Battery lower case, battery case and battery pack

Abstract

The application discloses a battery lower box, a battery box and a battery pack. The battery lower box comprises a bottom shell and a frame structure. The bottom shell is a single-layer structure and is an integral piece. The bottom shell comprises a bottom plate and a side plate surrounding the periphery of the bottom plate. The frame structure is connected to the inside of the bottom shell. The structural design of the battery lower box provides technical conditions for the lightweight design of the battery box and is beneficial to reducing the manufacturing cost.

Description

Technical Field

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

[0002] With the development of new energy vehicle technology, the demand for vehicle range is increasing, the energy density requirement for battery packs is rising, and higher requirements are being placed on the lightweighting of battery packs, especially the battery housing.

[0003] In related technologies, battery boxes are mainly made of steel sheet metal and aluminum profile. Steel sheet metal boxes have a cost advantage, but a significant weight disadvantage. Aluminum profile boxes have a significant weight advantage, but they are welded structures, resulting in higher manufacturing costs. Utility Model Content

[0004] The purpose of this application is to provide a lower battery housing, a battery housing, and a battery pack. The lower battery housing provides the technical conditions for lightweight design of the battery housing and helps to reduce manufacturing costs.

[0005] To address the aforementioned technical problems, this application provides a battery lower housing, comprising a bottom shell and a frame structure. The bottom shell is a single-layer structure and is an integral piece. The bottom shell includes a bottom plate and side plates surrounding the bottom plate. The frame structure is connected to the interior of the bottom shell.

[0006] In one feasible embodiment, the side panel includes a left side panel and a right side panel opposite to each other; the frame structure includes a front side beam, a rear side beam, a left side beam, and a right side beam, the front side beam connecting between a first end of the left side beam and a first end of the right side beam, the rear side beam connecting between a second end of the left side beam and a second end of the right side beam; the left side beam is connected to the left side panel, and the right side beam is connected to the right side panel.

[0007] In one feasible embodiment, the frame structure further includes a central crossbeam located between the front beam and the rear beam, with both ends of the central crossbeam connected to the left beam and the right beam, respectively.

[0008] In one feasible embodiment, the side panel includes a front side panel; the frame structure further includes a front reinforcing beam located on the side of the front side panel away from the rear side beam, and a longitudinal beam connects the front reinforcing beam and the front side panel; the front reinforcing beam is connected to the front side panel.

[0009] In one feasible solution, the connection between the base plate and the side plate is a rounded corner structure, and the bottom of the beam structure of the frame structure connected to the side plate has a relief recess to avoid the rounded corner structure.

[0010] In one feasible solution, the beam structure of the frame structure is formed by extrusion of aluminum profiles; and / or, the bottom shell is formed by hot stamping of aluminum plates.

[0011] In one feasible solution, the lower battery housing includes several mounting blocks, which are connected to the outer wall of the side plate facing away from the frame structure; some mounting blocks are located at the corresponding ends of the front beams of the frame structure, some mounting blocks are located at the corresponding ends of the rear beams of the frame structure, and some mounting blocks are located at the corresponding ends of the middle crossbeams of the frame structure.

[0012] In one possible embodiment, the end of the side panel away from the base plate includes a flange that folds away from the frame structure, the flange having mounting holes.

[0013] This application also provides a battery housing, including the lower battery housing described in any of the above embodiments.

[0014] This application also provides a battery pack, including the battery housing described above.

[0015] The battery lower housing provided in this application embodiment serves as a component of a battery housing and can be applied to battery packs. The bottom shell of this battery lower housing is a single-layer, integral piece. Combined with the internal frame structure of the bottom shell, it ensures the overall strength and rigidity of the battery lower housing, exhibiting good mechanical reliability. Compared to traditional profile housings, the single-layer structure of the bottom shell results in significant weight reduction. Furthermore, the integrally molded bottom shell provides excellent sealing, ensuring the battery housing meets IP protection standards. This eliminates the need for redundant structures added to ensure sealing in traditional profile housings, contributing to weight reduction and lower manufacturing costs. Attached Figure Description

[0016] Figure 1 This is a structural diagram of the lower battery housing provided in one embodiment of this application;

[0017] Figure 2 for Figure 1 The diagram shows the structure of the lower battery housing from another perspective.

[0018] Figure 3 for Figure 1 Top view of the lower battery housing shown;

[0019] Figure 4 for Figure 1 The exploded view of the lower casing of the battery shown.

[0020] Figure 5 for Figure 1 Structural diagram of the middle and bottom shell;

[0021] Figure 6 for Figure 1 Structural diagram of the mid-frame structure;

[0022] Figure 7 This is a cross-sectional view of the lower battery housing provided in one embodiment of this application;

[0023] Figure 8 for Figure 7 A magnified view of a portion of the image.

[0024] Explanation of reference numerals in the attached figures:

[0025] 10. Bottom shell, 11. Bottom plate, 12. Front side plate, 13. Rear side plate, 14. Left side plate, 15. Right side plate, 16. Rounded corner structure, 17. Flanged edge.

[0026] Frame structure 20, front reinforcing beam 21, front side beam 22, rear side beam 23, left side beam 24, right side beam 25, central crossbeam 26, longitudinal beam 27, clearance recess 28

[0027] Mount block 30. Detailed Implementation

[0028] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0029] The directional terms "front," "rear," "left," "right," "top," and "bottom" used in this document are defined based on the normal operating state of the battery box or lower battery box. The length direction of the lower battery box is the front-rear direction, the width direction is the left-right direction, and the height direction is the up-down direction. Here, the side of the battery box or lower battery box facing the front of the vehicle is defined as "front," and correspondingly, the side facing the rear of the vehicle is defined as "rear." It is understood that the use of directional terms is only for the clarity and convenience of describing the technical solution and does not constitute a limitation on the scope of protection.

[0030] Please refer to Figures 1 to 6 , Figure 1 This is a structural diagram of the lower battery housing provided in one embodiment of this application. Figure 2 for Figure 1 The diagram shown is a structural representation of the lower battery housing from another perspective. Figure 3 for Figure 1 The top view of the lower battery housing shown. Figure 4 for Figure 1 The exploded view of the lower casing of the battery shown. Figure 5 for Figure 1 Structural diagram of the middle shell. Figure 6 for Figure 1 A structural diagram of the medium-sized frame structure.

[0031] In this embodiment, the lower battery housing includes a bottom shell 10 and a frame structure 20. The bottom shell 10 is an integral structure and also a single-layer structure. The frame structure 20 is connected to the interior of the bottom shell 10.

[0032] The bottom shell 10 includes a bottom plate 11 and side plates surrounding the bottom plate 11. The bottom shell 10 has a box-shaped structure with an open top. The shape of the bottom shell 10 can be set as needed. The following description uses the bottom shell 10, which has an approximately rectangular structure as shown in the figure, as an example. The side plates of the bottom shell 10 may include a front side plate 12, a rear side plate 13, a left side plate 14, and a right side plate 15.

[0033] The single-layer structure of the bottom shell 10 refers to the fact that each plate constituting the bottom shell 10 is a single-layer plate structure, that is, the bottom plate 11, the front side plate 12, the rear side plate 13, the left side plate 14 and the right side plate 15 are all single-layer plate structures.

[0034] Using the above solution, the bottom shell 10 of the battery lower housing is a single-layer, integral piece. Combined with the internal frame structure 20 of the bottom shell 10, it ensures the overall strength and rigidity of the battery lower housing, exhibiting good mechanical reliability. Compared to traditional profile housings, the single-layer structure of the bottom shell 10 results in a significant weight reduction. Furthermore, the integrally molded inner cavity of the bottom shell 10 provides excellent sealing, ensuring the battery housing meets IP protection standards. This eliminates the need for the additional structures required by traditional profile housings to ensure sealing, thus contributing to weight reduction and lower manufacturing costs.

[0035] In practical applications, the front panel 12 can be configured as a bent structure, such as... Figures 1 to 3 As shown in the image.

[0036] In practice, the bottom shell 10 can be made of aluminum plate to further reduce the weight of the lower battery housing.

[0037] In practice, the bottom shell 10 can be formed by hot stamping of aluminum sheet. The hot stamping process utilizes the principle of thermoplastic forming of metal, which can achieve quenching heat treatment of the sheet material at the same time as forming, thereby improving forming accuracy and surface quality.

[0038] In application examples, the wall thickness of the bottom shell 10 formed by hot stamping can be as thin as 1.5mm, while the depth of the bottom shell 10 can reach 105mm, and the draft angle can be 2°. While ensuring structural performance, the weight of the bottom shell 10 can be further reduced, providing technical conditions for the lightweighting of the battery lower casing.

[0039] In some implementations, the side plate of the bottom shell 10, at the end away from the bottom plate 11, i.e., the upper end of the side plate of the bottom shell 10, includes a flange 17 that folds away from the frame structure 20, and mounting holes may be provided on the flange 17. This facilitates the connection between the bottom shell 10 and the upper battery housing.

[0040] The side plates of the bottom shell 10 include a front side plate 12, a rear side plate 13, a left side plate 14, and a right side plate 15, that is, the top of the front side plate 12, the rear side plate 13, the left side plate 14, and the right side plate 15 are all provided with flanges 17.

[0041] In some embodiments, the frame structure 20 includes a front beam 22, a rear beam 23, a left beam 24, and a right beam 25. The front beam 22 is connected between the first end of the left beam 24 and the first end of the right beam 25, that is, the front beam 22 is connected between the front end of the left beam 24 and the front end of the right beam 25. The rear beam 23 is connected between the second end of the left beam 24 and the second end of the right beam 25, that is, the rear beam 23 is connected between the rear end of the left beam 24 and the rear end of the right beam 25. The left beam 24 is connected to the left side plate 14 of the bottom shell 10, and the right beam 25 is connected to the right side plate 15 of the bottom shell 10.

[0042] In this way, the front beam 22, rear beam 23, left beam 24, and right beam 25 of the frame structure 20 and the bottom plate 11 of the bottom shell 10 can enclose a space for installing the battery cell assembly. At the same time, the left beam 24 is connected to the left plate 14 of the bottom shell 10, and the right beam 25 is connected to the right plate 15 of the bottom shell 10, which can improve the structural strength of the left and right walls of the battery lower box and help improve the side impact protection capability of the battery lower box.

[0043] In practical applications, there can be a certain distance between the front beam 22 of the frame structure 20 and the front plate 12 of the bottom shell 10. This creates an installation space between the front beam 22 and the front plate 12, which can be used to install electrical components that are electrically connected to the battery cell assembly, as well as related accessories (such as wiring harnesses).

[0044] In practical applications, there can be a certain gap between the rear beam 23 of the frame structure 20 and the rear plate 13 of the bottom shell 10, and a cavity structure can be formed between the rear beam 23 and the rear plate 13, which is beneficial to improving the anti-collision protection capability of the lower battery box.

[0045] For example, the connection between the front beam 22 and the left beam 24 and the right beam 25, as well as the connection between the rear beam 23 and the left beam 24 and the right beam 25, can be achieved by welding. This method is simple to operate and provides high connection reliability.

[0046] Other examples include the front beam 22 being connected to the left beam 24 and the right beam 25 by bolting or riveting; and the rear beam 23 being connected to the left beam 24 and the right beam 25 by bolting or riveting.

[0047] For example, the connection between the left beam 24 and the left plate 14, and the connection between the right beam 25 and the right plate 15, can also be achieved by welding.

[0048] Other examples include the left beam 24 and the left plate 14, and the right beam 25 and the right plate 15, which can be connected by screws or rivets.

[0049] In practical applications, the beams of the frame structure 20 can be connected as a whole before being assembled with the bottom shell 10.

[0050] In some embodiments, the frame structure 20 may also include a central crossbeam 26 located between the front beam 22 and the rear beam 23, with its two ends connected to the left beam 24 and the right beam 25, respectively.

[0051] As mentioned above, the central crossbeam 26 increases the load-bearing capacity of the frame structure 20, thereby further enhancing the structural strength of the lower battery housing. When the length dimension (i.e., the dimension in the front-to-back direction) of the lower battery housing is large, the central crossbeam 26 can significantly improve the structural strength of the lower battery housing.

[0052] In the illustrated embodiment, the frame structure 20 includes a central crossbeam 26. In other embodiments, depending on structural and layout requirements, the frame structure 20 may also have two or more central crossbeams 26, and this application does not impose any restrictions on this.

[0053] For example, the connection between the middle crossbeam 26 and the left beam 24 and the right beam 25 is also made by welding, which has high reliability.

[0054] Other examples include the connection between the central crossbeam 26 and the left beam 24 and right beam 25, which can be achieved by riveting or bolting.

[0055] In some embodiments, the frame structure 20 may also include a front reinforcing beam 21, which is located in front of the front side beam 22, that is, the front reinforcing beam 21 is located on the side of the front side beam 22 away from the rear side beam 23. A longitudinal beam 27 connects the front reinforcing beam 21 and the front side beam 22. The front reinforcing beam 21 is connected to the front side plate 12 of the bottom shell 10.

[0056] As mentioned above, the front reinforcing beam 21 connected to the front side plate 12 can improve the structural strength of the front side plate 12. The structural cooperation of the front side plate 12, the front reinforcing beam 21, the front side beam 22 and the longitudinal beam 27 forms a good energy absorption structure at the front end of the battery lower box. When subjected to a frontal collision, the front end of the battery lower box has a good compression force transmission path along the length direction (front-back direction), which has a good energy absorption and buffering effect, effectively improving the frontal collision protection capability of the battery lower box.

[0057] The number of longitudinal beams 27 can be set as needed. In the case of two or more longitudinal beams 27, each longitudinal beam 27 can be arranged at intervals along the width direction (left and right direction) of the lower battery box.

[0058] In the illustrated example, there are three longitudinal beams 27. In other embodiments, there may be one, two, four, five, or other longitudinal beams 27.

[0059] In practice, the extension direction of the longitudinal beam 27 can be parallel to the length direction of the bottom shell 10, as shown in the example in the figure.

[0060] In some implementation schemes, the beam structure of the frame structure 20 can be made of aluminum, specifically aluminum profiles extruded. This helps reduce the weight of the lower battery housing, facilitates processing, and improves the load-bearing capacity of the frame structure 20. Here, the beam structure of the frame structure 20 refers to the beams that make up the frame structure 20, including the aforementioned front beam 22, rear beam 23, left beam 24, and right beam 25, as well as the aforementioned central crossbeam 26, and the aforementioned front reinforcing beam 21 and longitudinal beam 27.

[0061] In some implementations, the lower battery housing includes several mounting blocks 30, which are connected to the outer peripheral wall of the bottom shell 10. Here, the outer peripheral wall refers to the peripheral side wall of the bottom shell 10 away from its inner cavity. In other words, the mounting blocks 30 are connected to the outer wall of the side panel facing away from the frame structure 20. The mounting blocks 30 facilitate the installation of the lower battery housing on the vehicle and also facilitate the relocation of the lower battery housing during routine maintenance and repairs.

[0062] In practice, several mounting blocks 30 are divided into two groups, which are respectively connected to the outer wall of the left side plate 14 and the outer wall of the right side plate 15. In this way, the force can be balanced when the battery is hoisted into the lower housing.

[0063] In the illustrated embodiment, three mounting blocks 30 are spaced apart along the length of the outer wall of the left side plate 14, and three mounting blocks 30 are spaced apart along the length of the outer wall of the right side plate 15. The positions of the three mounting blocks 30 connected to the left side plate 14 and the three mounting blocks 30 connected to the right side plate 15 correspond one-to-one. During hoisting, the force on the lower battery casing is balanced, which can avoid safety hazards or damage to the lower battery casing.

[0064] In other embodiments, the number and layout of mounting blocks 30 can be adjusted as needed.

[0065] In practice, the position of the mounting block 30 on the left side plate 14 corresponds to the end position of the beam structure extending in the left and right directions of the frame structure 20. Taking the frame structure 20 with a middle crossbeam 26 as an example, the end of the front beam 22 is provided with a mounting block 30, the end of the rear beam 23 is provided with a mounting block 30, and the end of the middle crossbeam 26 is provided with a mounting block 30.

[0066] Specifically, a mounting block 30 is provided at the corresponding position where the left side plate 14 connects to the left end of the front beam 22, and a mounting block 30 is provided at the corresponding position where the right side plate 15 connects to the right end of the front beam 22; a mounting block 30 is provided at the corresponding position where the left side plate 14 connects to the left end of the rear beam 23, and a mounting block 30 is provided at the corresponding position where the right side plate 15 connects to the right end of the rear beam 23; a mounting block 30 is provided at the corresponding position where the left side plate 14 connects to the left end of the middle crossbeam 26, and a mounting block 30 is provided at the corresponding position where the right side plate 15 connects to the right end of the middle crossbeam 26.

[0067] With the above settings, the position of the mounting block 30 corresponds to the beam structure extending in the left and right directions of the frame structure 20. When subjected to a side impact, the mounting block 30 first bears the side impact force, and then the side impact force is absorbed and transmitted through the left side plate 14 or the right side plate 15. Finally, the force is transmitted through the beam structure extending in the left and right directions of the frame structure 20, which can effectively improve the side collision protection capability of the battery lower box.

[0068] In practice, the mounting block 30 can be made of aluminum. This facilitates a lightweight design for the battery housing and also makes it easier to connect the mounting block 30 to the bottom shell 10.

[0069] For example, the mounting block 30 can be formed using a die-casting process, resulting in good structural strength.

[0070] For example, the mounting block 30 is fixedly connected to the bottom shell 10 by welding. The connection reliability is good.

[0071] Other examples include the mounting block 30 and the bottom shell 10 being connected by riveting, screwing, or other methods.

[0072] Please refer to this as well. Figure 7 and Figure 8 , Figure 7 This is a cross-sectional view of the lower battery housing provided in one embodiment of this application. Figure 8 for Figure 7 A magnified view of a portion of the image.

[0073] In this embodiment, the connection between the bottom plate 11 and the side plate of the bottom shell 10 is a rounded corner structure 16. The side plates here include the front side plate 12, the rear side plate 13, the left side plate 14, and the right side plate 15. The rounded corner structure 16 facilitates molding and avoids stress concentration at the connection between the bottom plate 11 and the side plate, thereby improving the structural strength of the bottom shell 10.

[0074] The bottom of the beam structure of the frame structure 20, which is connected to the side plate of the bottom shell 10, can be provided with a relief recess 28 to avoid the rounded corner structure 16 of the bottom shell 10, so as to ensure the reliability of the connection between the frame structure 20 and the bottom shell 10.

[0075] In this embodiment, the beam structure connecting the frame structure 20 to the side plate of the bottom shell 10 includes a left beam 24 connected to the left side plate 14, a right beam 25 connected to the right side plate 15, and a front reinforcing beam 21 connected to the front side plate 12.

[0076] Figure 8 The diagram illustrates the structure of the connection between the left side plate 14 and the left side beam 24. As can be seen from the diagram, the outer side wall of the left side beam 24 fits against the inner side wall of the left side plate 14 to ensure the reliability of the connection between the two. The bottom of the left side beam 24 has a relief recess 28 to avoid the rounded corner structure 16 of the connection between the left side plate 14 and the bottom plate 11.

[0077] The connection structure between the right side plate 15 and the right side beam 25, as well as the connection structure between the front side plate 12 and the front reinforcing beam 21, are similarly configured and will not be described again.

[0078] This application also provides a battery housing, which includes the lower battery housing described in the foregoing embodiments, and the battery housing also includes an upper battery housing connected to the lower battery housing.

[0079] This application also provides a battery pack, which includes the battery housing described in the foregoing embodiments and cell assemblies installed inside the battery housing. This battery pack can be used in electric vehicles.

[0080] The aforementioned battery housing and battery pack both possess the same technical effects as the aforementioned lower battery housing, and will not be repeated here. Other structural designs of the battery housing or battery pack can refer to existing designs, but are not considered the core of this invention and will not be elaborated upon here.

[0081] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A battery lower case characterized by, The system includes a bottom shell (10) and a frame structure (20). The bottom shell (10) is a single-layer structure and is an integral piece. The bottom shell (10) includes a bottom plate (11) and side plates surrounding the bottom plate (11). The frame structure (20) is connected to the interior of the bottom shell (10). The connection between the bottom plate (11) and the side plates is a rounded corner structure (16). The bottom of the beam structure of the frame structure (20) connected to the side plates has a relief recess (28) to avoid the rounded corner structure (16).

2. The battery lower case according to claim 1, characterized by, The side panel includes a right side panel (15) opposite to the left side panel (14); the frame structure (20) includes a front side beam (22), a rear side beam (23), a left side beam (24) and a right side beam (25), the front side beam (22) is connected between the first end of the left side beam (24) and the first end of the right side beam (25), the rear side beam (23) is connected between the second end of the left side beam (24) and the second end of the right side beam (25); the left side beam (24) is connected to the left side panel (14), and the right side beam (25) is connected to the right side panel (15).

3. The battery lower case according to claim 2, characterized by, The frame structure (20) also includes a central crossbeam (26), which is located between the front beam (22) and the rear beam (23), and the two ends of the central crossbeam (26) are connected to the left beam (24) and the right beam (25) respectively.

4. The battery lower case according to claim 2, characterized by, The side panel includes a front side panel (12); the frame structure (20) also includes a front reinforcing beam (21), the front reinforcing beam (21) is located on the side of the front side beam (22) away from the rear side beam (23), and a longitudinal beam (27) connects the front reinforcing beam (21) and the front side beam (22); the front reinforcing beam (21) is connected to the front side panel (12).

5. The battery lower case according to any one of claims 1 to 4, characterized by, The beam structure of the frame structure (20) is formed by extrusion of aluminum profiles; and / or the bottom shell (10) is formed by hot stamping of aluminum plates.

6. The battery lower case according to any one of claims 1 to 4, characterized by, The lower battery housing includes several mounting blocks (30), which are connected to the outer side wall of the side plate facing away from the frame structure (20). Some mounting blocks (30) are located at the end of the front beam (22) of the frame structure (20), some mounting blocks (30) are located at the end of the rear beam (23) of the frame structure (20), and some mounting blocks (30) are located at the end of the middle crossbeam (26) of the frame structure (20).

7. The battery lower case according to any one of claims 1 to 4, characterized by, The side plate includes a flange (17) at one end away from the base plate (11) that folds away from the frame structure (20), the flange (17) having mounting holes.

8. A battery case characterized by Includes the battery lower housing as described in any one of claims 1-7.

9. A battery pack, characterized by Includes the battery housing as described in claim 8.

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