Battery pack packaging structure

Abstract

The present application provides a battery pack packaging structure. The battery pack packaging structure comprises a pallet structure and a cover body; the pallet structure comprises a pallet body and a support portion, at least part of the support portion protruding from the periphery of the pallet body in the plane extension direction of the pallet body, and the support portion being fitted with the pallet body to form a groove located on the periphery of the pallet body; the cover body is provided on a first side of the pallet body; a cavity is formed in the side of the cover body facing the pallet body; a battery pack is located on the first side of the pallet body and is received in the cavity; at least part of the cover body is lapped within the groove, and the pallet body is received in the cavity.

Description

Battery pack packaging structure

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on December 28, 2023, with application number 202323661942.8. The entire contents of the above application are incorporated by reference into this application. Technical Field

[0002] The present application relates to the technical field of battery packs, and in particular to a battery pack packaging structure. Background Art

[0003] In the prior art, new energy battery packs are often transported and packaged in wooden boxes. The traditional wooden box structure consists of a top cover and a pallet. The outer short side panels of the top cover are lengthened and secured to the pallet's load-bearing blocks with wood screws. The lengthened outer short side panels are located on the outer surface of the wooden box. SUMMARY OF THE INVENTION

[0004] However, this arrangement makes the wooden boxes uneven, making them difficult to position during the battery packing process and hindering the placement and stacking of bulk boxes after packing. During long-distance transportation of battery packs, bumpy roads can cause the boxes to tip over, easily leading to collisions between the battery packs and the wooden box or the ground, potentially causing battery leakage, spontaneous combustion, or explosions.

[0005] In a first aspect, the present application provides a battery pack packaging structure, comprising:

[0006] A tray structure includes a tray body and a support portion, wherein the tray body includes a first side and a second side opposite to the first side in the first direction, and the tray body extends along a plane containing the second and third directions; the first side of the tray body is configured to accommodate a battery pack, the support portion is fixedly connected to the second side of the tray body, at least a portion of the support portion protrudes from a peripheral edge of the tray body in a plane extending direction of the tray body, the support portion and the tray body cooperate to form a groove located at a peripheral edge of the tray body, and the first, second, and third directions intersect with each other in pairs; and

[0007] The cover is arranged on the first side of the tray body. A cavity is formed on the side of the cover facing the tray body. The battery pack is located on the first side of the tray body and is accommodated in the cavity. At least a portion of the cover overlaps the groove, and the tray body is accommodated in the cavity. Beneficial effects

[0008] In an embodiment of the present application, the battery pack is placed on the first side of the tray body and the cover is closed on the tray structure to complete the assembly of the battery pack and the battery pack packaging structure. At least a portion of the cover overlaps the tray structure to complete the limited installation between the cover and the tray structure. Compared to the related art that requires adjusting the shape of the box top cover to complete the assembly between the box top cover and the tray, the technical solution of the embodiment of the present application does not require changing the shape of the cover. The cover and tray structure can be limited by the groove formed by the combination of the tray body and the support portion during assembly, thereby making the overall surface of the cover and the tray structure smooth, which is conducive to the placement, stacking and transportation of multiple battery pack packaging structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG1 is a perspective schematic diagram of a battery pack packaging structure provided in the present application;

[0010] FIG2 is an exploded schematic diagram of the battery pack packaging structure provided in this application;

[0011] FIG3 is an enlarged schematic diagram of point A in FIG2 ;

[0012] FIG4 is an exploded schematic diagram of the battery pack packaging structure provided in this application;

[0013] FIG5 is a schematic cross-sectional view of the battery pack packaging structure provided in the present application;

[0014] FIG6 is a perspective schematic diagram of a cover provided by the present application;

[0015] FIG7 is a perspective schematic diagram of a tray structure provided in the present application;

[0016] FIG8 is a schematic cross-sectional view of a cover provided by the present application;

[0017] FIG9 is a schematic structural diagram of the tray structure provided in this application.

[0018] Reference numerals:

[0019] 100. Battery pack packaging structure; 1. Tray structure; 11. Tray body; 12. Support portion; 1A. First side; 1B. Second side; 2. Groove; 3. Cover; 3A. Cavity; 4. Battery pack; 5. Limiting portion; 6. First buffer; 7. First strapping tape; 8. Protective member; 9. Second buffer; 12A. Support block; 12B. First plate; 10. Second plate; 31. First sub-section; 32. Second sub-section; 13. Second strapping tape; 14. First side panel; 15. Second side panel. Modes for Carrying Out the Invention

[0020] In the description of this application, unless otherwise specified or limited, the terms "connected," "connect," and "fixed" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and can refer to internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0021] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature includes the first feature being directly above and obliquely above the second feature, with the first feature having a higher horizontal height than the second feature. A first feature being "below," "below," and "below" a second feature includes the first feature being directly below and obliquely below the second feature, with the first feature having a lower horizontal height than the second feature.

[0022] In the description of this embodiment, terms such as "upper," "lower," "left," "right," "front," and "rear" are used to refer to positions or locations based on the positions or locations shown in the accompanying drawings. These terms are intended to facilitate description and simplify operation, and are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and do not have any special meanings.

[0023] The present application provides a battery pack packaging structure, and Figures 1 to 9 illustrate an embodiment of the present application. In Figure 2, the Z direction is the first direction, the Y direction is the second direction, and the X direction is the third direction. The first, second, and third directions intersect with each other in pairs, and the angles between the first, second, and third directions can be 80°, 85°, 90°, 95°, or 100°. In the following embodiments, the angles between the first, second, and third directions are 90°.

[0024] 1 to 4 , a battery pack packaging structure 100 includes a tray structure 1 and a cover 3. The tray structure 1 includes a tray body 11 and a support portion 12. The tray body 11 includes a first side 1A and a second side 1B opposite to the first side 1A in a first direction Z. The tray body 11 extends along a plane containing a second direction Y and a third direction X. The first side 1A of the tray body 11 is configured to accommodate a battery pack 4. The support portion 12 is fixedly connected to the second side 1B of the tray body 11. At least a portion of the support portion 12 protrudes from the periphery of the tray body 11 in the plane extending direction of the tray body 11. The support portion 12 cooperates with the tray body 11 to form a groove 2 located at the periphery of the tray body 11. The cover 3 is provided on the first side 1A of the tray body 11. The cover 3 has a cavity 3A formed on a side facing the tray body 11. The battery pack 4 is located on the first side 1A of the tray body 11 and is accommodated in the cavity 3A. At least a portion of the cover 3 overlaps the groove 2, and the tray body 11 is accommodated in the cavity 3A.

[0025] In the embodiment of the present application, the battery pack 4 is placed on the first side 1A of the tray body 11 and the cover 3 is placed on the tray structure 1 to complete the assembly of the battery pack 4 and the battery pack packaging structure 100. Among them, at least a portion of the cover 3 overlaps the tray structure 1 to complete the limited installation between the cover 3 and the tray structure 1. Compared with the related art that requires adjusting the shape of the box top cover to complete the assembly between the box top cover and the tray, the technical solution of the embodiment of the present application does not need to change the shape of the cover 3, and the cover 3 can be limited by the groove 2 formed by the combination of the tray body 11 and the support portion 12 when assembled with the tray structure 1, so that the overall surface of the cover 3 and the tray structure 1 is flat, which is conducive to the placement, stacking and transportation of multiple battery pack packaging structures 100.

[0026] It can be understood that, since the overall surface of the cover 3 and the tray structure 1 is flat, the tray body 11 is accommodated in the cavity 3A, which can also improve the overall aesthetics of the battery pack packaging structure 100.

[0027] Please refer to Figures 2, 3 and 9. It should be noted that the groove 2 is automatically formed when the tray body 11 and the support portion 12 are assembled. Therefore, there is no need to provide a separate groove 2 after the tray body 11 or the support portion 12 are assembled, which effectively reduces the preparation process flow of the battery pack packaging structure 100. Similarly, the groove 2 is combined with the tray body 11 to form the groove 2. Compared with forming the groove 2 on one of the tray body 11 or the support portion 12, the structural strength of the groove 2 will be higher. That is, when the groove 2 is formed on one of the tray body 11 or the support portion 12, part of the structure of the tray body 11 or the support portion 12 will be hollowed out. Therefore, when the groove 2 is formed, the structural strength of the tray body 11 or the support portion 12 will be reduced.

[0028] In the embodiment of the present application, to facilitate stacking and transport of the battery pack packaging structure 100, the cover 3 and tray body 11 are both rectangular. Compared to other shapes, such as circular or irregularly shaped covers 3 and tray bodies 11, this arrangement effectively improves the space utilization of the battery pack packaging structure 100 during transport.

[0029] Referring to Figure 2 , the tray body 11 extends along a plane encompassing the second direction Y and the third direction X, thereby forming a first side 1A facing the cover 3 for mounting the battery pack 4. The periphery of the tray body 11 refers to two opposing sides of the tray body 11 in the second direction Y and the third direction X. At least a portion of the support portion 12 protrudes beyond the periphery of the tray body 11. This means that the support portion 12 occupies a larger area than the tray body 11 in the plane encompassing the second direction Y and the third direction X. However, the support portion 12 is also directly visible when viewed from the cover 3 toward the tray structure 1 in the first direction Z.

[0030] Referring to Figures 2 and 5 , in some embodiments of the present application, the battery pack packaging structure 100 further includes multiple limiting portions 5 . These limiting portions 5 are fixed to the first side 1A of the tray body 11 and constrain the battery pack 4 . Specifically, in this embodiment, to prevent the battery pack 4 from moving in the direction of extension of the tray body 11 when placed on the first side 1A, multiple limiting portions 5 are provided around the periphery of the battery pack 4 , thereby limiting movement of the battery pack 4 in the second direction Y and the third direction X. The multiple limiting portions 5 are provided on the tray body 11 and, in conjunction with the tray body 11, enclose a mounting area for the battery pack 4 . Since the battery pack 4 is rectangular and has four sides extending in the second direction Y and the third direction X, two limiting portions 5 are provided on each side of the battery pack 4 , with the two limiting portions 5 located on one side of the battery pack 4 spaced apart from each other.

[0031] In some embodiments of the present application, the battery pack packaging structure 100 further includes a first buffer member 6 and at least one first strapping tape 7. The first buffer member 6 is located on the side of the battery pack 4 facing away from the tray body 11 in the first direction Z. The first strapping tape 7 is disposed around the tray body 11 and the battery pack 4, with the first buffer member 6 located between the first strapping tape 7 and the battery pack 4. In other words, in this embodiment, the provision of the first strapping tape 7 restricts the movement of the battery pack 4 in the first direction Z. The first buffer member 6 is disposed on one side of the battery pack 4 in the first direction Z to provide cushioning and shock absorption for the battery pack 4 in the first direction Z. Furthermore, the first buffer member 6 covers the side of the battery pack 4 facing away from the tray body 11 in the first direction Z, preventing the first strapping tape 7 on this side from directly contacting the battery pack 4 and causing scratches, damage, and marks on the battery pack 4. It is understandable that if the first strapping tape 7 is in direct contact with the battery pack 4, due to the small contact area between the first strapping tape 7 and the battery pack 4, when the battery pack 4 is subjected to a force in the first direction Z, it is easy to cause scratches and marks on the paint surface in the contact area between the first strapping tape 7 and the battery pack 4. In one embodiment of the present application, four first strapping tapes 7 are provided, and two first strapping tapes 7 form a group. The two groups of first strapping tapes 7 surround the tray body 11 and the battery pack 4 in the second direction Y and the third direction X, respectively. The two first strapping tapes 7 in the same group are spaced apart to ensure that the battery pack 4 and the tray body 11 are securely fixed relative to each other in the first direction Z.

[0032] The arrangement of the first strapping tape 7 and the limiting portion 5 can simultaneously limit the battery pack 4 in the first direction Z, the second direction Y and the third direction X. The first strapping tape 7 is installed after the battery pack 4 is placed so as not to interfere with the assembly of the battery pack 4.

[0033] In some embodiments of the present application, the battery pack packaging structure 100 further includes at least one protective member 8 disposed around the periphery of the first cushioning member 6. A portion of the protective member 8 overlaps the first cushioning member 6 and is positioned between the first cushioning member 6 and the first strapping tape 7. Another portion of the protective member 8 extends along the first direction Z and is positioned between the battery pack 4 and the first strapping tape 7. Because the first strapping tape 7 must be positioned around the battery pack 4 and the tray body 11, at least a portion of the first strapping tape 7 may contact one side of the battery pack 4 in the second direction Y or the third direction X, potentially causing scratches and marks on the painted surface of the battery pack 4. Therefore, the protective member 8 is provided to protect one side of the battery pack 4 in the second direction Y or the third direction X. To ensure that the protective member 8 can be secured between the first strapping tape 7 and the battery pack 4, at least a portion of the protective member 8 is positioned between the first cushioning member 6 and the first strapping tape 7, thereby securing the protective member 8 through the fixation of the first strapping tape 7 to the tray body 11 and the battery pack 4. In one embodiment of the present application, the protective member 8 is configured as a corner protector. The periphery of the first buffer member 6 is arranged to protrude from the periphery of the battery pack 4, so that when the first strapping tape 7 is tightened, the distance between the first strapping tape 7 and the battery pack 4 is larger, thereby further preventing the first strapping tape 7 from scratching the paint surface of the battery pack 4 after tightening the battery pack 4.

[0034] Referring to Figures 2 and 5 , the battery pack packaging structure 100 further includes a second buffer member 9 disposed between the battery pack 4 and the tray body 11 . The second buffer member 9 provides cushioning and shock absorption for the battery pack 4 in the first direction Z. Working in conjunction with the first buffer member 6 , the second buffer member 9 simultaneously cushions both sides of the battery pack 4 in the first direction Z, thereby enhancing the cushioning and shock absorption capabilities of the battery pack 4 . Both the first buffer member 6 and the second buffer member 9 are configured as pearl cotton.

[0035] Please refer to Figures 3 and 7. The support portion 12 includes a plurality of support blocks 12A connected to the pallet body 11. The plurality of support blocks 12A are arranged in an array. At least a portion of each support block 12A disposed near the periphery of the pallet body 11 protrudes from the periphery of the pallet body 11 in the plane extension direction of the pallet body 11. The support blocks 12A are used to support the pallet body 11. The plurality of support blocks 12A are arranged in an array, that is, there is a gap between two adjacent support blocks 12A to facilitate the insertion of the forklift's fork to place and transport the battery pack packaging structure 100. At least a portion of each support block 12A disposed near the periphery of the pallet body 11 protrudes from the periphery of the pallet body 11, thereby forming a groove 2 located on the pallet structure 1. In one embodiment of the present application, nine support blocks 12A are provided, and are arranged in an array along the plane where the second direction Y and the third direction X are located.

[0036] In some embodiments of the present application, the support portion 12 further includes at least one first plate member 12B. The first plate member 12B extends along the second direction Y or the third direction X. Each first plate member 12B is disposed on a side of the plurality of support blocks 12A facing away from the pallet body 11 in the first direction Z. Each first plate member 12B is connected to the plurality of support blocks 12A arranged in the second direction Y or the third direction X. In other words, in this embodiment, the first plate members 12B secure the plurality of support blocks 12A, thereby preventing the support blocks 12A from falling off during forklift loading and unloading.

[0037] Referring to Figure 4 , the battery pack packaging structure 100 also includes multiple second panels 10 disposed on the walls of cavity 3A. The presence of these second panels 10 reinforces the cover 3, improving its structural strength. Furthermore, these second panels 10 are disposed on the walls of cavity 3A so as not to be visible from the exterior of the cover 3. This enhances the structural strength of the cover 3 while maintaining a smooth appearance.

[0038] Referring to Figures 5, 6, and 8, the cover 3 includes a first subsection 31 and a second subsection 32 that are interconnected. A plurality of second panels 10 are connected to the first subsection 31, with at least a portion of the second subsection 32 overlapping the recess 2. In other words, in this embodiment, since a portion of the cover 3 will overlap the recess 2, the plurality of second panels 10 are disposed in the first subsection 31 to prevent the second panels 10 from interfering with the fit between the cover 3 and the recess 2. In one embodiment of the present application, the cover 3 includes two first side panels 14 disposed opposite each other in the second direction Y and two second side panels 15 disposed opposite each other in the third direction X. Five second panels 10 are disposed on each first side panel 14 or each second side panel 15. Four of the five second panels 10 on each first side panel 14 or each second side panel 15 form a rectangular frame structure, with the remaining second panel 10 located in the middle of the rectangular frame structure to enhance the structural strength of the first side panel 14 or second side panel 15. For ease of understanding, in FIG8 , the framed area B is the first sub-section 31 , and the framed area C is the second sub-section 32 .

[0039] Referring to Figure 8 , in some embodiments of the present application, a portion of the second plate 10 located in the first sub-portion 31 is installed near the second sub-portion 32, thereby improving the local structural strength of the cover 3 when embedded in the second sub-portion 32 of the groove 2. It is understood that the portion of the second plate 10 located near the second sub-portion 32 can be arranged to contact or not contact the tray body 11 in the first direction Z when the cover 3 is assembled with the tray structure 1.

[0040] Referring to Figure 1 , the battery pack packaging structure 100 further includes at least one second strapping tape 13, which is disposed around the tray body 11 and the cover 3. It is understood that the groove 2 between the cover 3 and the tray body 11 allows for movement restriction in the second direction Y and the third direction X. After the cover 3 and the tray body 11 are assembled, they can be secured using wood screws. When multiple battery pack packaging structures 100 need to be stacked and packaged, a second strapping tape 13 is provided to secure the cover 3 and the tray body 11 to ensure secure fixation. In one embodiment of the present application, four second strapping tapes 13 are provided, with two second strapping tapes 13 forming a group. The two groups of second strapping tapes 13 respectively surround the tray body 11 and the battery pack 4 in the second direction Y and the third direction X. The two second strapping tapes 13 in the same group are spaced apart to ensure secure fixation of the cover 3 in the first direction Z.

[0041] It should be noted that the battery pack 4 is positioned between the cover 3 and the tray body 11, and is restrained by the first strapping tape 7 and the plurality of limiting portions 5 in the first, second, and third directions Z, Y, and X. Furthermore, the first and second buffer members 6 and 9 provide cushioning protection for the battery pack 4, and the protective member 8 prevents scratches on the battery pack 4. This prevents the battery pack 4 from being scratched during long-distance transport, and also prevents leakage, spontaneous combustion, and explosions caused by bumpy roads. The quick separation between the cover 3 and the tray structure 1 via the groove 2 reduces the number of sealing steps required for the battery pack packaging structure 100 and increases product yield.

[0042] The present invention also provides a method for assembling a battery pack, comprising the following steps:

[0043] S1 : placing the first buffer member 6 on the first side 1A of the tray body 11 .

[0044] S2: placing the battery pack 4 on the side of the second buffer 9 facing away from the tray body 11 in the first direction Z.

[0045] S3 : placing the first buffer member 6 on a side of the battery pack 4 facing away from the tray body 11 in the first direction Z.

[0046] S4: placing a plurality of protective members 8 on a side of the first buffer member 6 facing away from the battery pack 4 in the first direction Z.

[0047] S5 : placing a plurality of limiting portions 5 on the circumferential sides of the battery pack 4 in the second direction Y and the third direction X, and fixing the plurality of limiting portions 5 to the tray body 11 .

[0048] S6: Use the first strapping tape 7 to fix the battery pack 4 and the tray body 11 .

[0049] S7: Cover the cover 3 on the tray body 11 and fix the tray body 11 and the cover 3 with wood screws.

[0050] It is understandable that, in step S7 , if multiple battery pack packaging structures 100 need to be transported, a second strapping tape 13 is required to further secure the cover 3 and the tray body 11 .

Claims

1. A battery pack packaging structure, comprising: A tray structure (1), comprising a tray body (11) and a support portion (12), wherein the tray body (11) comprises a first side (1A) and a second side (1B) opposite to the first side (1A) in a first direction, and the tray body (11) extends along a plane where the second direction and the third direction are located; the first side (1A) of the tray body (11) is configured to be installed with a battery pack (4), the support portion (12) is fixedly connected to the second side (1B) of the tray body (11), at least a portion of the support portion (12) protrudes from the periphery of the tray body (11) in the plane extension direction of the tray body (11), the support portion (12) cooperates with the tray body (11) to form a groove (2) located at the periphery of the tray body (11), and the first direction, the second direction and the third direction intersect each other in pairs; and, A cover body (3) is arranged on the first side (1A) of the tray body (11); the cover body (3) is formed with a cavity (3A) on a side facing the tray body (11); the battery pack (4) is located on the first side (1A) of the tray body (11) and is accommodated in the cavity (3A); at least a portion of the cover body (3) overlaps the groove (2); and the tray body (11) is accommodated in the cavity (3A).

2. The battery pack packaging structure according to claim 1, wherein, The battery pack packaging structure further comprises a plurality of limiting portions (5), wherein the plurality of limiting portions (5) are fixed to the first side (1A) of the tray body (11) and limit the battery pack (4).

3. The battery pack packaging structure according to claim 2, wherein, The plurality of limiting portions (5) are all arranged on the peripheral side of the battery pack (4); Wherein, two adjacent limiting portions (5) are arranged at intervals.

4. The battery pack packaging structure according to claim 1, wherein, The battery pack packaging structure also includes: a first buffer member (6) located on a side of the battery pack (4) facing away from the tray body (11) in the first direction; and At least one first packing belt (7) is arranged around the tray body (11) and the battery pack (4), and the first buffer (6) is located between the first packing belt (7) and the battery pack (4).

5. The battery pack packaging structure according to claim 4, wherein, The battery pack packaging structure further comprises at least one protective member (8), the protective member (8) being arranged at the periphery of the first buffer member (6), a portion of the protective member (8) being overlapped on the first buffer member (6) and being located between the first buffer member (6) and the first packing tape (7); another portion of the protective member (8) extending along the first direction and being located between the battery pack (4) and the first packing tape (7).

6. The battery pack packaging structure according to claim 4, wherein, The periphery of the first buffer member (6) protrudes from the periphery of the battery pack (4).

7. The battery pack packaging structure according to claim 1, wherein, The battery pack packaging structure further comprises a second buffer member (9), wherein the second buffer member (9) is arranged between the battery pack (4) and the tray body (11).

8. The battery pack packaging structure according to any one of claims 1 to 7, wherein, The support portion (12) comprises a plurality of support blocks (12A) connected to the tray body (11), wherein the plurality of support blocks (12A) are arranged in an array, and at least a portion of each of the support blocks (12A) disposed close to the periphery of the tray body (11) protrudes from the periphery of the tray body (11) in the plane extension direction of the tray body (11).

9. The battery pack packaging structure according to claim 8, wherein, The support portion (12) further includes at least one first plate member (12B), the first plate member (12B) extending along the second direction or the third direction, each of the first plate members (12B) being arranged on a side of the plurality of support blocks (12A) away from the tray body (11) in the first direction; each of the first plate members (12B) is connected to the plurality of support blocks (12A) arranged along the second direction or the third direction.

10. The battery pack packaging structure according to any one of claims 1 to 7, wherein, The battery pack packaging structure further comprises a plurality of second plates (10), wherein the plurality of second plates (10) are arranged on the cavity wall of the cavity (3A).

11. The battery pack packaging structure according to claim 10, wherein, The cover body (3) comprises a first sub-section (31) and a second sub-section (32) which are connected to each other, a plurality of the second plate members (10) are connected to the first sub-section (31), and at least a portion of the second sub-section (32) overlaps in the groove (2).

12. The battery pack packaging structure according to claim 11, wherein, At least one second plate (10) is arranged close to the second sub-portion (32).

13. The battery pack packaging structure according to any one of claims 1 to 12, wherein, The battery pack packaging structure further comprises at least one second packing belt (13), wherein the second packing belt (13) is arranged around the tray body (11) and the cover body (3).

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