A battery shell, power battery and vehicle

Abstract

The application provides a battery shell, a power battery and a vehicle, comprising: a vehicle body floor; a lower shell assembly connected with the vehicle body floor to form a cavity structure, the cavity structure being used for carrying a battery module; and a foaming assembly arranged between the vehicle body floor and the lower shell assembly and used for filling the cavity structure. Through the embodiment of the application, the integration of the battery cell and the vehicle body can be realized, and the strength and rigidity of the battery shell integrated with the battery cell and the vehicle body can be improved.

Description

Technical Field

[0001] This application relates to the field of power battery technology, and in particular to a battery casing, a power battery, and a vehicle. Background Technology

[0002] As a crucial component of the energy system in new energy vehicles, the power battery serves as the energy source for these vehicles, undertaking functions such as energy storage, discharging, charging, and battery management. However, the strength and rigidity of current battery casings are insufficient. Utility Model Content

[0003] In view of the above problems, this application is made in order to provide a battery casing, a power battery and a vehicle that overcome or at least partially solve the above problems.

[0004] To address the aforementioned problems, in the first aspect of this application, a battery casing is disclosed, comprising: Vehicle body floor; The lower housing assembly is connected to the vehicle floor to form a cavity structure, which is used to carry the battery module; A foaming component is disposed between the vehicle floor and the lower housing assembly for filling the cavity structure.

[0005] Optionally, the lower housing assembly includes: The lower housing base plate is used to support the battery module; The foaming component is disposed between the battery module and the vehicle floor.

[0006] Optionally, the lower housing assembly further includes: The lower housing side panel surrounds the lower housing bottom plate; The foaming component is disposed between the battery module and the lower housing side panel.

[0007] Optionally, the battery casing further includes: A heat insulation element is located on the side of the vehicle floor away from the lower housing assembly.

[0008] Optionally, the heat insulation component is made of heat-insulating and fire-resistant material.

[0009] Optionally, an explosion-proof valve is provided on the side of the battery module facing the vehicle floor, and the battery housing further includes: A vent pipe, located within the cavity structure, is connected to the outlet of the explosion-proof valve and is used to vent the explosion-proof valve.

[0010] Optionally, the foaming component is also used to secure the vehicle floor to the lower housing assembly.

[0011] Optionally, a seat crossbeam is provided on the vehicle floor for mounting vehicle seats.

[0012] In a second aspect of this application, embodiments of this application disclose a power battery, including a battery module and a battery casing as described above.

[0013] In a third aspect of this application, embodiments of this application disclose a vehicle including the power battery described above.

[0014] This application has the following advantages: This application embodiment utilizes a vehicle body floor and a lower housing assembly connected to the vehicle body floor to form a cavity structure, which is used to support the battery module. This allows the battery module to be integrated into the vehicle body for installation without a separate battery cover, achieving cell-to-body integration. This reduces the connection distance between the battery cover and the vehicle body, thereby saving space in the vehicle's height direction and lowering the vehicle's center of gravity. A foaming assembly is disposed between the vehicle body floor and the lower housing assembly to fill the cavity structure. By filling the cavity structure with the foaming assembly, the cavity structure receives support from the foaming assembly, improving the strength and rigidity of the battery casing. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a battery casing according to this application; Figure 2 This is a schematic diagram of another battery casing structure in this application; Figure 3 This is an exploded view of another battery casing structure in this application; Figure 4 This is an internal schematic diagram of another battery casing according to this application; Figure 5 This is a partial enlarged view of the interior of another battery casing according to this application.

[0016] Explanation of reference numerals in the attached figures: 100-Vehicle floor, 200-Lower housing assembly, 300-Foaming assembly, 400-Insulation component, 500-Ventilation duct, 600-Battery module, 700-Explosion-proof valve. Detailed Implementation

[0017] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] New energy vehicles have achieved rapid development due to their advantages such as low energy consumption, excellent driving performance, environmental friendliness, and high-tech features. The powertrain of a new energy vehicle comprises three main parts: the power battery system, the motor and transmission system, and the electronic control system. The power battery system, as a crucial component of new energy vehicles, is the energy source for the entire vehicle, responsible for storing, discharging, charging, and managing battery energy. However, current battery casings suffer from insufficient strength and rigidity, and the integration of the power battery with the vehicle is not high. To at least address some of these issues, embodiments of this application are proposed.

[0019] Reference Figure 1 The diagram shows a structural block diagram of a battery housing according to this application. The battery housing may specifically include the following components: Vehicle body floor 100; The lower housing assembly 200 is connected to the vehicle floor 100 to form a cavity structure, which is used to carry the battery module 600. A foaming component 300 is disposed between the vehicle floor 100 and the lower housing component 200 for filling the cavity structure.

[0020] In this embodiment, the battery casing includes a vehicle body floor 100, a lower casing assembly 200, and a foaming assembly 300. The vehicle body floor 100 serves as the bottom of the vehicle body, where interior equipment such as seats can be installed. The vehicle body floor 100 also serves as the upper cover of the battery casing, connecting with the lower casing assembly 200 to form a cavity structure. The connection between the vehicle body floor 100 and the lower casing assembly 200 can be direct, such as by adhesive bonding or welding, or indirect, using connectors such as threaded connectors or rivets. The cavity structure formed by the connection of the vehicle body floor 100 and the lower casing assembly 200 is a receiving cavity that can support and fix the battery module 600. The battery module 600 can be composed of multiple cells connected in series, parallel, or a hybrid configuration, and integrates a battery management system (BMS), a thermal management system, structural components, etc., to form a manageable energy storage unit. The foaming component 300 is disposed between the vehicle floor 100 and the lower housing component 200, which can fill the space between the vehicle floor 100 and the battery module 600. The foaming component 300 expands in the cavity structure and fills the entire cavity structure, so that the overall cavity structure can be supported by the foaming component 300, thereby providing full support for the battery housing and ensuring internal strength and rigidity.

[0021] This embodiment of the application utilizes a vehicle body floor 100 and a lower housing assembly 200, which are connected to the vehicle body floor 100 to form a cavity structure. This cavity structure supports the battery module 600, allowing the battery module 600 to be integrated into the vehicle body for installation without a separate battery cover. This achieves cell-to-body integration, reducing the connection distance between the battery cover and the vehicle body, thus saving space in the vehicle's height direction and lowering the vehicle's center of gravity. A foaming assembly 300 is disposed between the vehicle body floor 100 and the lower housing assembly 200 to fill the cavity structure. By filling the cavity structure with the foaming assembly 300, the cavity structure receives support from the foaming assembly 300, improving the strength and rigidity of the battery casing.

[0022] Reference Figure 2 This shows a schematic diagram of another battery casing structure according to this application; see reference. Figure 3 An exploded view of another battery housing structure of this application is shown; the battery housing may specifically include the following components: Vehicle body floor 100; The lower housing assembly 200 is connected to the vehicle floor 100 to form a cavity structure, which is used to carry the battery module 600; an explosion-proof valve 610 is provided on the side of the battery module 600 facing the vehicle floor 100. A foaming component 300 is disposed between the vehicle floor 100 and the lower housing component 200 for filling the cavity structure; The heat insulation element 400 is located on the side of the vehicle floor 100 away from the lower housing assembly 200; A ventilation pipe 500 is located in the cavity structure and is connected to the outlet of the explosion-proof valve 610 for venting the explosion-proof valve 610.

[0023] In this embodiment, the battery casing includes a vehicle floor 100, a lower casing assembly 200, a foaming assembly 300, a heat insulation component 400, and a ventilation duct 500. The vehicle floor 100 can be made of high-strength steel materials, such as phosphorus-added high-strength steel (BP steel plate), which achieves solid solution strengthening by adding phosphorus, significantly improving tensile strength while maintaining good formability; bake-hardening steel plate (BH steel plate), which, through specific chemical composition and production processes, increases yield strength and enhances surface hardness when the steel plate is painted and baked after stamping; low-alloy high-strength steel plate (BLa steel plate), which adds niobium or titanium alloy elements to form carbide and nitride precipitation strengthening, improving strength while maintaining good toughness; dual-phase high-strength steel (DP steel plate), which has martensite dispersed in a ferrite matrix, achieving a balance between high strength and good formability, with a low yield strength ratio and a high strain hardening index; and hot-formed steel, which forms a fully martensitic structure through high-temperature heating followed by rapid stamping and quenching, achieving a tensile strength of over 1500 MPa and minimal springback after forming. The vehicle floor 100 is equipped with a seat crossbeam for mounting the vehicle seats. The vehicle floor 100 serves as a structural component of the vehicle body, acting as the bottom of the vehicle and supporting the seats. It can also function as a cover for the power battery, thus enabling the reuse of parts, reducing material costs and overall vehicle weight. Furthermore, the reuse of the vehicle floor 100 eliminates the gap between the original floor and the battery cover, resulting in a lower center of gravity and a more compact structure.

[0024] The lower housing assembly 200 is connected to the vehicle floor 100 to form a cavity structure. The lower housing assembly 200 can be a square housing, so that the cavity structure can support the battery module 600 in an upright layout, making full use of the internal space of the cavity structure and improving the energy density of the battery module 600.

[0025] The foam component 300 is disposed between the vehicle floor 100 and the lower housing component 200, filling the cavity structure and thus filling the gap between the vehicle floor 100 and the battery module 600, thereby supporting the cavity structure. The foam component 300 can be an insulating foam material, and it must possess electrical insulation properties, temperature stability, low volatile organic compound (VOC) release, and be environmentally friendly and non-toxic. The materials of the foam component 300 include, but are not limited to, polyurethane foam, epoxy resin foam, silicone rubber foam, and acrylic foam. The polyurethane foam uses a polyurethane prepolymer as its core, combined with foaming agents, catalysts, and other components, and is encapsulated in a pressure-resistant aerosol can. When the polyurethane foam is sprayed from the can, the foamed polyurethane rapidly expands, reacting with air or moisture inside the cavity structure to form foam, thereby filling the gaps within the cavity structure. Epoxy resin foam is composed of modified epoxy resin, modified resins such as polysulfone, amine curing agents such as dicyandiamide, curing accelerators, inorganic fillers such as aluminum powder, and foaming agents such as OBSH (4,4-oxobisbenzenesulfonyl hydrazine). It is formed in film or strip form and can be inserted into the gap between the vehicle body floor 100 and the lower housing assembly 200 to fill the overall cavity structure. Silicone rubber foam uses solid or liquid silicone rubber as a carrier and forms a lightweight polymer material with controllable cell number and size through physical or chemical methods. It fills the cavity structure by spraying silicone rubber foam into it. Acrylic foam uses acrylic acid as its main component; acrylic acid is a high-molecular-weight, colorless, and transparent polymer. It can also fill the cavity structure by spraying acrylic acid foam into it.

[0026] In some embodiments, the foaming component 300 is further used to secure the vehicle floor 100 to the lower housing assembly 200. The foaming component 300 may be adhesive, and after filling the cavity structure, it will come into contact with the vehicle floor 100 and the lower housing assembly 200. The adhesiveness of the foaming component 300 securely connects the vehicle floor 100 and the lower housing assembly 200 to itself. The foaming component 300 secures the vehicle floor 100 and the lower housing assembly 200, thereby ensuring a stable connection between the vehicle floor 100 and the lower housing assembly 200 and improving the stability of the battery box.

[0027] The heat insulation component 400 is located on the side of the vehicle floor 100 away from the lower housing assembly 200, i.e. Figure 3As shown, the bottom of the vehicle floor 100 is connected to the lower housing assembly 200, while the top of the vehicle floor 100 is connected to the heat insulation component 400. Since the vehicle floor 100 is reused as a battery cover, heat from the battery module 600 will be transferred to the passenger compartment through the vehicle floor 100. To prevent users from feeling the heat and improve user comfort, the heat insulation component 400 is used to insulate the heat outside the passenger compartment, thereby reducing the amount of heat felt by the user and improving user comfort. Furthermore, even if thermal runaway occurs in the battery cells of the battery module 600, causing the temperature of the vehicle floor 100 to rise, the heat insulation component 400 can still prevent the heat from the vehicle floor 100 from spreading to the passenger compartment, preventing the vehicle floor 100 from overheating and providing a certain degree of protection for the user, thus improving the safety of the battery module 600 and the vehicle.

[0028] The heat insulation component 400 can be a thin-walled structure that provides heat insulation by covering the entire vehicle floor 100.

[0029] In some embodiments, the heat insulation component 400 is made of heat-insulating and fire-resistant material. The heat insulation component 400 made of heat-insulating and fire-resistant material can effectively provide heat insulation and fire protection. Heat-insulating and fire-resistant materials include, but are not limited to, the following types: aerogel, ceramicized foam, ceramicized silicone rubber, heat-insulating silicone foam, and mica board. Aerogel is a three-dimensional nanoporous solid material prepared by a sol-gel method combined with supercritical drying (or novel atmospheric pressure drying) technology. Ceramicized foam is a porous material with an organosilicon polymer as the matrix, foamed and molded through a special process, and can be transformed into a ceramic state under high temperature conditions. Ceramicized silicone rubber is a high-molecular composite material that can be transformed into a ceramic material at high temperatures, mainly composed of a silicone rubber matrix, ceramic filler, flux, reinforcing agent, and vulcanizing agent. Heat-insulating silicone foam is a porous, low-density, compressible high-molecular elastomer made from silicone rubber raw rubber, filler, vulcanization accelerator, foaming agent, etc., mixed evenly, and then processed under high pressure and high temperature using a special process. Mica board is an insulating material made by bonding mica paper with silicone rubber, heating and pressing.

[0030] It is possible Figure 4 and Figure 5As shown, an explosion-proof valve 610 is installed on the side of the battery module 600 facing the vehicle floor 100. That is, an explosion-proof valve 610 can be installed above the battery. When the internal pressure of the battery cell abnormally increases due to thermal runaway, overcharging, over-discharging, or short circuit, the explosion-proof valve 610 automatically opens to release internal gas, preventing the battery pack from exploding due to excessive pressure. Simultaneously, its design ensures directional gas emission, preventing flammable and toxic gases from directly threatening the safety of vehicle occupants. During thermal runaway of the battery cell, the internal temperature can rapidly rise to several hundred degrees Celsius, triggering a chain reaction such as electrolyte vaporization and separator melting. The explosion-proof valve 610, by timely pressure relief, blocks further diffusion of thermal runaway, buying time for the battery system to respond safely. The explosion-proof valve 610 uses an expanded polytetrafluoroethylene (e-PTFE) waterproof and breathable membrane, whose pore size is larger than the diameter of gas molecules but smaller than dust and water droplets, balancing internal and external air pressure while effectively preventing external contaminants from entering the battery pack. The explosion-proof valve 610 can be a piston-type explosion-proof valve 610, which relies on spring reset and pressure to open the piston body, allowing gas to be discharged through an unobstructed channel. It can also be a pin-type explosion-proof valve 610, which uses a pin structure to instantly puncture the sealing membrane, resulting in a larger exhaust volume and a shorter pressure relief time.

[0031] A vent pipe 500 can be installed within the cavity structure. The vent pipe 500 connects to the outlet of the explosion-proof valve 610. When the explosion-proof valve 610 is open, it can connect to the outside via the vent pipe 500, allowing it to vent air from the valve and thus enabling it to function as an explosion-proof device. The vent pipe 500 provides venting space in the event of thermal runaway of the battery module 600, ensuring smooth venting, preventing explosions, and improving safety.

[0032] In some embodiments, the lower housing assembly 200 includes: The lower housing base plate is used to support the battery module 600; The foaming component 300 is disposed between the battery module 600 and the vehicle floor 100.

[0033] In this embodiment, the lower housing assembly 200 includes a lower housing base plate. The lower housing base plate can securely fix multiple battery modules 600 within its internal bearing space using connectors such as slots, bolts, or quick-connect structures. The lower housing base plate can withstand mechanical stresses (such as bumps and collisions) during vehicle operation, protecting the battery modules 600 from physical damage and preventing displacement or damage caused by vibration, impact, or collision. Furthermore, an insulating layer can be provided between the lower housing base plate and the battery modules 600 to prevent short circuits or leakage risks. A high-voltage connector fixing position can also be integrated to ensure the stability of the electrical interface, thereby guaranteeing stable external output from the battery modules 600.

[0034] The foaming component 300 is disposed between the battery module 600 and the vehicle floor 100, filling the gap between the battery module 600 and the vehicle floor 100, thereby supporting the battery module 600 and the vehicle floor 100 in the vehicle height direction and improving the strength and rigidity of the battery box in the vehicle height direction.

[0035] In some embodiments, the lower housing assembly 200 further includes: The lower housing side panel surrounds the lower housing bottom plate; The foaming component 300 is disposed between the battery module 600 and the lower housing side panel.

[0036] In this embodiment, the lower housing assembly 200 includes a lower housing side panel that surrounds the lower housing bottom plate, sealing and reinforcing the strength of the lower housing bottom plate, and ensuring the lower housing assembly 200's ability to support the battery module 600.

[0037] Correspondingly, there is a gap between the battery module 600 and the lower housing side panel. A foaming assembly 300 is disposed between the battery module 600 and the lower housing side panel to fill the gap, further improving strength and rigidity. The side-mounted component can be formed by injecting foaming material into the gap between the battery module 600 and the lower housing side panel using an adhesive injection method.

[0038] This embodiment of the application utilizes a vehicle floor 100; a lower housing assembly 200 connected to the vehicle floor 100 to form a cavity structure, the cavity structure serving to support a battery module 600; an explosion-proof valve 610 disposed on the side of the battery module 600 facing the vehicle floor 100; a foaming assembly 300 disposed between the vehicle floor 100 and the lower housing assembly 200 for filling the cavity structure; a heat insulation component 400 located on the side of the vehicle floor 100 away from the lower housing assembly 200; and a venting pipe 500 located within the cavity structure, communicating with the vent of the explosion-proof valve 610 for venting the explosion-proof valve 610. The vehicle floor 100 can serve as a floor for the vehicle interior or as a cover for the battery, achieving high integration, saving space in the overall vehicle height, and reducing material weight and cost. A foamed component 300 is filled into the cavity structure to achieve high strength and rigidity of the entire battery box, thereby enabling the integration of the battery cells into the vehicle body. The foamed component 300 also provides side impact protection, improving the safety of the battery box. An exhaust channel is installed at the location of the explosion-proof valve 610 on the top of the battery module 600, resolving the conflict between top venting and potting, thus enabling thermal runaway management and further improving safety. A heat insulation component 400 is installed on the top of the vehicle floor 100 to prevent high temperatures from being conducted to the passenger compartment in the event of thermal runaway, ensuring safety.

[0039] This application also discloses a power battery, including a battery module and a battery casing as described above.

[0040] The battery module is installed inside the battery casing. The battery casing protects and seals the battery module.

[0041] In this embodiment, the power battery can be a chemical battery with various chemical systems. It can include the following types: 1. Lithium-ion batteries: Ternary lithium batteries (NCM / NCA), using nickel-cobalt-manganese (NCM) or nickel-cobalt-aluminum (NCA) as the positive electrode. Lithium iron phosphate batteries (LFP), using lithium iron phosphate as the positive electrode. Other lithium-ion batteries, such as lithium titanate batteries (LTO) and lithium manganese oxide batteries (LMO).

[0042] 2. Sodium-ion battery.

[0043] 3. Solid-state batteries use solid electrolytes instead of liquid electrolytes, offering high safety and great potential for energy density.

[0044] 4. Hydrogen fuel cell: A battery that generates electricity through a hydrogen-hydrogen chemical reaction.

[0045] This application also discloses a vehicle including the power battery described above.

[0046] By using the power battery as the vehicle's energy storage system and energy carrier, the power battery delivers the electrical energy it stores to other components of the vehicle, thereby driving the vehicle and enabling its corresponding functions.

[0047] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0048] The present application provides a detailed description of a battery casing, a power battery, and a vehicle. Specific examples have been used to illustrate the principles and implementation methods of the present application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of the present application. At the same time, those skilled in the art will recognize that there will be changes in the specific implementation methods and application scope based on the ideas of the present application. Therefore, the content of this specification should not be construed as a limitation of the present application.

Claims

1. A battery casing, characterized in that, include: Vehicle body floor; The lower housing assembly is connected to the vehicle floor to form a cavity structure, which is used to carry the battery module; A foaming component is disposed between the vehicle floor and the lower housing assembly for filling the cavity structure.

2. The battery casing according to claim 1, characterized in that, The lower housing assembly includes: The lower housing base plate is used to support the battery module; The foaming component is disposed between the battery module and the vehicle floor.

3. The battery casing according to claim 2, characterized in that, The lower housing assembly also includes: The lower housing side panel surrounds the lower housing bottom plate; The foaming component is disposed between the battery module and the lower housing side panel.

4. The battery casing according to any one of claims 1-3, characterized in that, The battery casing also includes: A heat insulation element is located on the side of the vehicle floor away from the lower housing assembly.

5. The battery casing according to claim 4, characterized in that, The heat insulation component is made of heat-insulating and fire-resistant materials.

6. The battery casing according to any one of claims 1-3, characterized in that, An explosion-proof valve is provided on the side of the battery module facing the vehicle floor, and the battery housing also includes: A vent pipe, located within the cavity structure, is connected to the outlet of the explosion-proof valve and is used to vent the explosion-proof valve.

7. The battery casing according to any one of claims 1-3, characterized in that, The foaming component is also used to secure the vehicle floor to the lower housing assembly.

8. The battery casing according to claim 1 or 2, characterized in that, A seat crossbeam is provided on the vehicle floor for mounting the vehicle seat.

9. A power battery, characterized in that, Includes a battery module and a battery casing as described in any one of claims 1-8.

10. A vehicle, characterized in that, Includes the power battery as described in claim 9.

Images