Battery case beam, battery case, and battery module

Abstract

A battery case beam, a battery case, and a battery module, which relate to the technical field of batteries and aim to solve the technical problems of insufficient connection strength at a joint of a rolled battery case beam and possible separation. The battery case beam comprises a main body wall (7); and a first beam wall (8) connected to one end of the main body wall (7), wherein the first beam wall (8) comprises a first pressure-bearing section (81), and the first pressure-bearing section (81) is arranged opposite the main body wall (7). A second pressure-bearing section (91) and the first pressure-bearing section (81) extend toward each other, and have an overlapping portion, and the second pressure-bearing section (91) is fixedly connected to the first pressure-bearing section (81) at the overlapping portion. The requirements of light weight and strength of the battery module can be considered.

Description

Battery box beam, battery box and battery module

[0001] This application claims priority to two Chinese patent applications filed with the China Patent Office on March 1, 2024, with application numbers 202410237163.5 and 202420408473.4. The entire contents of the above applications are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of battery technology, and in particular to a battery box beam, a battery box body and a battery module. Background Art

[0003] In the related art, it is proposed to use a rolling process to bend a plate to form a closed structure, and then use horizontal welding to connect the two ends of a plate to form an anti-expansion beam. SUMMARY OF THE INVENTION

[0004] Since the welding surface (weld) is in the same direction as the extrusion force when the battery cell expands, the weld between the two end walls of the anti-expansion beam is prone to cracking and the welding surface is separated.

[0005] In order to improve the defects of the existing technology, the main purpose of this application is to provide a battery box beam, a battery box body and a battery module to improve the technical problem of the anti-expansion and extrusion performance of the anti-expansion beam.

[0006] To achieve the above objectives, in a first aspect, the present application provides a battery box girder, which is a roll-pressed steel beam and includes:

[0007] Main wall;

[0008] a first beam wall connected to one end of the main body wall, the first beam wall comprising a first pressure-bearing section, the first pressure-bearing section being arranged opposite to the main body wall;

[0009] The second beam wall is connected to the other end of the main body wall. The second beam wall includes a second pressure-bearing section. The second pressure-bearing section is arranged opposite to the main body wall and extends toward and partially overlaps with the first pressure-bearing section.

[0010] In some embodiments of the present application, the second pressure-bearing section and the first pressure-bearing section are fixedly connected at an overlapping portion.

[0011] In some embodiments of the present application, the first pressure-bearing section includes a first extension section and a second extension section that are connected to each other and extend in the same direction. The second extension section is closer to the main body wall than the first extension section. The first extension section and the second extension section jointly define a connecting portion. The second pressure-bearing section is arranged at the connecting portion near the end of the first pressure-bearing section and is connected to the second extension section.

[0012] In some embodiments of the present application, the first pressure-bearing section also includes a bending section, the first extension section and the second extension section are connected through the bending section, the bending section is bent from the first extension section toward the main wall, the first extension section, the second extension section and the bending section jointly define the connecting portion, the second pressure-bearing section is arranged at the connecting portion near the end of the first pressure-bearing section, and is welded and fixed to the second extension section.

[0013] In some embodiments of the present application, the first extension section has a first surface facing away from the main body wall, the second pressure-bearing section has a second surface facing away from the main body wall, and the first surface and the second surface are coplanar.

[0014] In some embodiments of the present application, both ends of the bending section transition to the first extending section and the second extending section in circular arcs, respectively.

[0015] In some embodiments of the present application, the first extension section has a first surface facing away from the main body wall, the second pressure-bearing section has a second surface facing away from the main body wall, and the first surface and the second surface are coplanar.

[0016] In some embodiments of the present application, the first beam wall also includes a first connecting section, which is connected between the first pressure-bearing section and the main body wall. The second beam wall also includes a second connecting section, which is connected between the second pressure-bearing section and the main body wall and is arranged opposite to the first connecting section. The main body wall, the first connecting section, the first pressure-bearing section, the second pressure-bearing section and the second connecting end enclose an inner cavity of the beam.

[0017] In some embodiments of the present application, the first beam wall also includes a buffer section, which is connected to the end of the first pressure-bearing section near the second pressure-bearing section and extends toward the main wall. The buffer section is configured to support the first pressure-bearing section and the second pressure-bearing section when the first pressure-bearing section and the second pressure-bearing section are under pressure, and the buffer section has a tendency to slide along the main wall.

[0018] In some embodiments of the present application, the buffer section includes a supporting section and an abutting section, the supporting section is connected between the first pressure-bearing section and the abutting section, and the abutting section is parallel to and connected to the main body wall.

[0019] In some embodiments of the present application, the abutting section abuts against the main body wall, and the abutting section is configured to slide along the main body wall when the first pressure-bearing section and the second pressure-bearing section are under pressure, so as to buffer the extrusion force.

[0020] In some embodiments of the present application, the abutment section is fixedly connected to the main body wall, and the abutment section is configured to change from a fixed connection to a sliding connection with the main body wall when the first pressure-bearing section and the second pressure-bearing section are under pressure, and slide along the main body wall to buffer the extrusion force.

[0021] In some embodiments of the present application, the connection strength between the abutting section and the main body wall is less than the connection strength between the first pressure-bearing section and the second pressure-bearing section. When the first pressure-bearing section and the second pressure-bearing section are under pressure, the time node when the fixed connection between the abutting section and the main body wall changes to a sliding connection is earlier than the separation time node between the first pressure-bearing section and the second pressure-bearing section.

[0022] In some embodiments of the present application, the abutting section and the first pressure-bearing section extend in opposite directions.

[0023] In some embodiments of the present application, the extension line of the support segment and the extension line of the main wall have a first angle, and the extension line of the support segment and the extension line of the second extension segment have a second angle, and the first angle and the second angle are offset angles and complementary to each other.

[0024] In some embodiments of the present application, the battery box beam is a rolled steel beam with a wall thickness between 1 mm and 2 mm.

[0025] In a second aspect, the present application provides a battery box, the battery box including a first direction, the battery box including:

[0026] A rolling assembly encloses a fixed space for fixing a battery cell module, and the battery cell module has a tendency to expand along the first direction. The rolling assembly includes two anti-expansion beams arranged opposite to each other, and the two anti-expansion beams are arranged at relative intervals along the first direction. The two anti-expansion beams are both battery box beams as described in the first aspect.

[0027] In some embodiments of the present application, the battery box further includes a second direction, the first direction and the second direction intersect, and the rolling assembly further includes:

[0028] Two roller-pressed side beams are arranged opposite to each other along the second direction, and both ends of each anti-expansion beam are respectively connected to the two roller-pressed side beams to define the fixed space.

[0029] In some embodiments of the present application, the two rolled side beams are both battery box beams as described in the first aspect, the two rolled side beams have the same thickness, and the thickness of the rolled side beam is less than the thickness of the anti-expansion beam.

[0030] In some embodiments of the present application, the rolling assembly further includes:

[0031] At least one first cross beam and at least one second cross beam, the first cross beam and the second cross beam are both located in the fixed space, the first cross beam is cross-connected with the second cross beam, the two ends of the first cross beam are respectively welded to the two roller-pressed edge beams, and the two ends of the second cross beam are respectively connected to the two anti-expansion beams.

[0032] In some embodiments of the present application, both ends of the second cross beam are respectively welded to the two anti-expansion beams.

[0033] In some embodiments of the present application, the battery box also includes a first frame, both sides of which are respectively connected to one side of the two rolled edge beams, and the first frame is spaced apart from a battery box beam close to it to define an anti-extrusion area, and a plurality of anti-extrusion beams are spaced apart in the anti-extrusion area, and both ends of each anti-extrusion beam are respectively connected to the first frame and the anti-expansion beam close to the first frame.

[0034] In some embodiments of the present application, the battery box also includes a second frame, which is arranged opposite to the first frame, and the two ends of the second frame are respectively connected to the two roller-pressed edge beams, and the second frame is spaced apart from the anti-expansion beam close to it, and the spacing distance is greater than 5 mm.

[0035] In a third aspect, an embodiment of the present application provides a battery module, comprising:

[0036] base plate;

[0037] a bottom guard plate, provided on the bottom plate;

[0038] a liquid cooling plate, provided on the bottom guard plate;

[0039] The battery box as described in the second aspect is provided on the liquid cooling plate;

[0040] A plurality of battery cell modules are arranged in a fixed space of the battery box;

[0041] An integrated busbar, provided on the plurality of battery core modules;

[0042] An insulating layer is provided on a side of the integrated busbar facing away from the battery module;

[0043] A box cover is provided on the battery module, and the insulating layer is located between the box cover and the integrated busbar. Beneficial effects

[0044] In the embodiments of the present invention, the first and second pressure-bearing sections extend toward each other and partially overlap, with the weld surface located in the overlapping portion. Furthermore, the weld surface extends toward each other perpendicular to the direction of the extrusion force, effectively preventing the risk of the weld surface separating due to the extrusion force. Furthermore, the weld surface is perpendicular, allowing the first and second pressure-bearing sections to overlap in the direction of the extrusion force, thereby enhancing the ability to resist extrusion. In detail, first, the structure of the battery box beam is enclosed by connecting the main wall, the first beam wall and the second beam wall to each other, and then the first pressure-bearing section and the second pressure-bearing section are arranged opposite to the main wall, that is, the first pressure-bearing section and the second pressure-bearing section are located on the same side of the main wall, and then the first pressure-bearing section and the second pressure-bearing section are extended toward each other and partially overlapped, thereby improving the ability of the battery box beam to withstand the extrusion pressure in the direction of the first pressure-bearing section toward the main wall. The overlapping surface of the first pressure-bearing section and the second pressure-bearing section is the welding surface, which is different from the direction of the welding surface in the related art. The welding surface in this application is not parallel to the extrusion pressure, which can effectively reduce the risk of separation of the first pressure-bearing section and the second pressure-bearing section due to the extrusion pressure, and the first pressure-bearing section and the second pressure-bearing section can also increase the strength of withstanding the extrusion pressure due to the overlap. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings of the embodiments. Obviously, the drawings described below only relate to some embodiments of the present application and are not intended to limit the present application.

[0046] FIG1 is a schematic cross-sectional view of a battery box beam of the related art mentioned in the background art;

[0047] FIG2 is a schematic cross-sectional view of a battery box beam provided by an embodiment of the present invention;

[0048] FIG3 is a schematic diagram of the three-dimensional structure of a battery box provided by an embodiment of the present invention;

[0049] FIG4 is a schematic diagram of the explosion structure of FIG3 ;

[0050] FIG5 is a schematic top view of a battery box provided by an embodiment of the present invention;

[0051] FIG6 is an enlarged structural diagram of the mounting member in FIG3 ;

[0052] FIG7 is a schematic diagram of a three-dimensional structure of a battery module provided by an embodiment of the present invention;

[0053] FIG8 is a schematic diagram of the explosion structure of FIG7 .

[0054] Description of reference numerals:

[0055] 1-Battery box; 11-Rolling assembly; 111-Rolling side beam; 112-Anti-expansion beam; 113-First cross beam; 114-Second cross beam; 115-Fixed space; 12-First frame; 121-Anti-extrusion area; 13-Anti-extrusion beam; 14-Second frame; 15-Mounting member; 151-First mounting beam; 152-Second mounting beam; 1521-Hole; 153-Bushing; 154-Rust-proof gasket; 2-Bottom plate ;3-bottom guard plate;4-liquid cooling plate;5-battery cell module;6-integrated busbar;7-main body wall;8-first beam wall;81-first pressure-bearing section;811-first extension section;812-second extension section;813-first surface;814-bending section;82-first connecting section;83-buffer section;831-support section;832-abutting section;9-second beam wall;91-second pressure-bearing section;911-second surface;92-second connecting section. Modes for Carrying Out the Invention

[0056] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0057] In this application, the word "exemplary" is used to mean "serving as an example, instance, or illustration." The following description is provided to enable any person skilled in the art to make and use the present application. In the following description, details are listed for the purpose of explanation.

[0058] Please refer to Figure 1, which shows the cross-sectional structure of the battery box beam in the related technology described in the background technology. It can be seen from the figure that the connection surface of the battery box beam on the right side is parallel to the expansion and extrusion force. When the expansion and extrusion force is too large, the connection at both ends of the battery box beam may be at risk of separation.

[0059] To this end, referring to FIG2 , an embodiment of the present application provides a battery box beam, comprising:

[0060] Main body wall 7;

[0061] A first beam wall 8 is connected to one end of the main body wall 7. The first beam wall 8 includes a first pressure-bearing section 81. The first pressure-bearing section 81 is arranged opposite to the main body wall 7.

[0062] The second beam wall 9 is connected to the other end of the main body wall 7 . The second beam wall 9 includes a second pressure-bearing section 91 . The second pressure-bearing section 91 is arranged opposite to the main body wall 7 , and extends toward and partially overlaps with the first pressure-bearing section 81 .

[0063] Furthermore, the second pressure-bearing section 91 and the first pressure-bearing section 81 are fixedly connected at the overlapping portion.

[0064] The technical solution provided by this application primarily utilizes the first pressure-bearing section 81 and the second pressure-bearing section 91 to extend toward each other and partially overlap, with the weld surface located in this overlapping portion. Furthermore, the weld surface extends toward each other, perpendicular to the direction of the extrusion force. This effectively prevents the risk of the weld surface separating due to the extrusion force. Furthermore, the weld surface is perpendicular, allowing the first pressure-bearing section 81 and the second pressure-bearing section 91 to overlap in the direction of the extrusion force, thereby enhancing the ability to resist extrusion. In detail, first, the structure of the battery box beam is enclosed by connecting the main wall 7, the first roller-pressed wall 8 and the second roller-pressed wall 9 to each other, and then the first pressure-bearing section 81 and the second pressure-bearing section 91 are arranged opposite to the main wall 7, that is, the first pressure-bearing section 81 and the second pressure-bearing section 91 are located on the same side of the main wall 7, and then the first pressure-bearing section 81 and the second pressure-bearing section 91 are extended toward each other and partially overlapped, thereby improving the ability of the battery box beam to withstand the extrusion pressure in the direction of the first pressure-bearing section 81 toward the main wall 7. The overlapping surface of the first pressure-bearing section 81 and the second pressure-bearing section 91 is the welding surface, which is different from the direction of the welding surface in the related art. The welding surface in this application is not parallel to the extrusion force, which can effectively reduce the risk of separation of the first pressure-bearing section 81 and the second pressure-bearing section 91 due to the extrusion force, and the first pressure-bearing section 81 and the second pressure-bearing section 91 can also increase the strength of withstanding the extrusion force due to the overlap.

[0065] In some embodiments, the first pressure-bearing section 81 includes a first extension section 811 and a second extension section 812 that are interconnected and extend in the same direction. The second extension section 812 is closer to the main body wall 7 than the first extension section 811. The first extension section 811 and the second extension section 812 jointly define a connection portion. The end of the second pressure-bearing section 91 adjacent to the first pressure-bearing section 81 is disposed at the connection portion and connected to the second extension section 812. The first extension section 811 and the second extension section 812 are connected in an arc shape and are integrally bent, which helps to improve the strength of the connection and provide a smoother bend transition, thereby preventing fracture of the connection caused by excessive bending angles. The second extension section 812 is closer to the main wall 7 than the first extension section 811, which is equivalent to forming a fault at the first extension section 811 and the second extension section 812. The fault can serve as the overlapping position of the second pressure-bearing section 91 and the first pressure-bearing section 81, providing a overlapping position for the second pressure-bearing section 91, avoiding the formation of a more obvious bulge on one side of the battery box beam due to the overlap of the first pressure-bearing section 81 and the second pressure-bearing section 91 at the connection, which poses a risk of damage to the battery cell module 5.

[0066] Furthermore, the first pressure-bearing section 81 also includes a bent section 814. The first extension section 811 and the second extension section 812 are connected by the bent section. The bent section 814 bends from the first extension section 811 toward the main body wall 7 so that the second extension section 812 is closer to the main body wall 7 than the first extension section 811. The first extension section 811, the second extension section 812, and the bent section 814 collectively define a connection portion. The end of the second pressure-bearing section 91 adjacent to the first pressure-bearing section 81 is disposed at the connection portion and is welded to the second extension section 812. The first extension section 811 and the second extension section 812 form an arc transition and are integrally bent, which helps to improve the strength of the connection and provides a smoother bend transition, thereby preventing fracture of the connection due to excessive bending angles. The second extension section 812 is closer to the main wall 7 than the first extension section 811, which is equivalent to forming a fault at the first extension section 811 and the second extension section 812. The fault can serve as the overlapping position connecting the second pressure-bearing section 91 and the first pressure-bearing section 81, providing a overlapping position for the second pressure-bearing section 91, and avoiding the formation of a more obvious bulge on one side of the battery box beam due to the overlap of the first pressure-bearing section 81 and the second pressure-bearing section 91 at the overlapping position, which poses a risk of damage to the battery cell module 5.

[0067] Furthermore, the first extension section 811 has a first surface 813 facing away from the main wall 7, and the second pressure section 91 has a second surface 911 facing away from the main wall 7, and the first surface 813 and the second surface 911 are coplanar. The first surface 813 and the second surface 911 are coplanar, which can improve the flatness of the side of the battery box beam facing away from the main wall 7, and avoid the problem of uneven force on the battery cell module 5 caused by the appearance of bulges on the side of the battery box beam. Preferably, the bending section 814 has a first length in the vertical direction from the first pressure section 81 toward the main wall 7, and along the vertical direction of the first pressure section 81 toward the main wall 7, the thickness of the overlap between the second extension section 812 and the second pressure section 82 is the first thickness, and the first thickness is equal to the first length.

[0068] Furthermore, the two ends of the bent section 814 form arc transitions with the first extension section 811 and the second extension section 812, respectively. The arc transition effectively prevents the first pressure-bearing section 81 from being damaged due to excessive bending angles when bending. In addition, the first pressure-bearing section 81 with an arc transition also has a longer lifespan during use compared to a first pressure-bearing section 81 that is bent at right angles.

[0069] In some embodiments, the first beam wall 8 further includes a first connecting section 82, which is connected between the first pressure-bearing section 81 and the main body wall 7. The second beam wall 9 further includes a second connecting section 92, which is connected between the second pressure-bearing section 91 and the main body wall 7 and is arranged opposite to the first connecting section 82. The main body wall 7, the first connecting section 82, the first pressure-bearing section 81, the second pressure-bearing section 91 and the second connecting end enclose an inner beam cavity. The first beam wall 8, the second beam wall 9 and the main body wall 7 are enclosed and connected to each other, so that the cross-section of the battery box beam has a rectangular structure. It should be noted that the connections between the main body wall 7 and the first connecting section 82 and the second connecting section 92 are all integrally formed connections, formed by bending. The connection between the first connecting section 82 and the first pressure-bearing section 81 is also an integrally bent connection. The connection between the second connecting section 92 and the second pressure-bearing section 91 is also an integrally bent connection. The first pressure-bearing section 81 and the second pressure-bearing section 91 are overlapped and welded. Through such connection, the battery box beam has a hollow structure and the hole-making process is eliminated, thereby achieving the purpose of reducing the weight of the box beam.

[0070] In some embodiments, the first beam wall 8 also includes a buffer section 83, which is connected to the end of the first pressure-bearing section 81 near the second pressure-bearing section 91 and extends toward the main wall 7. The buffer section 83 is configured to support the first pressure-bearing section 81 and the second pressure-bearing section 91 when the first pressure-bearing section 81 and the second pressure-bearing section 91 are under pressure, and the buffer section 83 has a tendency to slide along the main wall 7. When the buffer section 83 is under too much pressure, it will slide along the main wall 7 to buffer the pressure. The connection between the buffer section 83 and the first pressure-bearing section 81 is still a one-piece bending molding. The two ends of the buffer section 83 are respectively connected to the main wall 7 and the first pressure-bearing section 81, which can play a role in supporting the first beam wall 8, the second beam wall 9 and the main wall 7, thereby improving the ability of the battery box beam to withstand extrusion pressure. Moreover, the buffer section 83 has a tendency to slide along the main wall 7. When the extrusion force is too large, the buffer section 83 deforms and slides along the main wall 7. Based on its force to restore the deformation, it plays a role in buffering the extrusion force and enhancing the force to resist the extrusion force.

[0071] Furthermore, the buffer section 83 includes a support section 831 and an abutting section 832. The support section 831 is connected between the first pressure-bearing section 81 and the abutting section 832. The abutting section 832 is parallel to and connected to the main wall 7. The connection method can be overlapping, abutting, welding, etc. The support section 831 plays a role of supporting to enhance the strength of the battery box beam. The abutting section 832 is parallel to and abuts the main wall 7, which can increase the contact area between the abutting section 832 and the main wall 7, and avoid excessive pressure of the abutting section 832 on the main wall 7 due to too small a contact area. In addition, when the extrusion force is too large, the support section 831 will transfer the extrusion force to the abutting section 832. The abutting section 832 moves along the main wall 7, thereby driving the support section 831 to deform and tilt, playing a buffering role against the extrusion force.

[0072] In another embodiment, the abutting section 832 is fixedly connected to the main body wall 7. The abutting section 832 is configured to transform from a fixed connection to a sliding connection with the main body wall 7 when the first pressure-bearing section 81 and the second pressure-bearing section 82 are under pressure, and slide along the main body wall 7 to buffer the extrusion force. In this embodiment, the abutting section 832 and the main body wall 7 are fixedly connected, such as welded. The transformation from a fixed connection to a sliding connection means that when the extrusion force applied to the beam is too large, the fixed connection between the abutting section 832 and the main body wall 7, such as the weld, will tear, resulting in weld failure. At this time, the abutting section 832 can also slide along the main body wall 7, thereby further playing a buffering role and forming secondary protection.

[0073] Furthermore, the connection strength between the abutting section 832 and the main wall 7 is less than the connection strength between the first pressure-bearing section 81 and the second pressure-bearing section 82. When the first pressure-bearing section 81 and the second pressure-bearing section 82 are under pressure, the time node at which the abutting section 832 and the main wall 7 change from a fixed connection to a sliding connection is earlier than the time node at which the first pressure-bearing section 81 and the second pressure-bearing section 82 separate. By limiting the connection strength and ensuring that the time node at which the abutting section 832 and the main wall 7 change from a fixed connection to a sliding connection is earlier than the time node at which the first pressure-bearing section 81 and the second pressure-bearing section 82 separate, it is possible to ensure that when the battery box girder is subjected to a large extrusion force, the abutting section 832 slides first, acting as a buffer, thereby preventing the first pressure-bearing section 81 and the second pressure-bearing section 82 from separating when subjected to the extrusion force, thereby causing damage to the box girder.

[0074] In some embodiments, the abutment section 832 extends in the opposite direction to the first pressure-bearing section 81, making the abutment section 832 more sensitive to the magnitude of the extrusion force. When subjected to a larger extrusion force, it can move along the main wall 7 to drive the support section 831 to deform, thereby playing a buffering role.

[0075] It should be noted that the battery box beam is made of steel profiles, specifically 780DP steel, produced using a roll-forming process. The wall thickness of the battery box beam ranges from 1mm to 2mm. Compared to aluminum profiles, this reduces costs and increases strength.

[0076] In some embodiments, the extension line of the support segment 831 forms a first angle with the extension line of the main body wall 7, and the extension line of the support segment 831 forms a second angle with the extension line of the second extension segment 812. The first and second angles are offset and complementary to each other. By limiting the offset and complementary angles, the support segment 831 is tilted in the second direction, which helps to assist the sliding of the abutment segment 832 and thus better provide a buffering effect.

[0077] Referring to Figures 2 to 6 , the present application further provides a battery box 1 , which includes a first direction and includes:

[0078] The rolling assembly 11 encloses a fixed space 115 for fixing the battery cell module 5. The battery cell module 5 has a tendency to expand along the first direction. The rolling assembly 11 includes two anti-expansion beams 112 arranged opposite to each other. The two anti-expansion beams 112 are arranged at relative intervals along the first direction. The two anti-expansion beams 112 are both battery box beams as described in the first aspect.

[0079] The battery box 1 is provided with the battery box beam described in any of the aforementioned embodiments as the anti-expansion beam 112, and utilizes the structure of the anti-expansion beam 112 to support and buffer the expansion and extrusion force, thereby effectively improving the anti-expansion ability of the battery box. For the specific beneficial effect derivation process, please refer to the aforementioned battery box beam embodiment, which will not be repeated here.

[0080] In some embodiments, the battery box 1 further includes a second direction, the first direction and the second direction intersect, and the rolling assembly 11 further includes:

[0081] Two roller-pressed side beams 111 are arranged opposite to each other along the second direction. Two ends of each anti-expansion beam 112 are respectively connected to the two roller-pressed side beams 111 to define a fixed space 115.

[0082] Further, referring to Figures 4 and 5, the two rolled side beams 111 are both battery box beams as described in any of the aforementioned embodiments, and the thickness of the two rolled side beams 111 is the same, and the thickness of the rolled side beam 111 is less than the thickness of the anti-expansion beam 112. By utilizing the structure of the battery box beam, the ability of the battery box 1 to resist the expansion and extrusion force of the battery cell can be enhanced. In addition, the limitation that the thickness of the rolled side beam 111 is less than the thickness of the anti-expansion beam 112 is mainly based on the main expansion direction of the battery cell, that is, the main expansion direction of the battery cell is the first direction. It should also be noted that the thickness refers to the sum of the wall thickness of the main wall 7 of the battery box beam itself, the wall thickness of the pressure-bearing section arranged opposite to the main wall 7, and the spacing distance between the pressure-bearing section and the main wall 7.

[0083] In some embodiments, the rolling assembly 11 further comprises:

[0084] At least one first cross beam 113 and at least one second cross beam 114, the first cross beam 113 and the second cross beam 114 are both located in a fixed space 115, the first cross beam 113 and the second cross beam 114 are cross-connected, the two ends of the first cross beam 113 are respectively connected to the two roller-pressed edge beams 111, and the two ends of the second cross beam 114 are respectively connected to the two anti-expansion beams 112.

[0085] By connecting two rolled side beams 111 and two anti-expansion beams 112 to each other, a fixed space 115 is enclosed, which is mainly used to install and fix the battery cell modules 5. The fixed space 115 enclosed in this way can accommodate large-sized battery cell modules 5. In some embodiments, by providing a first cross beam 113 and a second cross beam 114 in the fixed space 115 and cross-connecting the first cross beam 113 and the second cross beam 114, the fixed space 115 is divided into multiple fixed sub-spaces, so that multiple battery cell modules 5 can be installed and fixed in the fixed space 115. When each battery cell module 5 expands, each expanded battery cell module 5 will be subjected to an independent fixed extrusion force to suppress the expansion of each battery cell module 5. In addition, multiple battery cell modules 5 are arranged adjacent to each other and separated by cross beams. That is, when the battery cell modules 5 are fixedly installed, they will share the cross beam. Part of the expansion and extrusion force of two adjacent battery cell modules 5 will be offset by acting on the same cross beam, indirectly enhancing the ability of the rolled assembly 11 to suppress the expansion of the battery cell modules 5.

[0086] Furthermore, both ends of the second cross beam 114 are respectively welded to the two anti-expansion beams 112 to improve the connection strength.

[0087] It should be noted that the frame structure formed by the connection of the roll-formed side beam 111 and the anti-expansion beam 112 can be rectangular, rhombic or other closed quadrilaterals. Similarly, the fixed space 115 can also be rectangular, rhombic or other closed quadrilaterals, without limitation, and it is mainly adjusted according to the structure of the battery cell module 5. Since the common structure of the battery cell module 5 is rectangular, in this embodiment, both the frame structure and the fixed space 115 are preferably rectangular. For the first cross beam 113 and the second cross beam 114, in this embodiment, one of each is used and cross-connected to divide the fixed space 115 into four fixed sub-spaces. In other embodiments, two first cross beams 113 and two second cross beams 114 can also be used and cross-connected to define more fixed sub-spaces for placing more battery cell modules 5.

[0088] In addition, for the roll-formed side beam 111, the anti-expansion beam 112, the first cross beam 113 and the second cross beam 114, the roll-forming process is adopted, and they are all of hollow steel plate structure with a plate thickness of 1.0 - 2.0 mm, so as to meet the requirements of lightweight of the battery module. And, the cross-sections of the roll-formed side beam 111, the first cross beam 113, the second cross beam 114 and the anti-expansion beam 112 are all in the shape of a Chinese character 'Ri' to improve the ability of each beam to withstand the expansion extrusion force of the battery cell module 5.

[0089] In some embodiments, please refer to FIGS. 4 and 5. The battery box 1 further includes a first frame 12. The two sides of the first frame 12 are respectively connected to one side of the two roll-formed side beams 111. The first frame 12 is spaced from the adjacent anti-expansion beam 112 to define an anti-extrusion area 121. A plurality of anti-extrusion beams 13 are spaced in the anti-extrusion area 121. The two ends of each anti-extrusion beam 13 are respectively connected to the first frame 12 and the anti-expansion beam 112 adjacent to the first frame 12.

[0090] By using the anti-expansion beams 112 instead of the frame to withstand the extrusion force of the battery cell module 5 when it expands, and by arranging a plurality of anti-extrusion beams 13 in the anti-extrusion area 121 , the effect of suppressing the expansion of the battery cell module 5 is further improved. Specifically, since the cell module 5 has a tendency to expand in the first direction, the solution proposed in this application is mainly to form a fixed space 115 by using the rolling assembly 11, and to form an anti-extrusion area 121 between the first frame 12 and the anti-expansion beam 112, so that the cell module 5 is installed in the fixed space 115 without direct contact with the first frame 12. That is, the expansion and extrusion force of the cell module 5 does not directly act on the first frame 12, effectively preventing deformation of the first frame 12. In addition, an anti-extrusion beam 13 is provided in the anti-extrusion area 121, and the anti-extrusion beam 13 is used to connect the rolling assembly 11 and the first frame 12. The first frame 12 can not only enhance the strength of the rolling assembly 11 against the expansion and extrusion force to a certain extent, but also prevent the first frame 12 from deforming due to direct exposure to the expansion and extrusion force. The anti-extrusion beam 13 can also enhance the strength of the rolling assembly 11. In addition, the buffer section 83 provided in the anti-expansion beam 112 can also improve the anti-deformation ability of the anti-expansion beam 112 itself, thereby preventing the deformation extrusion force from being transferred to the first frame 12. Furthermore, arranging the plurality of anti-extrusion beams 13 at intervals can, to a certain extent, prevent the anti-expansion beams 112 from transmitting deformation to the first frame 12 compared to arranging the anti-extrusion beams 13 directly and densely.

[0091] In some embodiments, the battery case 1 further includes a second frame 14. The two ends of the second frame 14 are respectively connected to the two roll-pressed edge beams 111 and are arranged opposite to the first frame 12, and the second frame 14 is spaced apart from the anti-expansion beam 112 adjacent to it, and the spacing distance is greater than 5mm. Because the expansion range of the battery cell module 5 is 1-5mm, the spacing between the second frame 14 and the anti-expansion beam 112 adjacent to it can be set to be greater than 5mm, which can effectively prevent the anti-expansion beam 112 from moving or deforming and affecting the second frame 14. Specifically, the two ends of the roll-pressed edge beam 111 extend along the second direction and are respectively located on the outside of the two anti-expansion beams 112, so that when the first frame 12 is connected to the roll-pressed edge beam 111, the first frame 12 can form an anti-extrusion area 121 with the anti-expansion beam 112; and when the second frame 14 is connected to the roll-pressed edge beam 111, the second frame 14 and the anti-expansion beam 112 are spaced apart. By setting the distance between the second frame 14 and the anti-expansion beam 112 to be greater than 5 mm, it can be ensured that when the anti-expansion beam 112 is displaced, it will not cause displacement impact on the second frame 14, thereby avoiding affecting the airtightness of the second frame 14.

[0092] It should be noted that for the first frame 12 and the second frame 14, in this embodiment, they are both sheet metal stamping parts. Compared with using rolled parts, sheet metal stamping parts can reduce weight while also reducing the cost of punching holes. Because sheet metal stamping parts only need to use a mold for punching holes, while rolled parts need to use laser cutting for holes.

[0093] Also, for the above-mentioned first direction and second direction, the first direction is the direction in which the battery cell module 5 expands. The first direction intersects with the second direction. Preferably, the first direction is perpendicular to the second direction.

[0094] Furthermore, please refer to FIGS. 2 and 5. The rolled edge beam 111, the anti-expansion beam 112, the first cross beam 113, and the second cross beam 114 are all hollow steel plate structures and the plate thickness is 1.0 - 2.0 mm. The rolled edge beam 111, the anti-expansion beam 112, the first cross beam 113, and the second cross beam 114 are all formed by bending the steel plate, and the hollow structure formed by bending is the through hole. The buffer sections 8 are respectively arranged in the through holes of the rolled edge beam 111, the anti-expansion beam 112, the first cross beam 113, and the second cross beam 114. The buffer section 83 arranged in the rolled edge beam 111 is integrally formed with the rolled edge beam 111 and can be directly bent from the steel plate; the buffer section 83 arranged in the anti-expansion beam 112 is integrally formed with the anti-expansion beam 112 and can be directly bent from the steel plate; the buffer section 83 arranged in the first cross beam 113 is integrally formed with the first cross beam 113 and can be directly bent from the steel plate; the buffer section 83 arranged in the second cross beam 114 is integrally formed with the second cross beam 114 and can be directly bent from the steel plate. After being formed by bending, the cross-sections of the rolled edge beam 111, the anti-expansion beam 112, the first cross beam 113, and the second cross beam 114 are all in a structure of a Chinese character 'Ri' shape. By using the rolling process to form a cross-section of a Chinese character 'Ri' shape, compared with a completely hollow beam structure, the beam structure with a cross-section of a Chinese character 'Ri' shape has higher strength and can better withstand extrusion force. It should be noted that although the cross-sections of the rolled edge beam 111 and the cross beam are both in a structure of a Chinese character 'Ri' shape, the cross-sectional area of the rolled edge beam 111 and the cross-sectional area of the cross beam can be different to form a size difference, and the size can be selected according to actual needs; also, the Chinese character 'Ri' shape mainly means that when observed as a whole, the cross-section is approximately in the shape of the Chinese character 'Ri', but the cross-sectional shapes of the rolled edge beam 111 and the cross beam can be completely the same Chinese character 'Ri' shape or not completely the same Chinese character 'Ri' shape, which is not limited.

[0095] Specifically, the plate thickness of the rolled side beam 111 is 1.2 to 1.5 mm, and in the present embodiment, the preferred thickness is 1.3 mm. The plate thickness of the anti-expansion beam 112 is 1.5-2.0 mm, and in the present embodiment, the preferred thickness is 1.7 mm. The plate thickness of the first cross beam 113 and the second cross beam 114 is 1.5 to 2.0 mm, and in the present embodiment, the preferred thickness is 1.7 mm. By limiting the plate thickness of the rolled side beam 111, the anti-expansion beam 112 and the cross beam to the corresponding thickness value range mentioned above, it is possible to ensure the strength of the rolled side beam 111 and the cross beam, and avoid excessive difficulty in roll forming.

[0096] In some embodiments, referring to Figures 3 and 6 , a plurality of mounting members 15 are provided on the outer side of the rolled side beam 111, where the outer side refers to the side facing away from the fixing space 115. The plurality of mounting members 15 are spaced apart along the second direction and are used to fix the battery case 1 to other external structures. Compared to directly fixing the rolled side beam 111 and the anti-expansion beam 112 to the external structure, the mounting members 15 can, to a certain extent, isolate the rolled side beam 111 and the anti-expansion beam 112 from the effects of the external structure, thereby protecting the internal structure of the battery case 1 from unnecessary mechanical stress and damage.

[0097] Furthermore, the mounting member 15 includes a first mounting beam 151, a second mounting beam 152, and a bushing 153. The first mounting beam 151 is fixed to the outside of the rolled side beam 111, and the side of the first mounting beam 151 facing away from the rolled side beam 111 is embedded in the second mounting beam 152 to fix the second mounting beam 152. Specifically, one side of the second mounting beam 152 is open, and one side of the first mounting beam 151 is embedded in the second mounting beam 152 through the opening, and the other side of the first mounting beam 151 extends to the outside of the second mounting beam 152 and is welded to the rolled side beam 111. The side of the first mounting beam 151 extending into the second mounting beam 152 is spaced apart from the inner side of the second mounting beam 152 to define a space for the bushing 153 to pass through. The second mounting beam 152 is fixedly connected to the rolled side beam 111 on the side facing the rolled side beam 111. The connection method is welding or bonding, and welding is used in this embodiment. The second mounting beam 152 has a sleeve hole 1521, and the bushing 153 is fixed to the second mounting beam 152 through the sleeve hole 1521. The sleeve 153 and the sleeve hole 1521 have an interference fit.

[0098] Furthermore, referring to Figures 3 and 6, the mounting part 15 also includes an anti-rust gasket 154. In some embodiments, the anti-rust gasket 154 is a stainless steel sheet. The anti-rust gasket 154 is fixed to the side of the second mounting beam 152 away from the bushing 153 and is coaxially connected to the sleeve 1521. When the bolt passes through the bushing 153, it can coaxially pass through the anti-rust gasket 154 and connect with the nut on one side of the anti-rust gasket 154. In this embodiment, the anti-rust gasket 154 and the second mounting beam 152 are connected and fixed by welding. When the battery module is installed and locked to the vehicle, and the bolt and nut rotate in coordination, the provision of the anti-rust gasket 154 can effectively reduce the wear caused by the nut on the surface of the second mounting beam 152, and reduce the consumption of the electrophoretic anti-corrosion layer on the surface of the second mounting beam 152. Furthermore, even if the electrophoretic anti-corrosion layer of the anti-rust gasket 154 is exhausted, the surface of the anti-rust gasket 154 will not rust because it is made of stainless steel, thereby effectively ensuring the anti-corrosion performance of the battery module.

[0099] Referring to Figures 7 and 8 , the present application further provides a battery module, including:

[0100] Base plate 2;

[0101] Bottom guard plate 3, provided on bottom plate 2;

[0102] Liquid cooling plate 4, provided on bottom guard plate 3;

[0103] The battery box 1 as in any of the aforementioned embodiments is provided on the liquid cooling plate 4;

[0104] A plurality of battery cell modules 5 are arranged in a fixed space 115 of the battery box 1;

[0105] An integrated busbar 6 is provided on the plurality of battery modules 5;

[0106] The insulating layer is provided on the side of the integrated busbar 6 facing away from the battery module 5;

[0107] The box cover is placed on the battery module, and the insulating layer is located between the box cover and the integrated busbar 6.

[0108] It should be noted that, because the battery module includes the battery case 1 in any of the above embodiments, the battery module has similar beneficial effects to the battery case 1. For the specific derivation process of the beneficial effects, please refer to the embodiment of the battery case 1 part, which will not be repeated here.

[0109] At the same time, this application uses specific terms to describe the embodiments of this application. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "one embodiment," "an embodiment," or "an alternative embodiment" mentioned twice or multiple times in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this application may be appropriately combined.

[0110] In some embodiments, numbers describing the number of components and attributes are used. It should be understood that such numbers used in the description of the embodiments are modified by the modifiers "about", "approximately" or "substantially" in some examples. Unless otherwise stated, "about", "approximately" or "substantially" indicate that the numbers allow for ±% changes. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may change according to the required features of the individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and adopt the general method of retaining the digits. Although the numerical domains and parameters used to confirm the breadth of their range in some embodiments of the present application are approximate values, in specific embodiments, the settings of such numerical values ​​are as accurate as possible within the feasible range.

Claims

1. A battery box girder, wherein the battery box girder is a roll-pressed steel girder, and the battery box girder comprises: Main wall; a first beam wall connected to one end of the main body wall, the first beam wall comprising a first pressure-bearing section, the first pressure-bearing section being arranged opposite to the main body wall; The second beam wall is connected to the other end of the main body wall. The second beam wall includes a second pressure-bearing section. The second pressure-bearing section is arranged opposite to the main body wall and extends toward and partially overlaps with the first pressure-bearing section.

2. The battery box beam according to claim 1, wherein: The second pressure-bearing section and the first pressure-bearing section are fixedly connected at an overlapping portion.

3. The battery box beam according to claim 2, wherein: The first pressure-bearing section includes a first extension section and a second extension section that are connected to each other and extend in the same direction. The second extension section is closer to the main body wall than the first extension section. The first extension section and the second extension section jointly define a connecting portion. The end of the second pressure-bearing section close to the first pressure-bearing section is arranged on the connecting portion and is connected to the second extension section.

4. The battery box beam as described in claim 3, the first pressure-bearing section also includes a bending section, the first extension section and the second extension section are connected through the bending section, the bending section is bent from the first extension section toward the main wall, the first extension section, the second extension section and the bending section jointly define the connecting portion, the second pressure-bearing section is arranged at the connecting portion near the end of the first pressure-bearing section, and is welded and fixed to the second extension section.

5. The battery box beam according to claim 4, wherein: The first extension section has a first surface facing away from the main body wall, the second pressure-bearing section has a second surface facing away from the main body wall, and the first surface and the second surface are coplanar.

6. The battery box beam according to claim 4, wherein: Both ends of the bending section transition to the first extending section and the second extending section in circular arcs, respectively.

7. The battery box beam according to claim 1, wherein: The first beam wall also includes a first connecting section, which is connected between the first pressure-bearing section and the main body wall. The second beam wall also includes a second connecting section, which is connected between the second pressure-bearing section and the main body wall and is arranged opposite to the first connecting section. The main body wall, the first connecting section, the first pressure-bearing section, the second pressure-bearing section and the second connecting end enclose a beam inner cavity.

8. The battery box girder according to any one of claims 1 to 7, wherein: The first beam wall also includes a buffer section, which is connected to the end of the first pressure-bearing section near the second pressure-bearing section and extends toward the main wall. The buffer section is configured to support the first pressure-bearing section and the second pressure-bearing section when the first pressure-bearing section and the second pressure-bearing section are under pressure, and the buffer section has a tendency to slide along the main wall.

9. The battery box beam according to claim 8, wherein: The buffer section includes a supporting section and an abutting section, the supporting section is connected between the first pressure-bearing section and the abutting section, and the abutting section is parallel to and connected to the main body wall.

10. The battery box beam according to claim 9, wherein: The abutting section abuts against the main body wall, and is configured to slide along the main body wall when the first pressure-bearing section and the second pressure-bearing section are under pressure, so as to buffer the extrusion force.

11. The battery box beam according to claim 9, wherein: The abutment section is fixedly connected to the main body wall. When the first pressure-bearing section and the second pressure-bearing section are under pressure, the abutment section is configured to change from a fixed connection to a sliding connection with the main body wall and slide along the main body wall to buffer the extrusion force.

12. The battery box beam according to claim 9, wherein: The connection strength between the abutting section and the main body wall is less than the connection strength between the first pressure-bearing section and the second pressure-bearing section. When the first pressure-bearing section and the second pressure-bearing section are under pressure, the time node when the fixed connection between the abutting section and the main body wall changes to a sliding connection is earlier than the separation time node between the first pressure-bearing section and the second pressure-bearing section.

13. The battery box beam according to claim 9, wherein: The abutting section and the first pressure-bearing section extend in opposite directions.

14. The battery box beam according to claim 9, wherein: The extension line of the support section and the extension line of the main body wall have a first angle, the extension line of the support section and the extension line of the second extension section have a second angle, and the first angle and the second angle are offset angles and complementary to each other.

15. The battery box beam according to claim 1, wherein: The wall thickness of the battery box beam is between 1 mm and 2 mm.

16. A battery case, comprising a first direction, the battery case comprising: A rolling assembly encloses a fixed space for fixing a battery cell module, and the battery cell module has a tendency to expand along the first direction. The rolling assembly includes two anti-expansion beams arranged opposite to each other, and the two anti-expansion beams are arranged at relative intervals along the first direction. The two anti-expansion beams are both battery box beams as described in any one of claims 1 to 15.

17. The battery case according to claim 16, wherein: The battery box further includes a second direction, the first direction and the second direction intersect, and the rolling assembly further includes: Two roller-pressed side beams are arranged opposite to each other along the second direction, and both ends of each anti-expansion beam are respectively connected to the two roller-pressed side beams to define the fixed space.

18. The battery case according to claim 17, wherein: The two rolled side beams are both the battery box beams, the thickness of the two rolled side beams is the same, and the thickness of the rolled side beam is less than the thickness of the anti-expansion beam.

19. The battery case according to claim 15, wherein: The rolling assembly further comprises: At least one first cross beam and at least one second cross beam, the first cross beam and the second cross beam are both located in the fixed space, the first cross beam is cross-connected with the second cross beam, the two ends of the first cross beam are respectively welded to the two roller-pressed edge beams, and the two ends of the second cross beam are respectively connected to the two anti-expansion beams.

20. The battery case according to claim 19, wherein: Both ends of the second cross beam are respectively welded to the two anti-expansion beams.

21. The battery case according to claim 17, wherein: The battery box also includes a first frame, both sides of which are respectively connected to one side of the two rolled edge beams, and the first frame is spaced apart from a battery box beam adjacent to it to define an anti-extrusion area, wherein a plurality of anti-extrusion beams are spaced apart in the anti-extrusion area, and both ends of each anti-extrusion beam are respectively connected to the first frame and the anti-expansion beam adjacent to the first frame.

22. The battery case according to claim 21, wherein: The battery box also includes a second frame, which is arranged opposite to the first frame. The two ends of the second frame are respectively connected to the two roller-pressed edge beams, and the second frame is spaced apart from the anti-expansion beam close to it, and the spacing distance is greater than 5mm.

23. A battery module comprising: base plate; A bottom guard plate, provided on the bottom plate; a liquid cooling plate, arranged on the bottom guard plate; The battery box according to any one of claims 16 to 22, provided on the liquid cooling plate; A plurality of battery cell modules are arranged in a fixed space of the battery box; An integrated busbar, provided on the plurality of battery core modules; An insulating layer is provided on a side of the integrated busbar facing away from the battery module; A box cover is provided on the battery module, and the insulating layer is located between the box cover and the integrated busbar.

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