A battery pack assembly and an electrically powered vehicle

Abstract

This application discloses a battery pack assembly and an electric vehicle. The battery pack assembly includes: a battery pack; a liquid cooling plate, which is disposed opposite to and connected to the bottom of the battery pack; a bottom guard plate, located directly below the liquid cooling plate; on the side of the bottom guard plate opposite to the liquid cooling plate, the area of ​​the side of the bottom guard plate is not less than the area of ​​the side of the liquid cooling plate, and the bottom guard plate is also connected to the bottom of the battery pack; and a buffer structure, which is disposed between the opposite sides of the liquid cooling plate and the bottom guard plate and undergoes elastic deformation when the bottom guard plate is impacted. The bottom guard plate and the buffer structure are installed on the liquid cooling plate at the bottom of the battery pack. The bottom guard plate is located on the outermost side and replaces the liquid cooling plate when it scrapes against the road surface. The buffer structure is disposed in the gap between the liquid cooling plate and the bottom guard plate, and can simultaneously absorb the energy generated by the scrape, preventing the scraping force from being further transferred to the liquid cooling plate and the battery pack, thereby fully protecting the liquid cooling plate and the battery pack in the event of a scrape.

Description

Technical Field

[0001] This utility model relates to the field of battery auxiliary structure technology, and more specifically, to a battery pack assembly and an electric transportation vehicle. Background Technology

[0002] In the actual operation of new energy vehicles, battery pack safety is of paramount importance. Bottom scrapes or impacts from foreign objects are significant threats to battery pack safety, leading to an increasing number of battery pack damages and dangerous accidents, especially for off-road electric vehicles, which face a higher risk of bottom impacts due to their complex and challenging terrain.

[0003] Currently, most power battery packs use bottom-level cooling for the cells, with liquid cooling plates positioned beneath them. To protect the liquid cooling system, a bottom protective plate is typically added to the bottom of the battery pack. However, due to limitations in component costs, battery pack weight, and thickness, existing bottom protective plates cannot provide sufficient protection for the bottom of the battery pack housing. While bottom ball impact and scraping collision tests meet basic safety standards such as no fire or explosion, the battery packs tested are unusable, and the high cost of replacing them has led to consumer dissatisfaction. Utility Model Content

[0004] The purpose of this invention is to provide a battery pack assembly and an electric transport vehicle that can improve the protection of the battery pack.

[0005] The embodiments of this utility model are implemented as follows:

[0006] In a first aspect, this application provides a battery pack assembly, including:

[0007] Battery pack;

[0008] A liquid cooling plate, which is disposed opposite to and connected to the bottom of the battery pack;

[0009] A bottom protective plate is located directly below the liquid cooling plate; on the side of the bottom protective plate opposite to the liquid cooling plate, the area of ​​the side of the bottom protective plate is not less than the area of ​​the side of the liquid cooling plate, so as to completely cover the side of the liquid cooling plate, and the bottom protective plate is also connected to the bottom of the battery pack.

[0010] A buffer structure is provided between the liquid cooling plate and the bottom protective plate on opposite sides, and the bottom protective plate undergoes elastic deformation when it is subjected to impact.

[0011] In a possible implementation, the bottom guard plate includes:

[0012] A first plate is located directly below the liquid cooling plate and connected to the bottom of the battery pack; the area of ​​the side of the first plate opposite to the liquid cooling plate is not less than the area of ​​the side of the liquid cooling plate; the buffer structure is located between the opposite sides of the first plate and the liquid cooling plate.

[0013] The second plate is located below the first plate and is connected to the bottom of the battery pack; wherein the first plate has a set bending strength and the second plate has a set yield strength.

[0014] In a possible implementation, the first plate and the second plate are provided with matching first threaded holes to be connected by a corresponding number of first bolts.

[0015] An adhesive structure is also provided on the opposite sides of the first plate and / or the second plate.

[0016] In a possible implementation, the first threaded holes on the first plate and the second plate are arranged in a matrix, and the adhesive structure is respectively disposed between each pair of adjacent groups of the first threaded holes.

[0017] In a possible implementation, the sum of the thicknesses of the first plate and the second plate is in the range of 0.45mm-0.65mm; the first plate is an aluminum plate, and the second plate is a steel plate with a set yield strength, the set yield strength being not less than 950MPa.

[0018] In a possible implementation, the battery pack includes:

[0019] Battery pack body;

[0020] A battery pack cover, wherein the battery pack cover is disposed above the battery pack body;

[0021] The lower housing of the battery pack is located below the battery pack body and together with the upper cover of the battery pack forms a mounting cavity for placing the battery pack body.

[0022] In a possible implementation, the battery pack housing includes:

[0023] The housing body is frame-shaped with an opening at the top, and the battery pack body is located inside the housing body;

[0024] A frame beam, which is located on one side of the box body;

[0025] The first plate and the second plate are also provided with second threaded holes, so as to be connected to the box body and the frame beam respectively by the second bolt structure.

[0026] In a possible implementation, the buffer structure is one of a foam energy-absorbing structure, a metal energy-absorbing structure, or a composite energy-absorbing structure formed by combining a foam energy-absorbing structure and a metal energy-absorbing structure.

[0027] Secondly, this application also provides an electric vehicle including the aforementioned battery pack assembly.

[0028] In a possible implementation, the vehicle also includes a chassis on which the battery pack assembly is mounted.

[0029] The beneficial effects of this utility model embodiment are:

[0030] A bottom protector and a buffer structure are installed on the liquid cooling plate at the bottom of the battery pack. The bottom protector is located on the outermost side and replaces the liquid cooling plate in the event of a collision with the road surface. The buffer structure is located in the gap between the liquid cooling plate and the bottom protector, which can absorb the energy generated by the collision and prevent the energy from being further transferred to the liquid cooling plate and the battery pack. This provides sufficient protection for the liquid cooling plate and the battery pack in the event of a collision. In addition, the side area of ​​the bottom protector is slightly larger than that of the liquid cooling plate, thus completely covering the side of the liquid cooling plate and preventing the buffer structure from contacting the road surface in the event of a collision. This enhances the overall structural strength of the battery pack assembly. Even if a collision or impact occurs, it can still prevent the battery pack and the liquid cooling plate from directly contacting the road surface, thus providing complete protection for the battery pack and the liquid cooling plate. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a structural diagram of the bottom protective plate of the battery pack assembly according to an embodiment of the present utility model;

[0033] Figure 2 This is an embodiment of the present utility model. Figure 1 Cross-sectional view;

[0034] Figure 3 This is an embodiment of the present utility model. Figure 1 Top view;

[0035] Figure 4 This is a structural diagram of the battery pack assembly according to an embodiment of the present utility model;

[0036] Figure 5This is an embodiment of the present utility model. Figure 4 Top view.

[0037] Icons: 1. First plate; 2. Adhesive structure; 3. Second plate; 4. First bolt structure; 5. Second threaded hole; 6. Battery pack top cover; 7. Battery pack bottom casing; 8. Liquid cooling plate; 9. Bottom protective plate. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0040] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0041] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this utility model is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0042] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0043] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0044] First Embodiment

[0045] In the actual operation of new energy vehicles, the occurrence of battery pack damage and dangerous accidents due to bottom scrapes or impacts from foreign objects is increasing. Currently, most electric vehicles on the market, after a bottom impact, suffer from either severe damage to the power battery requiring replacement or, in severe cases, thermal runaway, endangering the life of the driver. The main reason for this is that the structural strength of the bottom-impact protection design of most electric vehicles on the market is insufficient to cover the intensity of bottom impacts that drivers may encounter in most situations. Furthermore, current mandatory industry regulations do not fully cover such safety evaluation requirements. Therefore, once a scrape occurs, it will cause serious property damage and endanger life. Because off-road electric vehicles travel on more complex and challenging terrain, the probability of such bottom impact failures is even higher.

[0046] Most power battery packs typically use bottom-level cooling for the cells, meaning the liquid cooling plate is placed underneath the cells and is bonded to them, making it non-removable. When the liquid cooling system suffers a puncture due to external force such as impact or collision, coolant leakage and system failure can occur. In severe cases, this can lead to abnormal battery pack insulation and cell overheating and fire, posing a safety risk. To protect the liquid cooling system, a bottom protective plate is usually added. This plate is bolted to the battery pack frame and is typically made of steel or aluminum profiles. The battery pack frame, cold plate, and bottom protective plate together constitute the main structure for bottom protection of the power battery.

[0047] However, conventional stamped steel plates or aluminum profile bottom guards do not provide sufficient protection for the bottom of the battery pack. Limited by component costs and the weight and thickness of the battery pack, under normal circumstances, the results of ball impact and scrape tests on the bottom of the battery pack (based on Appendix N of the CNCAP Management Rules (2024 Edition), Electric Vehicle Scratch Test Procedure) only meet safety standards such as no fire and no explosion. The battery pack's condition after the test is unsuitable for continued consumer use, and replacing the battery pack would result in significant property damage, which is widely criticized in the consumer market. This invention addresses these problems by providing a structural solution for the bottom guard plate of a range-extended off-road electric vehicle battery pack, which can effectively solve this problem.

[0048] Based on this, refer to Figures 1 to 5 This application provides a battery pack assembly, including: a battery pack, a liquid cooling plate 8, a bottom protective plate 9, and a buffer structure. The liquid cooling plate 8 is disposed opposite to and connected to the bottom of the battery pack, and the bottom protective plate 9 is located directly below the liquid cooling plate 8. On the side of the bottom protective plate 9 opposite to the liquid cooling plate 8, the area of ​​the side of the bottom protective plate 9 is not less than the area of ​​the side of the liquid cooling plate 8, so as to completely cover the side of the liquid cooling plate 8. The bottom protective plate 9 is also connected to the bottom of the battery pack. The buffer structure is disposed between the opposite sides of the liquid cooling plate 8 and the bottom protective plate 9, and undergoes elastic deformation when the bottom protective plate 9 is impacted.

[0049] The battery pack, the power source for electric vehicles, is typically mounted on the chassis and is therefore susceptible to damage from road debris. Such damage can easily occur to the battery pack and the liquid cooling plate 8, affecting the vehicle's usability, especially for off-road electric vehicles. To protect the battery pack and liquid cooling plate 8, a bottom guard plate 9 and a buffer structure are installed on the liquid cooling plate 8 at the bottom of the battery pack. The bottom guard plate 9 is located on the outermost side and replaces the liquid cooling plate 8 when it scrapes against the road. The buffer structure is positioned in the gap between the liquid cooling plate 8 and the bottom guard plate 9, absorbing the energy generated by the scrape and preventing further energy transfer to the liquid cooling plate 8 and the battery pack. This effectively protects the liquid cooling plate 8 and the battery pack in the event of a scrape. In addition, the area of ​​the side of the bottom guard plate 9 is slightly larger than the area of ​​the side of the liquid cooling plate 8, thus completely covering the side of the liquid cooling plate 8. At the same time, it prevents the buffer structure from contacting the road surface in the event of a scratch, thereby enhancing the overall structural strength of the battery pack assembly. Even if the road surface is scratched or bumped, the battery pack and the liquid cooling plate 8 can still be prevented from directly contacting the road surface, thus fully protecting the battery pack and the liquid cooling plate 8.

[0050] In some embodiments, the bottom protective plate 9 includes: a first plate 1 and a second plate 3. The first plate 1 is located directly below the liquid cooling plate 8 and is connected to the bottom of the battery pack; on the side of the first plate 1 opposite to the liquid cooling plate 8, the area of ​​the side of the first plate 1 is not less than the area of ​​the side of the liquid cooling plate 8; the buffer structure is located between the opposite sides of the first plate 1 and the liquid cooling plate 8. The second plate 3 is located below the first plate 1 and is connected to the bottom of the battery pack; wherein, the first plate 1 has a set bending strength, and the second plate 3 has a set yield strength.

[0051] The bottom guard plate 9 includes a first plate 1 and a second plate 3. Considering that the first plate 1 is in direct contact with the liquid cooling plate 8, the first plate 1 has a set bending strength to resist strong bending deformation, making the liquid cooling plate 8 less prone to deformation. Considering that the second plate 3 is located on the outermost side and will be in direct contact with the road surface when it scrapes or bumps against the road surface, the second plate 3 has a set yield strength, making the second plate 3 less prone to significant plastic deformation.

[0052] In some embodiments, the first plate 1 and the second plate 3 are provided with matching first threaded holes for connection by a corresponding number of first bolt structures 4. Adhesive structures 2 are also provided on opposite sides of the first plate 1 and / or the second plate 3.

[0053] The first plate 1 and the second plate 2 are connected by bolts on one hand and by adhesive structure 2 (such as adhesive) on the other hand, thereby enhancing the connection strength between the first plate 1 and the second plate 3 and preventing the first plate 1 and the second plate 3 from separating due to excessive scraping or impact force when they collide with the road surface.

[0054] In some embodiments, the first threaded holes on the first plate 1 and the second plate 3 are arranged in a matrix, and the gap between the first threaded holes is no greater than 200mm*200mm. The adhesive structure 2 is respectively disposed between each pair of adjacent groups of the first threaded holes. The structural adhesive is applied to the area without the first threaded holes, which can make the mating surfaces of the first plate 1 and the second plate 3 firmly bonded and avoid the generation of gaps.

[0055] The first threaded holes on the first plate 1 and the second plate 3 are arranged in a matrix, and the gap between the first threaded holes is no greater than 200mm*200mm. The adhesive structure 2 is respectively set between each pair of adjacent groups of first threaded holes. The structural adhesive is applied to the areas without first threaded holes, which can make the mating surfaces of the first plate 1 and the second plate 3 firmly bonded and avoid the formation of gaps.

[0056] In some embodiments, the sum of the thicknesses of the first plate 1 and the second plate 3 is in the range of 0.45mm-0.65mm; the first plate 1 is an aluminum plate and the second plate 3 is a steel plate.

[0057] The bottom protective plate 9 is a composite molding of aluminum profile sheet and high-strength steel plate. The high-strength steel plate uses ultra-high strength materials such as HC950 (yield strength between 950Mpa and 1250Mpa), with a preferred thickness of 0.5~0.6mm. It is riveted to the lower surface of the aluminum profile sheet, enhancing the overall impact and collision resistance of the bottom protective plate, and achieving low cost and lightweight design. The high-strength steel plate can also undergo electrophoretic treatment and surface powder coating to improve corrosion resistance. Because the second plate 3 (high-strength steel plate) has high yield strength and the first plate 1 (aluminum profile sheet) has high bending strength, their combined use at the bottom of the battery pack provides extremely strong protection against bottom impacts, preventing excessive deformation that could cause irreversible deformation and failure of the liquid cooling plate 8.

[0058] In some embodiments, the battery pack includes: a battery pack body, a battery pack top cover 6, and a battery pack bottom housing 7. The battery pack top cover 6 is disposed above the battery pack body, and the battery pack bottom housing 7 is disposed below the battery pack body, and together with the battery pack top cover 6, forms a mounting cavity for placing the battery pack body, thereby covering the battery pack body and providing a certain degree of protection for the battery pack body through the battery pack top cover 6 and the battery pack bottom housing 7.

[0059] In some embodiments, the battery pack housing 7 includes a housing body and a frame beam. The housing body is frame-shaped with an opening at the top. The battery pack body is located inside the housing body, and the frame beam is located on one side of the housing body. The first plate 1 and the second plate 3 are each provided with a second threaded hole 5 for connection to the housing body and the frame beam respectively via a second bolt structure. The composite bottom protective plate 9 retains bolt mounting holes for the battery pack housing frame beam, facilitating easy switching.

[0060] In some embodiments, the buffer structure is one of a foam energy-absorbing structure, a metal energy-absorbing structure, or a composite energy-absorbing structure formed by combining a foam energy-absorbing structure and a metal energy-absorbing structure. A buffer gap exists between the first plate 1 and the second plate 3. This gap is mainly filled with a buffer structure for the battery pack liquid cooling plate 8. The buffer structure can be a foam energy-absorbing structure, such as protective foam, or a metal energy-absorbing structure, such as a shape memory alloy, or a composite structure formed by protective foam and shape memory alloy in a certain proportion. This helps to mitigate the impact of deformation of the bottom protective plate caused by collisions with the bottom of the battery pack on the battery pack liquid cooling plate.

[0061] Second Embodiment

[0062] This application provides an electric transportation vehicle, including the aforementioned battery pack assembly and chassis, with the battery pack assembly mounted on the chassis. The power source for this transportation vehicle is the battery pack, such as in electric vehicles, range-extended electric vehicles, electric motorcycles, and electric bicycles. By installing a bottom guard plate 9 and a buffer structure on the liquid-cooled plate 8 at the bottom of the battery pack, the bottom guard plate 9, located on the outermost side, replaces the liquid-cooled plate when it scrapes against the road surface. The buffer structure, positioned in the gap between the liquid-cooled plate 8 and the bottom guard plate 9, can simultaneously absorb the energy generated by the scraping, preventing further transfer of the scraping force to the liquid-cooled plate 8 and the battery pack, thereby effectively protecting the liquid-cooled plate 8 and the battery pack in the event of a scrape. In addition, the area of ​​the side of the bottom guard plate 9 is slightly larger than the area of ​​the side of the liquid cooling plate 8, thus completely covering the side of the liquid cooling plate 8. At the same time, it prevents the buffer structure from contacting the road surface in the event of a scratch, thereby enhancing the overall structural strength of the battery pack assembly. Even if the road surface is scratched or bumped, the battery pack and the liquid cooling plate 8 can still be prevented from directly contacting the road surface, thus fully protecting the battery pack and the liquid cooling plate 8.

[0063] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A battery pack assembly, characterized in that, include: Battery pack; A liquid cooling plate, which is disposed opposite to and connected to the bottom of the battery pack; A bottom protective plate, which is located directly below the liquid cooling plate; In the side of the bottom protective plate opposite to the liquid cooling plate, the area of ​​the side of the bottom protective plate is not less than the area of ​​the side of the liquid cooling plate, so as to completely cover the side of the liquid cooling plate. The bottom protective plate is also connected to the bottom of the battery pack. A buffer structure is provided between the liquid cooling plate and the bottom protective plate on opposite sides, and the bottom protective plate undergoes elastic deformation when it is subjected to impact.

2. The battery pack assembly according to claim 1, characterized in that, The bottom protective plate includes: A first plate is located directly below the liquid cooling plate and connected to the bottom of the battery pack; the area of ​​the side of the first plate opposite to the liquid cooling plate is not less than the area of ​​the side of the liquid cooling plate; the buffer structure is located between the opposite sides of the first plate and the liquid cooling plate. The second plate is located below the first plate and is connected to the bottom of the battery pack; wherein the first plate has a set bending strength and the second plate has a set yield strength.

3. The battery pack assembly according to claim 2, characterized in that, The first plate and the second plate are provided with matching first threaded holes so as to be connected by a corresponding number of first bolts. An adhesive structure is also provided on the opposite sides of the first plate and / or the second plate.

4. The battery pack assembly according to claim 3, characterized in that, The first threaded holes on the first plate and the second plate are arranged in a matrix, and the adhesive structure is respectively set between each pair of adjacent groups of the first threaded holes.

5. The battery pack assembly according to claim 2, characterized in that, The sum of the thicknesses of the first plate and the second plate ranges from 0.45mm to 0.65mm; the first plate is an aluminum plate, and the second plate is a steel plate with a set yield strength, wherein the set yield strength is not less than 950MPa.

6. The battery pack assembly according to claim 2, characterized in that, The battery pack includes: Battery pack body; A battery pack cover, wherein the battery pack cover is disposed above the battery pack body; The lower housing of the battery pack is located below the battery pack body and together with the upper cover of the battery pack forms a mounting cavity for placing the battery pack body.

7. The battery pack assembly according to claim 6, characterized in that, The battery pack housing includes: The housing body is frame-shaped with an opening at the top, and the battery pack body is located inside the housing body; A frame beam, which is located on one side of the box body; The first plate and the second plate are also provided with second threaded holes, so as to be connected to the box body and the frame beam respectively by the second bolt structure.

8. The battery pack assembly according to claim 1, characterized in that, The buffer structure is one of the following: a foam energy-absorbing structure, a metal energy-absorbing structure, or a composite energy-absorbing structure formed by combining a foam energy-absorbing structure and a metal energy-absorbing structure.

9. An electric transport vehicle, characterized in that, Includes the battery pack assembly as described in any one of claims 1 to 8.

10. The electric transport vehicle according to claim 9, characterized in that, The vehicle also includes a chassis, on which the battery pack assembly is mounted.

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