray of the battery pack.

[0015] The second connecting part is used to connect with the first cover.

[0016] In some embodiments of this application, the bent portion includes a first bent segment and a second bent segment that are connected to each other; the extending directions of the first bent segment and the second bent segment intersect.

[0017] The first bent section is connected to the first connecting part, and the second bent section is connected to the second connecting part.

[0018] In some embodiments of this application, the first cover and / or the second cover comprises DP590 steel or DP780 steel.

[0019] In some embodiments of this application, the battery pack cover further includes a reinforcing member; the reinforcing member is disposed at the bending portion; the reinforcing member extends along a second direction extending from the cover, intersecting the first and second directions.

[0020] In some embodiments of this application, along a first direction, the first end of the reinforcing member and the end of the first bent segment opposite to the second bent segment are connected, and the second end of the reinforcing member and the end of the second bent segment opposite to the first bent segment are connected.

[0021] The reinforcing member, the first bending section, and the second bending section are connected in sequence to form a triangular structure.

[0022] In some embodiments of this application, the reinforcing member includes a first reinforcing segment, a second reinforcing segment, and a third reinforcing segment connected in sequence.

[0023] The first reinforcing section and the first bending section are connected by spot welding, and the extension direction of the first reinforcing section is parallel to the extension direction of the first bending section.

[0024] The third reinforcing section and the second bending section are connected by spot welding. The extension direction of the third reinforcing section is parallel to the extension direction of the second bending section.

[0025] In some embodiments of this application, the battery pack cover further includes a first beam, and the first beam and the first cover are connected.

[0026] Along a first direction extending from the top cover, the first beam is located in the middle section of the first cover; the first beam extends along a second direction extending from the top cover.

[0027] In some embodiments of this application, the battery pack cover further includes two second beams, which are connected to the second cover and the first cover.

[0028] Along the second direction, two second beams are respectively located at both ends of the first beam and connected to the first beam.

[0029] The second beam extends along the first direction.

[0030] In some embodiments of this application, the reinforcing member is a stamped part.

[0031] In some embodiments of this application, the thickness of the first cover is L1, and L1 satisfies: 0.8mm≤L1≤1.5mm.

[0032] In some embodiments of this application, the thickness of the second cover is L2, and L2 satisfies: 1.5mm≤L2≤2.5mm.

[0033] In some embodiments of this application, the thickness of the reinforcing member is L3, and L3 satisfies: 1.5mm≤L3≤2mm.

[0034] In some embodiments of this application, the connection between the first connecting part and the tray is a first connection point; the connection between the first connecting part and the lifting lug is a second connection point.

[0035] Along the first direction, the vertical distance between the first connection point and the second connection point is B, and B satisfies: 20mm≤B≤40mm.

[0036] In some embodiments of this application, the connection point between the second connecting part and the first cover is the third connecting point, the distance between the third connecting point and the end face of the battery cell near the second cover is A, the length of the battery cell is M, and A and M satisfy: 1 / 3M≤A≤1 / 2M.

[0037] In some embodiments of this application, the connection point between the first bending segment and the second bending segment is the fourth connection point, and the distance between the fourth connection point and the end face of the battery cell near the second cover is D, where D and B satisfy: 1.5B≤D≤2B.

[0038] In some embodiments of this application, the angle between the first bending segment and the first direction is X, where X satisfies: 60°≤X≤80°.

[0039] In some embodiments of this application, the extension length of the first reinforcing segment is E, the extension length of the third reinforcing segment is F, and the minimum weld nugget diameter of the spot weld is d.

[0040] E and d satisfy: E≥d+4mm.

[0041] F and d satisfy: F≥d+4mm.

[0042] In some embodiments of this application, the angle between the second reinforcing segment and the first direction is Y, where Y satisfies: 20°≤Y≤45°.

[0043] Secondly, embodiments of this application provide a battery pack cover, comprising:

[0044] The first cover is a one-piece molded part;

[0045] The second cover is connected to one side of the first cover along the thickness direction of the upper cover.

[0046] In some embodiments of this application, the second cover includes a first sub-cover and a second sub-cover that are interconnected.

[0047] Along the extension direction of the cover, the first cover body includes a first cover body segment, a second cover body segment, and a third cover body segment connected in sequence.

[0048] The first sub-cover body is connected to the first cover body segment; the second sub-cover body is connected to the third cover body segment.

[0049] Thirdly, embodiments of this application provide a battery pack housing, comprising:

[0050] The aforementioned battery pack cover;

[0051] The tray has a receiving cavity with an opening at one end, and the battery pack cover closes to the opening.

[0052] Fourthly, embodiments of this application provide a battery pack, including:

[0053] The aforementioned battery pack housing has a receiving cavity;

[0054] The battery cell module is located in the housing cavity.

[0055] Fifthly, embodiments of this application provide an electrical device including the aforementioned battery pack.

[0056] This application provides a battery pack cover, a battery pack housing, a battery pack, and an electrical device. The battery pack cover includes a first cover and a second cover. Along the extension direction of the cover, the second cover is connected to one side of the first cover by a welding and stamping process. The thickness of the second cover is not equal to the thickness of the first cover. Connecting the first and second cover by welding and stamping not only saves materials but also improves the connection strength. By setting the thicknesses of the first and second cover to be unequal, additional strength and rigidity can be provided where the cover needs them, while reducing material usage where it is not needed. In this way, the cost of the cover is reduced and the performance of the cover is improved while ensuring its strength. Attached Figure Description

[0057] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0058] Figure 1 A schematic diagram of the battery pack structure provided in the embodiments of this application. Figure 1 ;

[0059] Figure 2 This is a schematic diagram of the structure of the battery pack cover provided in an embodiment of this application;

[0060] Figure 3 A schematic diagram of the battery pack structure provided in the embodiments of this application. Figure 2 ;

[0061] Figure 4 for Figure 3 Magnification of region a Figure 1 ;

[0062] Figure 5 for Figure 3 Magnification of region a Figure 2 ;

[0063] Figure 6 for Figure 4 Magnification of region b Figure 1 ;

[0064] Figure 7 for Figure 4 Magnification of region b Figure 2 .

[0065] Explanation of reference numerals in the attached figures:

[0066] 100: First cover;

[0067] 200: Second cover; 210: First connecting part; 220: Bending part; 221: First bending segment; 222: Second bending segment; 230: Second connecting part;

[0068] 300: Reinforcing member; 310: First reinforcing section; 320: Second reinforcing section; 330: Third reinforcing section; 400: First beam; 410: Second beam;

[0069] 500: Battery pack cover; 510: Cell module; 520: Cold plate; 530: Foam; 540: Tray.

[0070] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0071] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0072] In the relevant technology, the top cover is a one-piece stamped steel cover. The thickness of the top cover is consistent throughout.

[0073] If the top cover is too thin, it will result in insufficient strength and rigidity, poor load-bearing capacity, and the battery pack may fail vibration simulation. Conversely, if the top cover is too thick, it will lead to excessive weight, reducing the gravimetric energy density (GED) of the battery pack. This is because the energy storage capacity of the battery pack does not increase proportionally with the increase in total weight, thus reducing the energy storage efficiency per unit weight. Furthermore, an excessively thick top cover will also increase the cost of the top cover materials.

[0074] Therefore, the top cover has poor performance, and its high performance and low cost are incompatible.

[0075] In view of this, this application provides a battery pack cover, a battery pack housing, a battery pack, and an electrical device. The battery pack cover includes a first cover body and a second cover body. Along the extending direction of the cover, the second cover body is connected to one side of the first cover body by a welding and stamping process; the thickness of the second cover body is not equal to the thickness of the first cover body. Connecting the first cover body and the second cover body by welding and stamping not only saves materials but also improves the connection strength; by setting the thicknesses of the first cover body and the second cover body to be unequal, additional strength and rigidity can be provided where the cover needs them, while reducing material usage where it is not needed. In this way, while ensuring the strength and rigidity of the cover, the cost of the cover is reduced and the performance of the cover is improved.

[0076] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0077] Firstly, referring to Figures 1 to 3 As shown, this application embodiment provides a battery pack cover 500, including:

[0078] First cover 100;

[0079] The second cover 200 is connected to one side of the first cover 100 by a welding and stamping process along the extension direction of the upper cover; the thickness of the second cover 200 is not equal to the thickness of the first cover 100.

[0080] By way of example, the battery pack cover 500 provided in this application embodiment is part of the battery pack housing, providing the necessary strength and rigidity. The battery pack cover 500 provides physical protection for the battery pack, preventing damage to the battery cells from external impacts, vibrations and other mechanical stresses.

[0081] In this embodiment of the application, the first cover 100 and the second cover 200 of the battery pack cover 500 are connected together by a tailor-welded blank stamping process. Tailor-welded blank stamping (TWB) is an advanced manufacturing process that combines welding and stamping.

[0082] In the process of manufacturing the battery pack cover 500, the pre-treated first cover 100 and the pre-treated second cover 200 are first welded into a single blank by means of laser welding, arc welding, etc. Then, the welded blank is placed into a mold and stamped into the required shape by a press.

[0083] In this way, by connecting the first cover 100 and the second cover 200 through welding and stamping, the use of a thick plate for the entire cover can be avoided, which not only saves materials but also improves the connection strength between the first cover 100 and the second cover 200. At the same time, compared with traditional technology, it reduces the process of splicing multiple parts, improves the overall integrity, and uses thick plates in areas requiring high strength and thin plates in other areas, reducing redundant weight.

[0084] In the battery pack cover 500 provided in this embodiment, by setting the thicknesses of the first cover 100 and the second cover 200 to be unequal, additional strength and rigidity can be provided where needed, while reducing material usage where it is not needed. This optimization reduces material waste and improves material utilization. Simultaneously, by rationally distributing the thickness of different parts of the cover, the overall weight of the cover is reduced. While ensuring the strength of the cover, a lightweight design of the battery pack cover 500 is achieved, reducing the cost of the battery pack cover 500 and improving its performance.

[0085] In summary, the battery pack cover 500 provided in this application embodiment connects the first cover 100 and the second cover 200 through a welding and stamping process, and sets the thicknesses of the first cover 100 and the second cover 200 to be unequal. Compared with conventional technology, in conventional technology, it is difficult to balance the lightweight, low-cost design and high strength of the battery pack by one-piece stamping. The battery pack cover 500 provided in this application embodiment connects the first cover 100 and the second cover 200 of different thicknesses through a welding and stamping process, achieving a good compatibility between high performance and cost reduction design of the battery pack cover 500.

[0086] As one feasible implementation, there are two second covers 200, with the first cover 100 positioned between the two second covers 200 along a first direction extending from the top cover. This allows for the use of materials of different thicknesses in different areas of the battery pack top cover 500. The first cover 100 and the second cover 200 can be selected with different thicknesses according to specific stress requirements, thereby optimizing material usage and reducing unnecessary weight and cost. Simultaneously, this modular design simplifies the manufacturing and assembly process. The first cover 100 and the second cover 200 can be manufactured and processed separately, and then joined together through a welding and stamping process.

[0087] Furthermore, when battery packs are used in vehicles, forces are typically transmitted from the tires on both sides to the vehicle frame first, and then to the battery pack during vehicle operation. Therefore, stress concentration often occurs in the lugs on both sides of the battery pack. This phenomenon is particularly pronounced in large-volume, high-mass battery packs, which necessitates higher load-bearing capacity and strength requirements for the battery pack's top cover. Therefore, as a feasible implementation, the thickness of the second cover 200 is greater than the thickness of the first cover 100.

[0088] For example, a thicker second cover 200 is located on both sides of the top cover. This thicker second cover 200 can more effectively absorb and disperse external shocks and vibrations, protecting the battery cells from damage. In this way, the thicker second cover 200 provides additional strength and stiffness to the edge areas of the battery pack. This is particularly important for withstanding concentrated stresses and impacts from the edge areas during vehicle operation. Thus, during vehicle operation, forces are transmitted from the tires on both sides of the vehicle to the frame, and then to the battery pack. The thicker second cover 200 alters the load-bearing capacity on both sides of the top cover, increasing the strength of both sides of the battery pack top cover 500 and avoiding potential stress concentration problems on both sides of the battery pack top cover 500.

[0089] At the same time, by using thicker material in the critical areas of the second cover 200 and thinner material in other areas of the first cover 100, optimized material usage can be achieved. This design strategy helps reduce unnecessary weight and material costs while ensuring the overall performance of the structure.

[0090] As one possible implementation, the second cover 200 has a bent portion 220.

[0091] The second cover 200 protrudes outward toward the battery cells of the battery pack to form a bent portion 220.

[0092] For example, the design of the bend 220 can significantly enhance the structural strength and stiffness of the second cover 200. The outwardly convex bend 220 increases the moment of inertia of the material, making it more resistant to bending and deformation. At the same time, the outwardly convex bend 220 can more effectively absorb and disperse external impact forces, providing additional protection when the vehicle encounters impacts and vibrations during operation.

[0093] Furthermore, the protruding bend 220 provides additional internal space without increasing the overall material usage of the top cover. This helps increase the volume of the battery pack housing's receiving cavity, facilitating the accommodation of more battery modules.

[0094] As one feasible implementation, along the first direction extending from the top cover, the second cover 200 further includes a first connecting portion 210 and a second connecting portion 230; the first connecting portion 210, the bending portion 220 and the second connecting portion 230 are connected in sequence.

[0095] The first connecting part 210 is provided with a lifting lug at one end away from the bending part 220; the first connecting part 210 is used to connect with the tray 540 of the battery pack.

[0096] The second connecting part 230 is used to connect with the first cover 100.

[0097] For example, a lifting lug is provided at the end of the first connecting portion 210 opposite to the bending portion 220. The lifting lug provides a convenient gripping point, facilitating handling and positioning using lifting equipment during production, transportation, and installation.

[0098] The first connecting part 210 is connected to the tray 540 by rivets. Connecting the first connecting part 210 and the tray 540 by rivets improves the connection strength between the top cover and the tray 540, and enhances the stability and safety of the overall structure of the battery pack casing.

[0099] The second connecting part 230 is used to connect with the first cover 100 to ensure the integrity and structural strength of the cover.

[0100] The bend 220 serves as a transition area between the first connecting portion 210 and the second connecting portion 230. The bend 220 helps to disperse and absorb stress and vibration generated during vehicle operation, reducing stress concentration.

[0101] As one feasible implementation method, refer to Figure 4 and Figure 6 As shown, the bending portion 220 includes a first bending segment 221 and a second bending segment 222 that are connected to each other; the extending direction of the first bending segment 221 and the extending direction of the second bending segment 222 intersect.

[0102] The first bent section 221 is connected to the first connecting part 210, and the second bent section 222 is connected to the second connecting part 230.

[0103] For example, the intersecting design of the first bend segment 221 and the second bend segment 222 increases the structural strength and stiffness of the bend portion 220. This geometry helps resist bending and torsional stresses, improving overall durability.

[0104] As one possible implementation, the first cover 100 and / or the second cover 200 comprise DP590 steel or DP780 steel.

[0105] For example, the microstructure of DP590 steel comprises ferrite and martensite. Ferrite provides ductility, while martensite provides high strength. This combination gives DP590 steel excellent strength and formability.

[0106] DP590 steel typically has a tensile strength of around 590 MPa and a relatively low yield strength, which allows it to maintain high strength while possessing good ductility.

[0107] The microstructure of DP780 steel consists of ferrite and martensite. Ferrite provides ductility, while martensite provides high strength. This combination gives DP780 steel an excellent balance of strength and ductility.

[0108] The tensile strength of DP780 steel is typically around 780 MPa, which is what the "780" in its name represents. Its yield strength is usually low, giving it good ductility and formability during forming.

[0109] Due to the high strength properties of DP590 and DP780 steel, thinner materials can be used without sacrificing strength. This helps to reduce the weight of the top cover.

[0110] Furthermore, there is no reinforcement structure in the width direction (y-direction) of the vehicle on both sides of the top cover. This results in insufficient resistance to compression in the y-direction of the battery pack. When the battery pack is subjected to compression in the y-direction, the top cover is prone to deformation, potentially contacting the battery cells and posing a risk of cell deformation, thus compromising battery pack safety. (y-direction reference) Figure 1 The direction is shown in the middle (y). Therefore, as one feasible implementation, the battery pack cover 500 also includes a reinforcing member 300; the reinforcing member 300 is disposed at the bend 220; the reinforcing member 300 extends along a second direction extending from the cover, intersecting the first and second directions. The first direction is referenced... Figure 1 The direction is indicated by y. The second direction is referenced. Figure 1 The direction indicated by x in the middle.

[0111] For example, by providing a reinforcement 300 at the bend 220, the structural strength and stiffness of this area can be significantly improved. The reinforcement 300 provides additional impact absorption capacity, enhancing the protection performance of the battery pack in the event of a collision or other impact.

[0112] Meanwhile, the reinforcement 300 extends along the second direction, and the extension direction of the reinforcement 300 intersects with the first direction. This design helps to disperse stress in multiple directions, reduce stress concentration, and improve the durability of the cover.

[0113] Furthermore, by designing a reinforcing member 300 at the bend 220, the structural performance can be enhanced without significantly increasing the overall weight of the top cover, thus achieving efficient use of materials.

[0114] Among them, the reinforcing component 300 can be integrated into the top cover by welding, which simplifies the manufacturing and assembly process and improves production efficiency.

[0115] In one feasible implementation, along the first direction, the first end of the reinforcing member 300 is connected to the end of the first bent segment 221 that is away from the second bent segment 222, and the second end of the reinforcing member 300 is connected to the end of the second bent segment 222 that is away from the first bent segment 221.

[0116] The reinforcing member 300, the first bending segment 221, and the second bending segment 222 are connected in sequence to form a triangular structure.

[0117] For example, a triangle is one of the most stable structures in geometry. By connecting the reinforcing member 300, the first bending segment 221, and the second bending segment 222 into a triangular structure, the structural stability and stiffness of this region can be significantly improved. The triangular structure provides additional shock absorption capacity, enhancing the battery pack's protective performance in the event of a collision or other impact.

[0118] By incorporating a triangular reinforcing structure, structural performance can be enhanced without significantly increasing weight, thus achieving efficient material utilization.

[0119] As one possible implementation, the reinforcing member 300 includes a first reinforcing segment 310, a second reinforcing segment 320 and a third reinforcing segment 330 connected in sequence.

[0120] The first reinforcing section 310 and the first bending section 221 are connected by spot welding. The extension direction of the first reinforcing section 310 is parallel to the extension direction of the first bending section 221.

[0121] The third reinforcing section 330 and the second bending section 222 are connected by spot welding. The extension direction of the third reinforcing section 330 is parallel to the extension direction of the second bending section 222.

[0122] For example, by setting the extension direction of the first reinforcing segment 310 and the extension direction of the first bending segment 221 to be parallel, the contact area between the first reinforcing segment 310 and the first bending segment 221 is increased. This increased contact area helps to disperse stress and improve the strength and reliability of the welded joint.

[0123] Similarly, by setting the extension direction of the second reinforcing section 320 and the extension direction of the second bending section 222 to be parallel, the contact area between the second reinforcing section 320 and the second bending section 222 is increased. This increased contact area helps to disperse stress and improve the strength and reliability of the welded joint.

[0124] Spot welding is a resistance welding process used to join metal sheets. Spot welding has the advantage of high speed and has been automated.

[0125] Spot welding involves sandwiching two metal surfaces between two electrodes and applying pressure and current, causing the metal at the contact point to melt and form a weld. The resistance heat generated by the current melting the metal, while the applied pressure helps form a strong weld joint.

[0126] The spot welding process is as follows:

[0127] Clamping: The two electrodes clamp the metal plate to be welded.

[0128] When electricity is applied: Current flows through the electrodes to the contact points of the metal plates, generating heat.

[0129] Melting: Heat melts the metal at the contact point, forming a molten pool.

[0130] Cooling and solidification: After the current is stopped, the molten metal cools and solidifies, forming a strong solder joint.

[0131] As one possible implementation, the battery pack cover 500 also includes a first beam 400, which is connected to the first cover 100.

[0132] Along a first direction extending from the top cover, the first beam 400 is disposed in the middle section of the first cover 100; the first beam 400 extends along a second direction extending from the top cover.

[0133] For example, the first beam 400 provides additional support, enhancing the overall structural strength and rigidity of the cover. By placing the beam in the middle section of the first cover 100, loads from different directions can be effectively distributed and borne.

[0134] By placing the first beam 400 in the middle section of the first cover 100, the bending resistance of the cover is improved, especially when subjected to vertical loads. This design helps prevent the cover from bending or deforming during use.

[0135] As one possible implementation, the battery pack cover 500 also includes two second beams 410, which are connected to the second cover 200 and the first cover 100.

[0136] Along the second direction, two second beams 410 are respectively disposed at both ends of the first beam 400 and connected to the first beam 400.

[0137] The second beam 410 extends along the first direction.

[0138] For example, the second beam 410 provides additional structural support, enhancing the overall strength and rigidity of the battery pack cover 500. Through their connection with the second cover 200 and the first cover 100, these beams help form a more robust frame. The two second beams 410 are respectively positioned at both ends of the first beam 400 and connected to it. This arrangement forms a closed frame structure, improving overall structural integrity and durability.

[0139] The second beam 410 extends along the first direction, providing additional support along that direction. This design helps resist bending and deformation along the first direction. The first beam 400 and the second beam 410 can be expansion beams. An expansion beam is a structural component capable of dimensional changes in response to temperature variations or other environmental conditions.

[0140] As one feasible implementation, the reinforcing member 300 is a stamped part.

[0141] For example, stamping is an efficient manufacturing process suitable for mass production. By using stamping technology, reinforcement parts 300 can be produced quickly.

[0142] As one feasible implementation, the thickness of the first cover 100 is L1, and L1 satisfies: 0.8mm≤L1≤1.5mm.

[0143] For example, by setting the thickness of the first cover 100 in the range of 0.8-1.5 mm, the first cover 100 of this thickness provides sufficient structural strength and rigidity to meet the mechanical performance requirements of the battery pack under normal use conditions. At the same time, while ensuring strength, the first cover 100 of this thickness helps to reduce the overall weight of the top cover.

[0144] When the thickness of the first cover 100 is within this range, the first cover 100 has good formability and is suitable for processing techniques such as stamping and bending. This allows the first cover 100 to be manufactured into complex geometries to meet design requirements.

[0145] As one feasible implementation, the thickness of the second cover 200 is L2, which satisfies: 1.5mm≤L2≤2.5mm.

[0146] For example, by setting the thickness of the second cover 200 in the range of 1.5-2.5 mm, the second cover 200 of this thickness provides sufficient structural strength and rigidity to meet the mechanical performance requirements of the battery pack under normal use conditions. At the same time, while ensuring strength, the first cover 100 of this thickness helps to reduce the overall weight of the top cover.

[0147] When the thickness of the second cover 200 is within this range, the first cover 100 has good formability and is suitable for processing techniques such as stamping and bending. This allows the first cover 100 to be manufactured into complex geometries to meet design requirements.

[0148] As one feasible implementation, the thickness of the reinforcing member 300 is L3, and L3 satisfies: 1.5mm≤L3≤2mm.

[0149] For example, by setting the thickness of the reinforcing member 300 to 1.5mm-2mm, the reinforcing member 300 is provided with strength and stiffness. This thickness can effectively support and reinforce the structure of the battery pack cover 500, especially when subjected to external loads and stresses.

[0150] Reinforcement components 300 with a thickness ranging from 1.5 to 2 mm are generally suitable for common metalworking processes such as stamping, cutting, and welding. This allows reinforcement components 300 to be manufactured and assembled efficiently.

[0151] As one feasible implementation method, refer to Figure 4 and Figure 5 As shown, the connection between the first connecting part 210 and the tray 540 is the first connection point; the connection between the first connecting part 210 and the lifting lug is the second connection point.

[0152] Along the first direction, the vertical distance between the first connection point and the second connection point is B, and B satisfies: 20mm≤B≤40mm.

[0153] For example, by setting the range of B to 20mm-40mm, within this range, the distance between the lug hole for mounting the lug and the bending portion 220 is avoided to be too small, thus avoiding low yield of the lug hole punching; at the same time, the distance between the lug hole and the bending portion 220 is avoided to be too large, thus avoiding the problem of uneven force on the first connecting portion 210 and the bending portion 220 caused by an excessive distance of B when the battery pack is installed in the vehicle through the lug.

[0154] In some embodiments, the value of B can be 20mm, 25mm, 30mm, 35mm, or 40mm.

[0155] As one feasible implementation method, refer to Figure 4 and Figure 5 As shown, the connection point between the second connecting part 230 and the first cover 100 is the third connecting point. The distance between the third connecting point and the end face of the battery cell near the second cover 200 is A. The length of the battery cell is M, and A and M satisfy: 1 / 3M≤A≤1 / 2M. The extension length of the battery cell along the first direction is the battery cell length.

[0156] For example, by setting the relationship between A and M as 1 / 3M≤A≤1 / 2M, A≥1 / 3M can effectively ensure the load-bearing capacity of the second cover 200, improve the rigidity of the top cover, solve the problem of excessive stress on the end face of the battery cell, and improve the vibration performance of the battery pack; A≤1 / 2M can avoid the problem of the second cover 200 being too large, which would result in excessive weight of the top cover.

[0157] As one feasible implementation method, refer to Figure 4 and Figure 5 As shown, the connection point of the first bending segment 221 and the second bending segment 222 is the fourth connection point. The distance between the fourth connection point and the end face of the battery cell near the second cover 200 is D. D and B satisfy: 1.5B≤D≤2B.

[0158] For example, D≥1.5B provides sufficient collapse space when the battery pack is subjected to Y-direction compression, so that the cavity of the second cover 200 phase battery pack housing will not touch the battery cells after collapse; D≤2B can avoid excessive compression of the cavity of the battery pack and improve the utilization rate of the cavity of the battery pack housing.

[0159] In some embodiments, D can be 1.5B, 1.8B, 2.1B, or 2.4B.

[0160] As one feasible implementation method, refer to Figure 6 and Figure 7 As shown, the angle between the first bending segment 221 and the first direction is X, and X satisfies: 60°≤X≤80°.

[0161] For example, when X ≥ 60°, it can avoid the crumple zone being too small, thus preventing the risk of cell damage when the battery pack is subjected to y-axis compression. Simultaneously, it avoids the first bending segment 221 having an excessively large horizontal projection C, thus preventing a high risk of top cover deformation during z-axis vibration. (z-direction reference) Figure 1 The direction indicated by z in the middle.

[0162] When X≤80°, the difficulty in stamping the bent part 220 can be avoided.

[0163] In some embodiments, X can be 60°, 65°, 70°, 75°, or 80°.

[0164] As one feasible implementation method, refer to Figure 5 As shown, the extension length of the first reinforcing section 310 is E, the extension length of the third reinforcing section 330 is F, and the minimum weld nugget diameter is d.

[0165] E and d satisfy: E≥d+4mm.

[0166] F and d satisfy: F≥d+4mm.

[0167] For example, in spot welding, the minimum weld nugget diameter refers to the smallest size of the weld nugget formed during the welding process to ensure that the weld joint has sufficient strength and reliability. The minimum weld nugget diameter is usually determined based on the thickness and type of the welding material. Specific values ​​for D can be found in GB / T43412-2023.

[0168] By setting E and F to satisfy: E≥d+4mm and F≥d+4mm respectively, sufficient weld size can be provided for spot welding to ensure the welding strength of the first bending segment 221 and the first reinforcing segment 310, the second bending segment 222 and the third reinforcing segment 330.

[0169] As one feasible implementation, the angle between the second reinforcing segment 320 and the first direction is Y, where Y satisfies: 20°≤Y≤45°.

[0170] For example, by setting Y in the range of 20-45°, such an angle design allows the reinforcement 300 to provide a greater reaction force to the top cover when it is compressed and collapsed in the Y direction, resisting the collapse deformation. At the same time, Y should be as large as possible while meeting the size range of E and F.

[0171] Secondly, embodiments of this application provide a battery pack cover 500, comprising:

[0172] The first cover 100 is a one-piece molded part;

[0173] The second cover 200 is connected to one side of the first cover 100 along the thickness direction of the upper cover.

[0174] For example, the first cover 100 is a one-piece molded part, manufactured by a single manufacturing process such as stamping, die casting, or injection molding. This design can improve the overall strength and rigidity of the structure because there are no seams or connection points that could become weaknesses. One-piece molding helps simplify the manufacturing process, reduce assembly steps and potential errors, and improve production efficiency.

[0175] The second cover 200 is connected to one side of the first cover 100 along the thickness direction of the upper cover. This connection method may be achieved by welding, bonding or mechanical fixing.

[0176] By placing the second cover 200 on one side of the first cover 100 in the thickness direction, the second cover 200 can be placed where the first cover 100 needs it. This provides additional strength and rigidity, while eliminating the need for the second cover 200 where it is not required by the first cover 100. This reduces material usage, minimizing waste and improving material utilization. Simultaneously, by rationally distributing the thickness of different parts of the cover, the overall weight of the cover is reduced, achieving a lightweight design for the battery pack cover 500 while maintaining its strength.

[0177] In one possible implementation, the second cover 200 includes a first sub-cover and a second sub-cover that are interconnected.

[0178] Along the extension direction of the cover, the first cover 100 includes a first cover segment, a second cover segment, and a third cover segment connected in sequence.

[0179] The first sub-cover body is connected to the first cover body segment; the second sub-cover body is connected to the third cover body segment.

[0180] For example, by connecting the first sub-cover and the first cover segment, and connecting the second sub-cover and the third cover segment, the thickness of the two sides of the top cover is greater than the thickness of the middle part of the top cover along the extension direction of the top cover. This allows the two sides of the top cover to more effectively absorb and disperse external impacts and vibrations, protecting the battery cells from damage. In this way, the two sides of the top cover provide additional strength and stiffness to the edge areas of the battery pack. This is particularly important for withstanding concentrated stresses and impacts from the edge areas during vehicle operation. Thus, during vehicle operation, forces are transmitted from the tires on both sides of the vehicle to the frame, and then to the battery pack. The increased thickness of the two sides of the top cover alters the load-bearing capacity of the two sides, improving the strength of the two sides of the battery pack top cover 500 and avoiding potential stress concentration problems on the two sides of the battery pack top cover 500.

[0181] Thirdly, embodiments of this application provide a battery pack housing, comprising:

[0182] The aforementioned battery pack cover is 500;

[0183] Tray 540 has a receiving cavity with an opening at one end, and battery pack cover 500 closes to the opening.

[0184] It is understood that since the battery pack housing of this application adopts the technical solution of the above-described battery pack cover 500 embodiment, it has at least the beneficial effects brought about by the technical solution of the above-described battery pack cover 500 embodiment, which will not be elaborated here.

[0185] Fourthly, embodiments of this application provide a battery pack, including:

[0186] The aforementioned battery pack housing has a receiving cavity;

[0187] The battery cell module 510 is located in the receiving cavity.

[0188] The battery pack includes a battery pack cover 500, a cell module 510, a cold plate 520, foam 530, and a tray 540.

[0189] The battery pack cover 500 is used to protect the internal components of the battery pack from external environmental factors such as dust, moisture, and physical impact.

[0190] The cell module 510 is the core component of the battery pack, comprising multiple battery cells. These cells can be lithium-ion batteries, lithium iron phosphate batteries, etc., and are responsible for storing and releasing electrical energy.

[0191] The 520 cold plate is used for thermal management, helping to dissipate heat and keep the battery within its optimal operating temperature range. Effective thermal management can improve battery performance and lifespan.

[0192] Foam is used for shock absorption and isolation, protecting the battery cell module from vibration and impact. It also provides some thermal insulation.

[0193] Tray 540 is the bottom structure of the battery pack, supporting and securing the cell modules and other components. It provides structural integrity and protection.

[0194] It is understood that since the battery pack of this application adopts the technical solution of the above-described battery pack housing embodiment, it has at least the beneficial effects brought about by the technical solution of the above-described battery pack housing embodiment, which will not be elaborated here.

[0195] Fifthly, embodiments of this application provide an electrical device including the aforementioned battery pack.

[0196] It is understood that since the electrical equipment of this application adopts the technical solution of the above-described battery pack embodiment, it has at least the beneficial effects brought about by the technical solution of the above-described battery pack embodiment, which will not be elaborated here.

[0197] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the utility models disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0198] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A battery pack cover, characterized in that, include: First cover (100); The second cover (200) is connected to one side of the first cover (100) by a welding and stamping process along the extension direction of the upper cover; the thickness of the second cover (200) is not equal to the thickness of the first cover (100).

2. The battery pack cover according to claim 1, characterized in that, The number of the second cover (200) is two, and the first cover (100) is disposed between the two second cover (200) along a first direction extending from the upper cover.

3. The battery pack cover according to claim 1, characterized in that, The thickness of the second cover (200) is greater than the thickness of the first cover (100).

4. The battery pack cover according to claim 2, characterized in that, The second cover (200) has a bent portion (220); The second cover (200) protrudes outward toward the direction away from the battery cell of the battery pack to form the bent portion (220).

5. The battery pack cover according to claim 4, characterized in that, Along a first direction extending from the top cover, the second cover (200) further includes a first connecting portion (210) and a second connecting portion (230); the first connecting portion (210), the bent portion (220), and the second connecting portion (230) are connected in sequence; The first connecting part (210) is provided with a lifting lug at the end opposite to the bent part (220); the first connecting part (210) is used to connect with the tray (540) of the battery pack; The second connecting part (230) is used to connect with the first cover (100).

6. The battery pack cover according to claim 5, characterized in that, The bending portion (220) includes a first bending segment (221) and a second bending segment (222) that are connected to each other; the extension direction of the first bending segment (221) and the extension direction of the second bending segment (222) intersect. The first bent segment (221) is connected to the first connecting part (210), and the second bent segment (222) is connected to the second connecting part (230).

7. The battery pack cover according to any one of claims 1-6, characterized in that, The first cover (100) and / or the second cover (200) comprise DP590 steel or DP780 steel.

8. The battery pack cover according to claim 6, characterized in that, It also includes a reinforcing member (300); the reinforcing member (300) is disposed on the bending portion (220); the reinforcing member (300) extends in a second direction along the upper cover; the first direction and the second direction intersect.

9. The battery pack cover according to claim 8, characterized in that, Along the first direction, the first end of the reinforcing member (300) is connected to the end of the first bent segment (221) away from the second bent segment (222), and the second end of the reinforcing member (300) is connected to the end of the second bent segment (222) away from the first bent segment (221); The reinforcing member (300), the first bent segment (221), and the second bent segment (222) are connected in sequence to form a triangular structure.

10. The battery pack cover according to claim 8, characterized in that, The reinforcing member (300) includes a first reinforcing section (310), a second reinforcing section (320) and a third reinforcing section (330) connected in sequence. The first reinforcing section (310) and the first bending section (221) are connected by spot welding. The extension direction of the first reinforcing section (310) is parallel to the extension direction of the first bending section (221). The third reinforcing section (330) and the second bending section (222) are connected by spot welding. The extension direction of the third reinforcing section (330) is parallel to the extension direction of the second bending section (222).

11. The battery pack cover according to any one of claims 1-6, characterized in that, It also includes a first beam (400) that is connected to the first cover (100); Along a first direction extending from the top cover, the first beam (400) is disposed in the middle section of the first cover (100); the first beam (400) extends along a second direction extending from the top cover.

12. The battery pack cover according to claim 11, characterized in that, It also includes two second beams (410), which are connected to the second cover (200) and the first cover (100); Along the second direction, two second beams (410) are respectively disposed at both ends of the first beam (400) and connected to the first beam (400); The second beam (410) extends in a first direction along the upper cover.

13. The battery pack cover according to claim 8, characterized in that, The reinforcing member (300) is a stamped part.

14. The battery pack cover according to claim 8, characterized in that, The thickness of the first cover (100) is L1, and L1 satisfies: 0.8mm≤L1≤1.5mm; And / or, the thickness of the second cover (200) is L2, wherein L2 satisfies: 1.5mm≤L2≤2.5mm; And / or, the thickness of the reinforcing member (300) is L3, wherein L3 satisfies: 1.5mm≤L3≤2mm.

15. The battery pack cover according to claim 6, characterized in that, The connection between the first connecting part (210) and the tray (540) is the first connection point; the connection between the first connecting part (210) and the lifting lug is the second connection point; Along the first direction, the vertical distance between the first connection point and the second connection point is B, where B satisfies: 20mm≤B≤40mm.

16. The battery pack cover according to claim 5, characterized in that, The connection point between the second connecting part (230) and the first cover (100) is the third connection point. The distance between the third connection point and the end face of the battery cell near the second cover (200) is A. The length of the battery cell is M. A and M satisfy: 1 / 3M≤A≤1 / 2M.

17. The battery pack cover according to claim 15, characterized in that, The connection point of the first bending segment (221) and the second bending segment (222) is the fourth connection point. The distance between the fourth connection point and the end face of the battery cell of the battery pack near the second cover (200) is D. The distance between D and the distance between B satisfies: 1.5B≤D≤2B.

18. The battery pack cover according to claim 6, characterized in that, The angle between the first bending segment (221) and the first direction is X, and X satisfies: 60°≤X≤80°.

19. The battery pack cover according to claim 10, characterized in that, The extension length of the first reinforcing section (310) is E, the extension length of the third reinforcing section (330) is F, and the minimum weld nugget diameter of the spot weld is d; The conditions E and d satisfy: E≥d+4mm; The given F and d satisfy: F≥d+4mm.

20. The battery pack cover according to claim 10, characterized in that, The angle between the second reinforcing segment (320) and the first direction is Y, wherein Y satisfies: 20°≤Y≤45°.

21. A battery pack cover, characterized in that, include: The first cover (100) is a one-piece molded part; The second cover (200) is connected to one side of the first cover (100) along the thickness direction of the upper cover.

22. The battery pack cover according to claim 21, characterized in that, The second cover (200) includes a first sub-cover and a second sub-cover that are interconnected; Along the extending direction of the upper cover, the first cover body (100) includes a first cover body segment, a second cover body segment, and a third cover body segment connected in sequence; The first sub-cover is connected to the first cover segment; the second sub-cover is connected to the third cover segment.

23. A battery pack housing, characterized in that, include: Battery pack cover according to any one of claims 1-22; The tray (540) has a receiving cavity with an opening at one end, and the battery pack cover closes to the opening.

24. A battery pack, characterized in that, include: The battery pack housing of claim 23 has a receiving cavity; The battery cell module (510) is located in the receiving cavity.

25. An electrical appliance, characterized in that, Includes the battery pack as described in claim 24.

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