Battery box, skateboard frame and electric vehicle

Abstract

This presentation concerns a battery case, a skateboard chassis, and an electric vehicle. The battery case comprises a housing with an opening at one end and a cover over the opening. The case includes a base plate and four side walls connected vertically to the base plate. The base plate and each of the side walls have the same multilayer composite structure. The multilayer composite structure includes a first protective plate located relatively on one inner side of the case, a second protective plate located relatively on one outer side of the case, and an energy-absorbing pad sandwiched between the first and second protective plates. The sandwiched energy-absorbing pad comprises a layer with an octahedral porous core structure and a layer with a spiral vortex structure. Abstract drawing: Fig. 2

Description

Title of the invention: Battery case, skateboard chassis and electric vehicle. Technical field

[0001] The present exposition relates to the field of battery components for electric vehicles, and in particular a battery case for a skateboard chassis of the cell-frame (CTC) type. Background

[0002] The skateboard chassis is a highly integrated chassis formed by integrating the motor, battery, electrical controls, and steering, braking, and suspension systems into a single, independent chassis. In the CTC battery integration solution, the battery cell is directly integrated into the floor frame, and the upper and lower floor panels are used as the battery casing; that is, battery body integration is achieved. The CTC battery integration solution is perfectly suited to the high integration characteristics of the skateboard chassis.However, the CTC battery integration solution is distinguished by the fact that the battery housing is used as a component to house and protect the battery power system, and therefore needs to assume the functions of the chassis frame, including contributing to load-bearing capacity, rigidity, and strength, as well as providing collision protection for the vehicle. However, prior art battery housings often fail to consider rigidity, strength, and collision protection capabilities. Summary.

[0003] In view of the above problems, the present disclosure provides a battery case with an optimized structure. Based on the battery case, a skateboard chassis with the battery case and an electric vehicle are also provided.

[0004] The present presentation is implemented by the following technical solutions.

[0005] The present description provides a battery case, comprising a case with an opening at one end and a case cover over the case opening. The case comprises a base plate and four side panels connected vertically to the base plate. The base plate and each of the side panels have the same multilayer composite structure. The multilayer composite structure includes a first protective plate located relatively on one inner side of the case, and a second protective plate located relatively on one outer side. of the casing, and an energy-absorbing pad sandwiched between the first protective plate and the second protective plate.

[0006] Preferably, the sandwich energy-absorbing pad comprises a layer with an octahedral porous core structure. The layer with an octahedral porous core structure is formed from a network of octahedral elements. Each of the octahedral elements is a structure in which each corner of a hollow octahedron has a flat section to transform each corner cutout into a square hole.

[0007] Preferably, the paired octahedral elements arranged in a network are mutually joined through the flat section to make the hollow internal cavities of all the octahedral elements communicate.

[0008] Preferably, the sandwich energy-absorbing pad further comprises a separating panel and a spiral vortex structure layer. The octahedral porous core layer is located in an inner layer. The spiral vortex structure layer is located in an outer layer. The separating panel is arranged between the octahedral porous core layer and the spiral vortex structure layer to isolate them.

[0009] Preferably, the spiral vortex layer is formed from a network of spiral vortex elements. The spiral vortex element is composed of N elastic semicircular monomers of the same radius. Each of the N semicircular monomers has one end intersecting at a center. The adjacent semicircular monomers are distributed at an angle of (360 / N)° with the center serving as the center of rotation, where N is greater than or equal to 3 and N is an integer.

[0010] Preferably, the layer with an octahedral porous core structure is injected with a thermoregulated liquid.

[0011] Preferably, all of the first protective plate, the second protective plate and the separation panel are aluminum plates.

[0012] Preferably, an outer layer of the second protective plate is combined with a layer of carbon fibers.

[0013] Preferably, the housing cover comprises an inner layer of an aluminum plate and an outer layer of resin and carbon fiber material. The outer layer of resin and carbon fiber material of the housing cover and the carbon fiber layer at the outermost layer of the housing form a complete carbon fiber wrap for the battery housing.

[0014] Preferably, the outer left and right sides of the housing are further fixed with a lateral anti-collision device.

[0015] Preferably, the lateral anti-collision device comprises a rectangular hollow tube body, and a honeycomb core body filling the tube body.

[0016] Preferably, the honeycomb core is formed by a tight network of a number of honeycomb cells. Each honeycomb cell comprises a hexagonal outer frame and a circular inner frame arranged within the outer frame. Six connecting plates extend inward from six inner corners of the outer frame and are externally tangent to the inner frame to connect the outer and inner frames.

[0017] Based on the above battery case, the present disclosure further provides a skateboard chassis comprising the above battery case.

[0018] Based on the above skateboard chassis, the present presentation further provides an electric vehicle comprising the above skateboard chassis.

[0019] The present exposition has the following advantageous effects: the battery housing made available by the present exposition has an anti-collision function while ensuring rigidity and strength, and has excellent characteristics of mechanical properties, vibration damping, heat resistance, corrosion resistance, as well as excellent characteristics of thermal regulation capacity and energy absorption effect and buffering effect. Brief description of the drawings

[0020] [Fig-1] The [Fig.1] is a structural decomposition diagram of a housing of battery in embodiment 1;

[0021] [Fig.2] Fig.2 is a schematic diagram of a composite structure multilayer of a side wall in embodiment 1;

[0022] [Fig.3] The [Fig.3] is a schematic diagram of a core-structured layer porous octahedral in embodiment 1;

[0023] [Fig.4] The [Fig.4] is a schematic diagram of an octahedral element in the embodiment 1;

[0024] [Fig. 5] [Fig. 5] is a schematic diagram of a vortex structure layer spiral in embodiment 1;

[0025] [Fig. 6] [Fig. 6] is a schematic diagram of a spiral vortex element in embodiment 1;

[0026] [Fig.7] [Fig.7] is a schematic diagram of a honeycomb core body in embodiment 1;

[0027] [Fig.8] Fig.8 is a schematic diagram of a honeycomb cell in embodiment 1; and

[0028] [Fig.9] The [Fig.9] is a schematic diagram of a housing cover in the method of implementation 1. Detailed description of the implementation methods

[0029] To further illustrate the embodiments, the present document provides accompanying drawings. The accompanying drawings, as part of this document, are primarily used to illustrate the embodiments and may explain the operational principles of the embodiments by reference to the corresponding descriptions in this document. By reference to this content, persons with ordinary technical knowledge can understand other possible implementations and the advantages of this document. The components in the drawings are not drawn to scale, and similar reference numbers are usually used to represent similar components.

[0030] The present exposition will be further described below with reference to the accompanying drawings and specific implementations.

[0031] Embodiment 1

[0032] With reference to [Fig. 1], a battery case that is particularly suitable for a skateboard chassis is presented as a preferred embodiment of the present disclosure. The battery case comprises a housing 101 with an opening at one end and a housing cover 103 covering the opening of the housing. The housing 101 includes a base plate and four side walls connected vertically to the base plate. In the present embodiment, the base plate and the side walls are connected to form a single unit. Both the base plate and the side wall have a multilayer composite structure. [Fig. 2] shows a schematic diagram of the multilayer composite structure of the side wall. The multilayer composite structure of the base plate is identical to that of the side wall.The multi-layer composite structure comprises a first protective plate 201 positioned relatively on an inner side of the housing 101, a second protective plate 205 positioned relatively on an outer side of the housing 101, and an energy-absorbing pad 200 sandwiched between the first protective plate 201 and the second protective plate 205. With such an arrangement, based on the fact that the first protective plate 201 and the second protective plate 205 can ensure the firmness and rigidity of the battery housing, the energy-absorbing pad sandwiched 200 can also form a sufficient impact buffer to ensure that the battery housing is not damaged by excessive shock energy in the event of a collision.

[0033] The sandwich energy-absorbing pad 200 specifically comprises an octahedral porous core layer 202, a separating panel 203, and a spiral vortex layer 204. The octahedral porous core layer 202 is located in an inner layer. The spiral vortex layer 204 is located in an outer layer. The separating panel 203 is arranged between the octahedral porous core layer 202. and the spiral vortex structure layer 204 to isolate the octahedral porous core structure and the spiral vortex structure layer. A specific structure of the octahedral porous core structure layer 202 is shown in [Fig. 3] and [Fig. 4]. The octahedral porous core structure layer 202 is formed by a network of octahedral elements 202A. Each of the octahedral elements 202A is a structure in which each corner of a hollow octahedron has a flat section 202A-1 to transform each corner cutout into a square hole 202A-2. The paired octahedral elements 202A are mutually butted through the flat section 202A-1 to communicate hollow internal cavities of all the octahedral elements 202A, so as to form the structural layer of the porous core (i.e. comprising a porous cavity structure of each octahedral element 202A and a space between the paired octahedral elements 202A).The matched octahedral elements 202A are connected via a surface-to-surface contact, which offers superior rigidity and contact strength compared to traditional porous structures that use wire-to-wire contact connections, thus enhancing the mechanical properties of the casing. The octahedral porous core layer 202 exhibits excellent vibration damping and can act as a buffer for the battery casing. Furthermore, due to its octahedral porous core structure, the internal volume of the layer is significant, yet its contact area with the first protective plate 201 and the separation panel 203 is small. In actual battery casing use, a temperature-controlled liquid can be injected into the octahedral porous core layer 202 to maintain the optimal operating temperature range of the battery within the casing.

[0034] A specific structure of the spiral vortex layer 204 is shown in [Fig. 5] and [Fig. 6]. The spiral vortex layer 204 is formed from a network of spiral vortex elements 204A. The spiral vortex element 204A is composed of six semicircular monomers of the same radius. Each of the six semicircular monomers has one end intersecting at a center. Adjacent semicircular monomers are distributed at an angle of 60° with the center serving as the center of rotation. The semicircular monomer is made of an elastic metal. In the case of a collision or impact, it can undergo effective collapse after three stages, namely the elastic deformation stage, the elastic limit stage, and the densification stage, and has an excellent shock energy absorption effect.It provides sufficient cushioning for the battery case in the event of a significant impact, and effectively reduces the impact force on the battery during a collision. The battery case's puncture protection capability is improved, and the 204 spiral vortex structure layer can be folded. To some extent, this is convenient for the formation of the battery case structure.

[0035] In other embodiments, there may also be other numbers of semicircular monomers in the spiral vortex element 204A, such as 3, 8, and 12, provided that the adjacent semicircular monomers among the N semicircular monomers are arranged regularly at an angle of (360 / N)° around the center of rotation. N is greater than or equal to 3 and N is an integer. Preferably, N is divisible by 360. In the present embodiment, the solution of selecting six semicircular monomers can maintain a low manufacturing cost and ensure performance.

[0036] In the present embodiment, the layer with octahedral porous core structure 202 and the layer with spiral vortex structure 204 can be made of an aluminum alloy material or of a magnesium and aluminum alloy by a metal 3D printing or wire cutting process.

[0037] In this embodiment, all of the first protective plate 201, the second protective plate 205, and the separation panel 203 are aluminum plates, so as to enhance the thermal conductivity of the housing. Furthermore, in this embodiment, preferably, an outer layer of the second protective plate 205 is combined with a layer of carbon fibers 206, so as to enhance the mechanical properties of the housing.

[0038] Still with reference to [Fig.1] and [Fig.2], a support beam 207 is welded and fixed in the housing 101. The support beam 207 is a structure of two offset cross members on a longitudinal beam connected by aluminium profiles. The left and right outer sides of the housing 101 (i.e., the two sides of the housing 101 in the width direction) are further fixed by means of a lateral anti-collision device 102. The lateral anti-collision device 102 comprises a rectangular hollow tube body and a honeycomb core body filling the tube body, so as to amplify the energy absorption effect of the lateral anti-collision device 102. As shown in [Fig. 7] and [Fig. 8], the honeycomb core body in the present embodiment is formed by a tight network of a number of honeycomb cells 102A.Each 102A honeycomb cell comprises a hexagonal outer frame 102A-1 and a circular inner frame 102A-2 arranged within the outer frame. Six connecting plates 102A-3 extend inward from six inner corners of the outer frame 102A-1 and are externally tangent to the inner frame 102A-2 to connect the outer frame 102A-1 and the inner frame 102A-2. The honeycomb core has excellent energy absorption characteristics and can effectively fill the rectangular hollow tube body.

[0039] As shown in [Fig. 9], the housing cover 103 has a layered structure of carbon fiber-reinforced aluminum alloy. The housing cover comprises an inner layer of aluminum plate 802 and a layer of carbon fiber resin material 801, which enhances the mechanical properties of the housing cover 103 while achieving a lightweight design. The combination of the two reduces the size of the housing cover 103 and ensures its strength and rigidity. The outer layer of carbon fiber resin material 801 of the housing cover 103 and the carbon fiber layer 206 at the outermost layer of the housing form a complete carbon fiber wrap for the battery housing, which ensures the overall strength of the battery housing.A gasket is embedded at the junction between the profiled aluminium plate 802 and the housing 101 to form a seal.

[0040] The battery housing provided by this embodiment has the following advantages.

[0041] 1. Excellent mechanical properties. Carbon fiber is a fibrous material Having high strength and a high modulus with a carbon content of at least 95%, which has tensile strength superior to that of aluminum. Aluminum is a lightweight and very strong material, and unlike carbon fibers, aluminum has excellent compressive strength. The combination of the two has complementary advantages. In the present embodiment, the outermost layer of the housing 101 and the housing cover 103 incorporates a layer of carbon fibers and an aluminum plate. The carbon fibers are in the outer layer and the aluminum plate is in the inner layer, which strengthens the battery housing and provides excellent resistance to impact and deformation.

[0042] 2. Excellent buffering and energy absorption effects. Firstly, the buffer The energy-absorbing layer 200 of the casing 101 has a spiral vortex structure layer 204 made of a metallic material. In the event of a collision or impact, it undergoes three stages: an elastic deformation stage, an elastic limit stage, and a densification stage. As deformation increases, its elastic limit stress also tends to increase, indicating that the casing structure can absorb a large amount of energy under relatively low stress during compression. Secondly, when the spiral vortex structure layer 204 encounters a significant impact, it can effectively collapse and provide sufficient buffering to ensure normal battery operation.

[0043] 3. An excellent vibration damping characteristic. The vibrations are transmitted in the form of waves. When the vibrational waves pass through the octahedral porous core structure layer 202, the sandwich has a relaxation modulus less because the density of the sandwich is significantly lower than that of the solid wall of a traditional battery case, and the amplitude and energy transmitted by the vibrations are absorbed layer by layer to achieve damping of the vibrations, so as to ensure that the battery is not damaged by vibrations.

[0044] 4. Excellent thermal regulation capabilities. The core-structured layer The octahedral porous core layer 202 is embedded in a closed cavity, and a thermal regulation liquid can be injected inside. The octahedral porous core layer 202 has a small contact area with the first protective plate 201 and the separation panel 203, which allows for complete surface contact with the thermally regulated liquid and its transmission to the battery, making thermal regulation more efficient.

[0045] 5. Excellent resistance to heat and corrosion. Firstly, the fibers Carbon fibers can withstand high temperatures, at least 3000 degrees Celsius, and have extraordinary heat resistance. Secondly, carbon fibers have excellent chemical stability and corrosion resistance to alkalis, acids, and common organic solvents; they are insoluble and do not expand, and they exhibit exceptional corrosion resistance, eliminating any risk of rust. The outermost layer of the casing is made of carbon fibers, which offer excellent heat and corrosion resistance.

[0046] 6. A replaceable, energy-absorbing outer protective side and low cost Maintenance. The 102 side impact protection device, designed to protect and absorb shocks to the battery case, is mounted on the outer side of the battery case. The device's exterior features a hollow rectangular tube, while its interior is filled with a honeycomb core for energy absorption. The 102 side impact protection device adheres to the battery case using a structural adhesive. This adhesive offers high strength, can withstand heavy loads, is resistant to aging, fatigue, and corrosion, provides stable performance, and does not damage the main body of the battery case.

[0047] Embodiment 2:

[0048] The present embodiment provides a skateboard chassis, including the battery box of embodiment 1, and having the same technical effect of the same structure.

[0049] Embodiment 3:

[0050] The present embodiment provides an electric vehicle, comprising the skateboard chassis of embodiment 2, and having the same technical effect of the same structure.

[0051] Although the present exposition is specifically illustrated and described in combination with preferred implementations, a person skilled in the art should understand that various changes to the present exposition in terms of form and detail without departing from the spirit and scope of the present exposition, as defined in the attached claims, will fall within the scope of protection of the present exposition.

Claims

Demands

1. Battery case, comprising a case (101) with an opening at one end and a case cover (103) covering the case opening, wherein the case comprises a base plate and four side walls connected vertically to the base plate, the base plate and each of the side walls having the same multilayer composite structure, and the multilayer composite structure comprises a first protective plate (201) located relatively on an inner side of the case, a second protective plate (205) located relatively on an outer side of the case, and an energy-absorbing pad sandwiched (200) between the first protective plate and the second protective plate, wherein the energy-absorbing pad sandwiched comprises an octahedral porous core structure layer (202), the octahedral porous core structure layer being formed of an array of octahedral elements,and each of the octahedral elements (202A) is a structure in which each corner of a hollow octahedron is provided with a flat section (202A-1) to transform each corner cutout into a square hole (202A-2), paired octahedral elements arranged in a lattice are mutually abutted through the flat section to connect the hollow internal cavities of all the octahedral elements, thus forming a layer with a porous core structure.

2. Battery case according to claim 1, wherein the sandwich energy-absorbing pad (200) further comprises a separation panel (203) and a spiral vortex structure layer (204), the octahedral porous core structure layer (202) is relatively in an inner layer, the spiral vortex structure layer is relatively in an outer layer, and the separation panel is disposed between the octahedral porous core structure layer and the spiral vortex structure layer to isolate the octahedral porous core structure layer and the spiral vortex structure layer.

3. Battery casing according to claim 2, wherein the spiral vortex structure layer (204) is formed of a network of spiral vortex elements (204A), the spiral vortex element being composed of N elastic semicircular monomers of the same radius, each of the N semi-circular monomers has one end crossing at a center, and the adjacent semi-circular monomers are distributed at an angle of (360 / N)° with the center serving as the center of rotation, where N is greater than or equal to 3 and N is an integer.

4. Battery case according to claim 2, wherein the octahedral porous core structure layer (202) is injected with a thermoregulated liquid.

5. Battery housing according to claim 2, wherein all of the first protective plate (201), the second protective plate (205) and the separating panel (203) are aluminum plates, and an outer layer of the second protective plate is combined with a layer of carbon fibers.

6. Battery case according to claim 5, wherein the case cover (103) comprises an inner layer of an aluminum plate and an outer layer of resin and carbon fiber material, and the outer layer of resin and carbon fiber material of the case cover and the carbon fiber layer at the outermost layer of the case form a complete carbon fiber wrap for the battery case.

7. Battery case according to claim 1, wherein the outer left and right sides of the case are further fixed with a lateral anti-collision device.

8. Battery housing according to claim 7, wherein the lateral anti-collision device comprises a rectangular hollow tube body, and a honeycomb core body filling the tube body.

9. Battery case according to claim 8, wherein the honeycomb core body is formed by a tight network of a number of honeycomb cells, each of the honeycomb cells comprising a hexagonal outer frame and a circular inner frame disposed in the outer frame, and six connecting plates extend inwards from six inner corners of the outer frame and are externally tangent to the inner frame to connect the outer frame and the inner frame.

10. Skateboard chassis including battery box according to any one of claims 1 to 9.

11. Electric vehicle comprising the skateboard chassis according to claim 10.

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