Battery pack box body, battery pack, electrical apparatus and method for manufacturing battery pack box body

Abstract

A battery pack box body (100), a battery pack (1000), an electrical apparatus, and a method for manufacturing the battery pack box body (100), belonging to the technical field of batteries. The battery pack box body (100) comprises: a bottom plate (110); a side wall assembly (130), which surrounds and extends in the circumferential direction of the bottom plate (110) and is connected to the bottom plate (110); a moldable material assembly (120), at least part of the moldable material assembly (120) extending in the circumferential direction of the side wall assembly (130) so as to provide support on the inner side and the outer side of the side wall assembly (130); and a composite material member (140), the composite material member (140) extending in the circumferential direction of the side wall assembly (130) and forming on the inner side of the side wall assembly (130) a cavity (190) capable of accommodating battery cells (180) of the battery pack (1000).

Description

Battery pack case, battery pack, electrical device, and method for manufacturing battery pack case

[0001] Cross-references

[0002] This application refers to Chinese Patent Application No. 202410008049.5 filed on January 2, 2024, entitled “Battery Pack Case, Battery Pack, Electrical Device, and Method for Manufacturing Battery Pack Case,” which is incorporated herein by reference in its entirety. Technical Field

[0003] The present application relates to the field of battery technology, and in particular to a battery pack case, a battery pack, an electrical device, and a method for manufacturing a battery pack case. Background Art

[0004] In the field of new energy technology, the battery pack casing, as the supporting and protective structure of the battery cells, has always attracted much attention.

[0005] The battery pack box generally includes mechanical components such as the top plate, various metal profile brackets and bolts, which can effectively provide support, resistance to mechanical impact and environmental protection (such as waterproof and dustproof).

[0006] However, various metal profile brackets formed into a box body through welding and screwing often lead to a series of problems, such as high overall box quality, relatively complex manufacturing process, and poor thermal insulation effect of the battery pack box.

[0007] Summary of the Invention

[0008] In view of the above problems, the present application provides a battery pack case, a battery pack, an electrical device and a method for manufacturing a battery pack case, aiming to alleviate, reduce or eliminate at least one of a series of problems caused by the metal profile bracket forming the case.

[0009] In the first aspect, the present application provides a battery pack case, comprising: a bottom plate; a side wall assembly, which extends around the circumference of the bottom plate and is connected to the bottom plate; a formable material assembly, at least a portion of which extends along the circumference of the side wall assembly to provide support on the inner and outer sides of the side wall assembly; and a composite material member, which extends along the circumference of the side wall assembly and forms a cavity on the inner side of the side wall assembly that can accommodate the battery cells of the battery pack.

[0010] In the technical solutions of the embodiments of the present application, the use of formable material assemblies and composite materials makes it possible to alleviate, mitigate, or eliminate at least one of a series of problems caused by the use of metal profile brackets to form the battery case. For example, because the density of formable material assemblies and composite materials is generally lower than that of metal profiles, the overall weight of the battery pack case can be reduced, thereby promoting lightweighting of the battery pack case. For another example, the thermal conductivity efficiency of formable material assemblies and composite materials is generally lower than that of metal profiles, which can improve the thermal insulation of the battery pack case, thereby alleviating the problem of poor thermal insulation of the battery pack case.

[0011] In some embodiments, the sidewall assembly includes a first sidewall member and a third sidewall member, the first sidewall member and the third sidewall member being opposite to each other in a first direction; and a second sidewall member and a fourth sidewall member, the second sidewall member and the fourth sidewall member being opposite to each other in a second direction, the second direction intersecting the first direction, wherein the first sidewall member, the second sidewall member, the third sidewall member, and the fourth sidewall member are sequentially connected. This design can form a frame-shaped sidewall assembly and is simple to manufacture.

[0012] In some embodiments, the moldable material assembly includes: a first moldable material piece and a third moldable material piece, the first moldable material piece and the third moldable material piece are opposite to each other in a first direction, wherein the first moldable material piece and the third moldable material piece are laid on a bottom plate, and the first moldable material piece and the third moldable material piece are used to fit the outer wall surface of the first side wall piece and the third side wall piece; and a second moldable material piece and a fourth moldable material piece, the second moldable material piece and the fourth moldable material piece are opposite to each other in a second direction, wherein the second moldable material piece and the fourth moldable material piece are used to fit the inner wall surface of the second side wall piece and the fourth side wall piece. By arranging the first moldable material piece and the third moldable material piece to fit the outer wall surface of the first side wall piece and the third side wall piece and arranging the second moldable material piece and the fourth moldable material piece to fit the inner wall surface of the second side wall piece and the fourth side wall piece, the lateral rigidity of the battery pack case can be enhanced.

[0013] In some embodiments, the formable material assembly further includes a fifth formable material piece, which is laid on the bottom plate. Laying the fifth formable material piece on the bottom plate can enhance the vertical rigidity of the battery pack case.

[0014] In some embodiments, the fifth formable material comprises a first formable material portion, a second formable material portion, and a third formable material portion, wherein the first formable material portion, the second formable material portion, and the third formable material portion are arranged on the base plate in pairs. By dividing the fifth formable material into three mutually spaced portions, material usage of the formable material can be reduced, thereby further reducing costs.

[0015] In some embodiments, the composite material, the bottom plate, and the first sidewall define a first accommodation space for accommodating the first moldable material, and the composite material, the bottom plate, and the third sidewall define a second accommodation space for accommodating the third moldable material. This design reduces the possibility of the first and third moldable materials detaching from the battery pack case after integral molding, thereby increasing the reliability of the battery pack case.

[0016] In some embodiments, the composite material member and the second sidewall member define a third accommodation space for accommodating a second moldable material member, and the composite material member and the fourth sidewall member define a fourth accommodation space for accommodating a fourth moldable material member. This design reduces the possibility of the second and fourth moldable material members detaching from the battery pack case after integral molding, thereby increasing the reliability of the battery pack case.

[0017] In some embodiments, a portion of the composite material also covers the formable material component. Because the composite material has high strength but relatively low stiffness and large deformation, while the formable material component has high stiffness but relatively low strength, the combination of the two can enhance the overall stiffness of the box without reducing the overall strength of the box.

[0018] In some embodiments, the composite material member includes: a bottom wall; a frame wall disposed on the bottom wall, the bottom wall and the frame wall enclosing a cavity for a battery cell; and at least one spacer, the at least one spacer disposed within the cavity along a second direction, the at least one spacer extending along a first direction to divide the interior of the cavity into a plurality of chambers arranged along the second direction. By using the at least one spacer to divide the interior of the cavity into a plurality of chambers, space can be reserved for placing multiple battery cells side by side.

[0019] In some embodiments, the battery pack case further includes at least one end plate, each of which is configured to be inserted into a corresponding spacer in the at least one spacer. Inserting the end plate into the spacer enhances the strength of the spacer and further allows for internal mounting of bolts.

[0020] In some embodiments, the battery pack case further includes a top plate for connecting to the sidewall assembly to enclose the cell cavity. The top plate serves to enclose the cell cavity and can be further fixedly connected to other fixtures, such as the vehicle body frame.

[0021] In some embodiments, the formable material component and the composite material component are integrally molded. This design can reduce the number of battery pack manufacturing steps and lower process costs.

[0022] In some embodiments, the composite material is selected from at least one of glass fiber and carbon fiber. In such a design, this makes the density of the composite material lower, thereby reducing the overall weight of the battery pack body.

[0023] In a second aspect, the present application provides a battery pack, comprising: a battery cell; and the battery pack case in the above embodiment, wherein the battery cell is arranged inside the cavity.

[0024] Such a battery pack can provide the advantages described above with respect to the battery pack housing, which will not be elaborated on for the sake of brevity.

[0025] In a third aspect, the present application provides an electrical device, which includes the battery pack in the above embodiment, and the battery pack is used to provide electrical energy.

[0026] Such an electrical device can provide the advantages described above with respect to the battery pack housing, which will not be described in detail for the sake of brevity.

[0027] In a fourth aspect, the present application provides a method for manufacturing a battery pack case, comprising: laying a bottom plate at the bottom of a mold; laying a side wall assembly on the bottom plate; laying a portion of a formable material assembly on the bottom plate and laying it around the side wall assembly; laying a composite material part on the side wall assembly and the formable material assembly; and integrally molding the laid bottom plate, side wall assembly, formable material assembly and composite material part.

[0028] Such a method for manufacturing a battery pack case can provide the advantages described above with respect to the battery pack case, which will not be described in detail for the sake of brevity.

[0029] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] By reading the detailed description of the embodiments below, various other advantages and benefits will become clear to those of ordinary skill in the art. The accompanying drawings are only used for the purpose of illustrating the embodiments and are not considered to be limitations of the present application. Moreover, the same reference numerals are used to represent the same components throughout the accompanying drawings. In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments of the present application. Obviously, the drawings described below are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on the drawings without creative work. In the drawings:

[0031] FIG1 is an exploded schematic diagram of a battery pack case according to some embodiments of the present application;

[0032] FIG2 is an exploded schematic diagram of a sidewall assembly according to some embodiments of the present application;

[0033] FIG3 is a schematic structural diagram of a formable material assembly according to some embodiments of the present application;

[0034] FIG4 is a top view of the battery pack case of FIG1 ;

[0035] FIG5 is a cross-sectional view of the battery pack case taken along section line AA of FIG4 ;

[0036] FIG6 is an enlarged schematic diagram of a portion C of FIG5 ;

[0037] FIG7 is a cross-sectional view of the battery pack case taken along section line BB of FIG4 ;

[0038] FIG8 is an enlarged schematic diagram of a portion D of FIG7 ;

[0039] FIG9 is a schematic structural diagram of a composite material member according to some embodiments of the present application;

[0040] FIG10 is a schematic structural diagram of a portion of a battery pack according to some embodiments of the present application;

[0041] FIG11 is a schematic structural diagram of a vehicle according to some embodiments of the present application.

[0042] FIG12 is a flow chart of a method for manufacturing a battery pack case according to some embodiments of the present application.

[0043] The reference numerals in the specific embodiments are as follows: first direction X, second direction Y; battery pack case 100, bottom plate 110, formable material assembly 120, side wall assembly 130, composite material member 140, end plate 150, top plate 160, battery cell 180, cavity 190; first side wall member 200, second side wall member 210, third side wall member 220, fourth side wall member 240; first formable material member 300, second formable material member 310, third formable material member 330, fourth formable material member 340, fifth formable material member 350, first formable material portion 360, second formable material portion 370, third formable material portion 380; first accommodating space 500, second accommodating space 510; third accommodating space 700, fourth accommodating space 710; bottom wall 900, frame wall 910, spacer 920, cavity 930; Battery pack 1000 , vehicle 1100 , motor 1300 , controller 1400 . DETAILED DESCRIPTION

[0044] The following embodiments of the technical solution of the present application will be described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present application and are therefore only examples and are not intended to limit the scope of protection of the present application.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" and any variations thereof in the specification and claims of this application and the above-mentioned figure descriptions are intended to cover non-exclusive inclusions.

[0046] In the description of the embodiments of this application, the technical terms "first" and "second" are used only to distinguish different objects and should not be understood to indicate or imply relative importance or implicitly specify the quantity, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, the meaning of "plurality" is more than two, unless otherwise clearly and specifically defined.

[0047] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0048] In the description of the embodiments of this application, the term "and / or" is simply a description of the association relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can represent the following three situations: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " in this document generally indicates that the associated objects are in an "or" relationship.

[0049] In the description of the embodiments of the present application, the term "multiple" refers to more than two (including two). Similarly, "multiple groups" refers to more than two groups (including two groups), and "multiple pieces" refers to more than two pieces (including two pieces).

[0050] In the description of the embodiments of the present application, the technical terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the embodiments of the present application.

[0051] In the description of the embodiments of the present application, unless otherwise expressly specified or limited, technical terms such as "installed," "connected," "connected," 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; internal connections between two components or interactions between two components. Those skilled in the art can understand the specific meanings of the above terms in the embodiments of the present application based on specific circumstances.

[0052] In describing the embodiments of the present application, flow charts are used to illustrate the operations performed by the system according to the embodiments of the present disclosure. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, the steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0053] Currently, a battery pack case serving as a supporting and protective structure for the battery cells of the battery pack is manufactured by welding and screwing various metal profile brackets.

[0054] If only various metal profile brackets are used to make the battery pack box, the overall quality of the battery pack box is often high, and due to the high heat conduction efficiency of metal, the thermal insulation effect of the battery pack box is poor, which may in turn affect the battery life.

[0055] In order to alleviate, mitigate, or eliminate at least one of the problems caused by the use of metal profile brackets to form the battery case, moldable material components and composite materials can be used. For example, because the density of moldable material components and composite materials is generally lower than that of metal profiles, the overall weight of the battery pack case can be reduced, thereby promoting the lightweighting of the battery pack case. For another example, the thermal conductivity efficiency of moldable material components and composite materials is generally lower than that of metal profiles, which can improve the thermal insulation effect of the battery pack case, which is beneficial for the battery pack to operate at high and low temperatures and extend the battery life.

[0056] Based on the above considerations, a battery pack case is designed to alleviate, mitigate or eliminate at least one of a series of problems caused by the metal profile bracket forming the case by adopting formable material components and composite material parts.

[0057] The battery pack case disclosed in the embodiment of the present application can be used in a battery. The battery pack case disclosed in the present application can be used to form a power supply system for the electrical device.

[0058] Refer to Figure 1 and further to Figures 2 through 8. Figure 1 is an exploded schematic diagram of a battery pack case according to some embodiments of the present application; Figure 2 is an exploded schematic diagram of a sidewall assembly according to some embodiments of the present application; Figure 3 is a schematic diagram of the structure of a formable material assembly according to some embodiments of the present application; Figure 4 is a top view of the battery pack case of Figure 1; Figure 5 is a cross-sectional view of the battery pack case taken along section line AA in Figure 4; Figure 6 is an enlarged schematic diagram of a portion C in Figure 5; Figure 7 is a cross-sectional view of the battery pack case taken along section line BB in Figure 4; and Figure 8 is an enlarged schematic diagram of a portion D in Figure 7. The battery pack case 100 includes a bottom plate 110, a sidewall assembly 130, a formable material assembly 120, and a composite material member 140. The sidewall assembly 130 extends around the circumference of the bottom plate 110 and is connected to the bottom plate 110. A first sidewall member 200, a second sidewall member 210, a third sidewall member 220, and a fourth sidewall member 240 are connected in sequence. At least a portion of the moldable material component 120 extends circumferentially of the sidewall component 130 to provide support on the inner and outer sides of the sidewall component 130. The composite material member 140 extends circumferentially of the sidewall component 130 and forms a cavity 190 inside the sidewall component 130 for accommodating the battery cells 180 of the battery pack 1000.

[0059] As shown in the figure, the first direction X is the width direction of the battery pack case 100 , and the second direction Y is the length direction of the battery pack case 100 .

[0060] As used herein, the term "formable material" refers to a material that can be manually deformed, maintains a defined shape after deformation, and can subsequently be manually changed to its original shape. In some embodiments, the formable material may include PET (Polyethylene terephthalate) foam, etc. In some embodiments, the density of PET foam is between 0.055 and 0.3 grams per cubic centimeter (g / cm 3 ) range, compared with metals (such as aluminum alloy 2.75g / cm 3 ) density, which can reduce the overall weight of the battery pack box. In addition, PET foam has strong thermal insulation properties, which can improve the thermal insulation performance of the battery pack box.

[0061] By using formable material components and composite parts, the overall weight of the battery pack case can be reduced due to their lower density compared to metal profiles, thereby promoting lightweighting. Furthermore, the thermal conductivity efficiency of formable material components and composite parts is also lower than that of metal profiles, which improves the thermal insulation of the battery pack case.

[0062] According to some embodiments of the present application, the sidewall assembly 130 includes a first sidewall member 200 and a third sidewall member 220 , which are opposite to each other in a first direction X. The sidewall assembly 130 also includes a second sidewall member 210 and a fourth sidewall member 240 , which are opposite to each other in a second direction Y, which intersects the first direction X.

[0063] As shown in Figure 2, the side wall assembly 130 can be composed of four separate independent components, namely a first side wall component 200, a second side wall component 210, a third side wall component 220 and a fourth side wall component 240. In some embodiments, the first side wall component 200, the second side wall component 210, the third side wall component 220 and the fourth side wall component 240 can be fixedly connected to each other in sequence by welding, thereby forming a side wall assembly 130 similar to a rectangular frame. However, it is understandable that the first side wall component 200, the second side wall component 210, the third side wall component 220 and the fourth side wall component 240 can also be integrally formed, and the present disclosure does not limit this. According to some embodiments of the present application, the side wall assembly 130 may include an aluminum profile frame. In the example shown in Figure 6, the side wall assembly 130 may have three rectangular profile cavities.

[0064] In such a design, a side wall assembly that is simply formed into a frame shape can be manufactured.

[0065] Please continue to refer to Figures 3 to 8. According to some embodiments of the present application, the moldable material assembly 120 includes a first moldable material piece 300 and a third moldable material piece 330. The first moldable material piece 300 and the third moldable material piece 330 are opposite to each other in a first direction X. The first moldable material piece 300 and the third moldable material piece 330 are laid on the base plate 110. The first moldable material piece 300 and the third moldable material piece 330 are configured to conform to the outer surfaces of the first sidewall piece 200 and the third sidewall piece 220. The moldable material assembly 120 also includes a second moldable material piece 310 and a fourth moldable material piece 340. The second moldable material piece 310 and the fourth moldable material piece 340 are opposite to each other in a second direction Y. The second moldable material piece 310 and the fourth moldable material piece 340 are configured to conform to the inner surfaces of the second sidewall piece 210 and the fourth sidewall piece 240.

[0066] In the example shown in FIG. 3 , the moldable material assembly 120 includes four separate moldable material pieces, namely a first moldable material piece 300 , a second moldable material piece 310 , a third moldable material piece 330 and a fourth moldable material piece 340 , which together constitute four sidewall regions of the moldable material assembly 120 .

[0067] In the examples shown in Figures 5 and 6 , the first moldable material piece 300 is aligned with the outer wall surface of the first sidewall piece 200, and the third moldable material piece 330 is aligned with the outer wall surface of the third sidewall piece 220. In the examples shown in Figures 7 and 8 , the second moldable material piece 310 is aligned with the inner wall surface of the second sidewall piece 210, and the fourth moldable material piece 340 is aligned with the inner wall surface of the fourth sidewall piece 240.

[0068] By arranging the first and third formable material pieces to fit with the outer wall surfaces of the first and third side wall pieces and arranging the second and fourth formable material pieces to fit with the inner wall surfaces of the second and fourth side wall pieces, the lateral stiffness of the battery pack case can be enhanced.

[0069] According to some embodiments of the present application, the formable material assembly 120 further includes a fifth formable material piece 350 . The fifth formable material piece 350 is laid on the base plate 110 .

[0070] In the example shown in FIGS. 5-7 , a fifth piece of formable material 350 is disposed on the base plate 110 .

[0071] By laying the fifth formable material piece on the bottom plate, the vertical rigidity of the battery pack case can be enhanced.

[0072] According to some embodiments of the present application, the fifth moldable material piece 350 includes a first moldable material portion 360, a second moldable material portion 370, and a third moldable material portion 380. The first moldable material portion 360, the second moldable material portion 370, and the third moldable material portion 380 are laid on the bottom plate 110 in pairs.

[0073] In the example shown in FIG3 , the fifth moldable material piece 350 includes a first moldable material portion 360 and a third moldable material portion 380 located on either side, and a second moldable material portion 370 located therebetween. However, it is understood that the first moldable material portion 360, the second moldable material portion 370, and the third moldable material portion 380 may also be integrally formed, and this disclosure is not limited thereto.

[0074] By dividing the fifth formable material piece into three mutually spaced parts, the material usage of the formable material piece can be saved, thereby further reducing the cost.

[0075] Continuing with Figures 5 and 6 , in some embodiments, the composite material piece 140, the bottom plate 110, and the first sidewall 200 define a first receiving space 500. The first receiving space 500 is used to receive the first moldable material piece 300. The composite material piece 140, the bottom plate 110, and the third sidewall 220 define a second receiving space 510. The second receiving space 510 is used to receive the third moldable material piece 330.

[0076] In the example shown in FIG. 6 , the composite material piece 140 , the bottom plate 110 and the first sidewall piece 200 together enclose a first receiving space 500 , and the first formable material piece 300 is installed in the first receiving space 500 .

[0077] In such a design, the possibility of the first formable material piece and the third formable material piece detaching from the battery pack case after integral molding is reduced, thereby increasing the reliability of the battery pack case.

[0078] 7 and 8 , the composite material member 140 and the second sidewall member 210 define a third receiving space 700. The third receiving space 700 is used to receive the second moldable material member 310. The composite material member 140 and the fourth sidewall member 240 define a fourth receiving space 710. The fourth receiving space 710 is used to receive the fourth moldable material member 340.

[0079] In the example shown in FIG. 8 , the composite material piece 140 and the second sidewall piece 210 enclose a third accommodating space 700 , and the second formable material piece 310 is installed in the third accommodating space 700 .

[0080] In such a design, the possibility of the second formable material piece and the fourth formable material piece detaching from the battery pack case after integral molding is reduced, thereby increasing the reliability of the battery pack case.

[0081] According to some embodiments of the present application, a portion of the composite material piece 140 further covers the formable material component 120 .

[0082] 6 , the composite material piece covers the first and fifth moldable material pieces 300 and 350 of the moldable material assembly 120 . In the example shown in FIG. 7 , the composite material piece covers the second and fifth moldable material pieces 310 and 350 of the moldable material assembly 120 .

[0083] Since composite materials have high strength but relatively low stiffness and large deformation, while formable material components have high stiffness but relatively low strength, the overall stiffness of the box can be enhanced without reducing its overall strength by using the two in conjunction with each other.

[0084] Referring further to FIG. 9 , FIG. 9 is a schematic structural diagram of a composite material component according to some embodiments of the present application. Composite material component 140 includes a bottom wall 900, a frame wall 910, and at least one spacer 920. Frame wall 910 is disposed on the bottom wall. Bottom wall 900 and frame wall 910 enclose a cavity 190 for battery cell 180. At least one spacer 920 is disposed within cavity 190 along a second direction Y. At least one spacer 920 extends along a first direction X to partition the interior of cavity 190 into a plurality of chambers 930 arranged along the second direction Y.

[0085] In the example shown in FIG. 9 , four spacers 920 divide the interior of the cavity 190 into three chambers 930 arranged along the second direction Y to accommodate the electric core 180 .

[0086] According to some embodiments of the present application, the bottom wall 900 and the frame wall 910 are formed of a long-fiber composite material, and the at least one spacer 920 is formed of a short-fiber composite material.

[0087] By using at least one spacer to divide the interior of the cavity into a plurality of chambers, space can be reserved for placing a plurality of battery cells side by side.

[0088] According to some embodiments of the present application, the battery pack case 100 further includes at least one end plate 150 . Each end plate of the at least one end plate 150 is configured to be inserted into a corresponding spacer of the at least one spacer 920 .

[0089] In the example shown in FIG. 8 , the end plate 150 is sleeved onto the spacer 920 of the composite material member 140 at the outer side of the spacer 920 .

[0090] By inserting the end plates on the spacers, the strength of the spacers can be increased and further used for internal mounting bolts.

[0091] 1 , the battery pack case 100 further includes a top plate 160 . The top plate 160 is used to be connected to the side wall assembly 130 to close the cavity 190 of the battery cell 180 .

[0092] In the example shown in FIG. 6 , both the top plate 160 and the bottom plate 110 may be fixed to the side wall assembly 130 (eg, the first side wall member 200 ) by bolts.

[0093] By providing a top plate, the cavity of the battery cell can be sealed, and the top plate can be further fixedly connected to other fixing parts, such as the vehicle body frame.

[0094] According to some embodiments of the present application, the formable material component 120 and the composite material piece 140 are integrally molded.

[0095] According to some embodiments of the present application, the formable material component 120 and the composite material component 140 may be placed in a mold and then integrally molded together.

[0096] Such a design can reduce the number of battery pack manufacturing steps and lower process costs.

[0097] According to some embodiments of the present application, the composite material member 140 is selected from at least one of glass fiber and carbon fiber.

[0098] In some embodiments, the density of the glass fiber composite material 140 is 1.5-2.0 g / cm 3 In some embodiments, the density of the carbon fiber composite material 140 is 1.0-1.5 g / cm 3 .

[0099] In such a design, this makes the density of the composite material lower, thereby reducing the overall weight of the battery pack body.

[0100] According to some embodiments of the present application, referring to FIG1 , the present application provides a battery pack case 100, which includes a bottom plate 110, a side wall assembly 130, a formable material assembly 120, and a composite material member 140. The side wall assembly 130 extends along the circumference of the bottom plate 110 and is connected to the bottom plate 110. The side wall assembly 130 includes a first side wall member 200 and a third side wall member 220, and the first side wall member 200 and the third side wall member 220 are opposite to each other in a first direction X. The side wall assembly 130 also includes a second side wall member 210 and a fourth side wall member 240, and the second side wall member 210 and the fourth side wall member 240 are opposite to each other in a second direction Y, and the second direction Y intersects with the first direction X. The first side wall member 200, the second side wall member 210, the third side wall member 220, and the fourth side wall member 240 are connected in sequence. At least a portion of the moldable material assembly 120 extends circumferentially along the sidewall assembly 130 to provide support on both the inside and outside of the sidewall assembly 130. The composite material member 140 extends circumferentially along the sidewall assembly 130 and forms a cavity 190 on the inside of the sidewall assembly 130 that can accommodate the battery cells 180 of the battery pack 1000. Furthermore, the composite material member 140, the bottom plate 110, and the first sidewall member 200 define a first accommodation space 500. The first accommodation space 500 is used to accommodate the first moldable material member 300. The composite material member 140, the bottom plate 110, and the third sidewall member 220 define a second accommodation space 510. The second accommodation space 510 is used to accommodate the third moldable material member 330. The composite material member 140 and the second sidewall member 210 define a third accommodation space 700. The third accommodation space 700 is used to accommodate the second moldable material member 310. The composite material member 140 and the fourth sidewall member 240 define a fourth accommodation space 710. The fourth receiving space 710 is used to receive the fourth formable material piece 340 .

[0101] 10 , which is a schematic diagram of a portion of a battery pack according to some embodiments of the present application, shows that the battery pack 1000 includes at least one battery cell 180 . In some embodiments, the battery cell 180 is disposed within a cavity 190 .

[0102] In one example, the at least one battery cell 180 may be electrically connected to each other. In one example, the battery pack case 100 is used to provide a space for accommodating the battery cell 180. In some embodiments, the battery pack case 100 may be in various shapes, such as a rectangular parallelepiped.

[0103] In some embodiments, each battery cell 180 may be a secondary battery or a primary battery; may also be a lithium-sulfur battery, a sodium-ion battery, or a magnesium-ion battery, but is not limited thereto. The battery cell 180 may be cylindrical, flat, rectangular, or in other shapes.

[0104] In some embodiments, each battery cell 180 may be composed of multiple battery cells connected in series, in parallel, or in a hybrid connection. A hybrid connection refers to a combination of series and parallel connections among the multiple battery cells 180. The battery pack 1000 may also include other structures. For example, the battery pack 1000 may also include a busbar component for achieving electrical connection between the multiple battery cells 180.

[0105] The specific structure and function of the battery pack case 100 have been described in detail above and will not be repeated here for the sake of brevity.

[0106] In some embodiments, an electrical device may include the battery pack 1000 of the above-described embodiment, and the battery pack 1000 is used to provide electrical energy. Examples of electrical devices include, but are not limited to, electric vehicles, ships, and spacecraft. Spacecraft may include, for example, airplanes, rockets, space shuttles, and spacecraft.

[0107] For the convenience of explanation, an electric device according to an embodiment of the present application is taken as an example, that is, a vehicle 1100 .

[0108] Please refer to Figure 11, which is a schematic structural diagram of a vehicle in some embodiments of the present application. The vehicle can be a fuel vehicle, a gas vehicle or a new energy vehicle. The new energy vehicle can be a pure electric vehicle, a hybrid vehicle or an extended-range vehicle, etc. A battery pack 1000 is provided inside the vehicle 1100, and the battery pack 1000 can be provided at the bottom, head or tail of the vehicle 1100. In some embodiments, the battery pack 1000 can be used to power the vehicle 1100. For example, the battery pack 1000 can serve as an operating power source for the vehicle 1100. The vehicle 1100 may also include a controller 1400 and a motor 1300. The controller 1400 is used to control the battery pack 1000 to power the motor 1300, for example, for starting, navigating and driving the vehicle 1100.

[0109] In some embodiments of the present application, the battery pack 1000 can not only serve as the operating power source of the vehicle 1100, but also serve as the driving power source of the vehicle 1100, replacing or partially replacing fuel or natural gas to provide driving power for the vehicle 1100.

[0110] The electric device is powered by the battery pack 1000 including the battery pack case 100 of the above embodiment. The specific structure and function of the battery pack case 100 in the battery pack 1000 have been described in detail above.

[0111] 12 is a flow chart of a method for manufacturing a battery pack case according to some embodiments of the present application. Method 1200 includes steps S1210 to S1250.

[0112] Step S1210: Lay the base plate 110 on the bottom of the mold;

[0113] Step S1220: Lay the side wall assembly 130 on the bottom plate 110;

[0114] Step S1230 , partially laying the formable material component 120 on the bottom plate 110 and laying it around the side wall component 130 ;

[0115] Step S1240 , laying the composite material member 140 on the sidewall component 130 and the formable material component 120 ; and

[0116] Step S1250 , integrally molding the laid bottom plate 110 , the side wall assembly 130 , the formable material assembly 120 and the composite material component 140 .

[0117] In the above step S1240, long fiber prepreg of composite material may be laid on top of the entire structure, and short fiber prepreg may be arranged at the position of the internal crossbeam.

[0118] In the above step S1250, integrally molding the battery pack case 100 can reduce the number of manufacturing steps for the battery pack case and lower the process cost.

[0119] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application, and they should all be included in the scope of the claims and specification of the present application. In particular, as long as there is no structural conflict, the various technical features mentioned in the various embodiments can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions that fall within the scope of the claims.

Claims

1. A battery pack housing (100), comprising: A bottom plate (110); A side wall assembly (130) that extends circumferentially around the bottom plate (110) and is connected to the bottom plate (110); A formable material assembly (120), at least a portion of the formable material assembly (120) extends circumferentially along the side wall assembly (130) to provide support on the inner and outer sides of the side wall assembly (130); And A composite material member (140), the composite material member (140) extends circumferentially along the side wall assembly (130) and forms a cavity (190) on the inner side of the side wall assembly (130) for accommodating the battery cells (180) of the battery pack (1000).

2. The battery pack housing (100) according to claim 1, wherein, The side wall assembly (130) includes: A first side wall member (200) and a third side wall member (220), the first side wall member (200) and the third side wall member (220) are opposite to each other in a first direction (X); and A second side wall member (210) and a fourth side wall member (240), the second side wall member (210) and the fourth side wall member (240) are opposite to each other in a second direction (Y), the second direction (Y) intersects with the first direction (X), wherein the first side wall member (200), the second side wall member (210), the third side wall member (220), and the fourth side wall member (240) are sequentially connected.

3. The battery pack housing (100) according to claim 2, wherein, The formable material assembly (120) includes: A first formable material member (300) and a third formable material member (330), the first formable material member (300) and the third formable material member (330) are opposite to each other in the first direction (X), wherein the first formable material member (300) and the third formable material member (330) are laid on the bottom plate (110), and the first formable material member (300) and the third formable material member (330) are used to fit against the outer wall surfaces of the first side wall member (200) and the third side wall member (220); and A second formable material member (310) and a fourth formable material member (340), the second formable material member (310) and the fourth formable material member (340) are opposite to each other in the second direction (Y), wherein the second formable material member (310) and the fourth formable material member (340) are used to fit against the inner wall surfaces of the second side wall member (210) and the fourth side wall member (240).

4. The battery pack housing (100) according to any one of claims 1-3, wherein, The formable material assembly (120) further includes a fifth formable material member (350), and the fifth formable material member (350) is laid on the bottom plate (110).

5. The battery pack housing (100) according to claim 4, wherein, The fifth formable material member (350) includes: A first formable material portion (360), a second formable material portion (370), and a third formable material portion (380), the first formable material portion (360), the second formable material portion (370), and the third formable material portion (380) are laid on the bottom plate (110) at intervals of two by two.

6. The battery pack housing (100) according to any one of claims 2-5, wherein, The composite material part (140), the bottom plate (110) and the first side wall part (200) define a first accommodation space (500) for accommodating the first formable material part (300), and the composite material part (140), the bottom plate (110) and the third side wall part (220) define a second accommodation space (510) for accommodating the third formable material part (330).

7. The battery pack housing (100) according to any one of claims 2-5, wherein, The composite material part (140) and the second side wall part (210) define a third accommodation space (700) for accommodating the second formable material part (310), and the composite material part (140) and the fourth side wall part (240) define a fourth accommodation space (710) for accommodating the fourth formable material part (340).

8. The battery pack housing (100) according to any one of claims 1-7, wherein, A part of the composite material part (140) also covers the formable material assembly (120).

9. The battery pack housing (100) according to any one of claims 2-8, wherein, The composite material part (140) includes: a bottom wall (900); a frame wall (910) provided on the bottom wall, and the bottom wall (900) and the frame wall (910) enclose a cavity (190) of the battery cell (180); and at least one spacer (920) disposed inside the cavity (190) along the second direction (Y), and the at least one spacer (920) extends along the first direction (X) to divide the interior of the cavity (190) into a plurality of chambers (930) arranged along the second direction (Y).

10. The battery pack housing (100) according to claim 9, wherein, It further includes: at least one end plate (150), and each end plate in the at least one end plate (150) is used to be inserted on a corresponding spacer in the at least one spacer (920).

11. The battery pack housing (100) according to any one of claims 1-10, wherein, It further includes: a top plate (160) for connecting to the side wall assembly (130) to close the cavity (190) of the battery cell (180).

12. The battery pack housing (100) according to any one of claims 1-11, wherein, The formable material assembly (120) and the composite material part (140) are integrally molded.

13. The battery pack housing (100) according to any one of claims 1-12, wherein, The composite material part (140) is selected from at least one of glass fiber or carbon fiber.

14. A battery pack (1000) includes: a battery cell (180); and the battery pack housing (100) according to any one of claims 1-13, and the battery cell (180) is disposed inside the cavity (190).

15. An electrical device (1100), the electrical device includes the battery pack (1000) according to claim 14, and the battery pack (1000) is used to provide electrical energy.

16. A method (1200) for manufacturing a battery pack housing (100) includes: laying the bottom plate (110) at the bottom of the mold; laying the side wall assembly (130) on the bottom plate (110); partially laying the formable material assembly (120) on the bottom plate (110) and laying it around the side wall assembly (130); Lay a composite material part (140) on the side wall assembly (130) and the formable material assembly (120); and Integrally mold the laid bottom plate (110), the side wall assembly (130), the formable material assembly (120) and the composite material part (140).

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