Multi-layer pack structure for heavy duty applications

Abstract

This battery pack assembly for a vehicle comprises a plurality of sub-packs, wherein each sub-pack includes a box frame and an inner frame assembly disposed within the box frame, the box frame includes a front wall, a rear wall and a pair of side walls, either the front wall or the rear wall includes a first plurality of mounting flanges disposed to be spaced apart in the vertical direction, each of the pair of side walls includes a second plurality of mounting flanges disposed to be spaced apart in the vertical direction, the inner frame assembly includes a plurality of cooling plate structures directly mounted on at least one of the first and second plurality of mounting flanges, a thermal hose assembly is connected to each of the plurality of cooling plate structures, and a plurality of battery modules are supported on the plurality of cooling plate structures.

Description

Multilayer pack structure for large applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 559,502, filed February 29, 2024, and U.S. Provisional Patent Application No. 19 / 032,576, filed January 21, 2025, the entire disclosures of which are incorporated herein by reference.

[0002] The present disclosure relates to a battery pack, and more particularly to a multilayer battery pack structure having an integral cooling plate for heavy duty vehicle applications.

[0003] This section provides background information related to the present disclosure that is not necessarily prior art.

[0004] Electric vehicles (EVs) are gaining popularity as environmentally friendly alternatives to conventional internal combustion engine vehicles (ICEs). Compared to conventional ICE vehicles, EVs offer significant potential for reducing greenhouse gas emissions and mitigating the impacts of climate change. The environmental benefits of EVs can be particularly significant for heavy-duty applications, such as trucks and buses, which typically consume large amounts of fossil fuels and generate significant emissions during operation. Battery pack design plays a critical role in realizing the climate mitigation potential of electric heavy-duty vehicles. Optimizing factors such as energy density, thermal management, and lifespan can help maximize the practical range and usable lifespan of these vehicles.

[0005] A key component of electric vehicles is the battery pack, which provides the energy storage and power supply necessary for vehicle operation. As electric vehicles are developed for larger applications such as trucks and buses, the need for battery pack designs capable of meeting the increasing power and energy requirements of these large vehicles is increasing.

[0006] Large electric vehicles present unique challenges for battery pack design. Battery packs must be able to store and supply significantly greater amounts of energy than those used in passenger cars. At the same time, there are constraints on the size, weight, and packaging of the battery pack within the vehicle frame. Optimizing the energy density and power capacity of the battery pack while working within these constraints is crucial.

[0007] Thermal management is another important consideration for battery packs in large electric vehicles. High power demands can generate significant heat within battery cells and modules. Efficient cooling is essential to maintain battery performance and lifespan. Efficiently integrating thermal management systems, such as cooling plates, into the battery pack structure is an area of ​​ongoing development.

[0008] The mechanical structure and mounting of the battery pack are also crucial for large-scale applications. The pack must be able to withstand the increased vibration, shock, and other mechanical stresses associated with operating a large vehicle. At the same time, the mounting system must be user-friendly and facilitate potential battery replacement.

[0009] Most current battery application structures for electric vehicles, such as those for cars and light trucks, feature wide, flat single-layer and sometimes two-layer cells / modules. Large trucks typically utilize multiple stacked sub-packs. Multi-stacked sub-pack structures for large trucks increase weight and utilize more space, resulting in lower energy density efficiency. Furthermore, the internal stacking of battery components can make battery pack component replacement and maintenance more difficult.

[0010] This section provides a general overview of the present disclosure and is not intended to be a comprehensive disclosure of its full scope or all mechanisms.

[0011] The present disclosure relates to a structure intended to address packaging space considerations by minimizing internal frame clearance and external boundaries, thereby allowing for more rechargeable energy storage space. Generally, the structure disclosed herein comprises an integrated cooling plate assembly and a housing interface that provides superior structural support to the assembly while reducing the assembly's mass.

[0012] According to one aspect of the present disclosure, a battery pack assembly for a vehicle includes a plurality of sub-pack assemblies, each of which includes a box frame. An inner frame assembly is disposed within the box frame. The box frame includes a front wall, a rear wall, and a pair of side walls, one of the front wall and the rear wall including a first plurality of mounting flanges spaced vertically apart from each other, and each of the pair of side walls including a second plurality of mounting flanges spaced vertically apart from each other. The inner frame assembly includes a plurality of first cooling plate structures directly mounted to at least one of the first and second plurality of mounting flanges. A heat hose assembly is connected to each of the plurality of first cooling plate structures, and a plurality of battery modules are supported on the plurality of first cooling plate structures.

[0013] According to one aspect of the present disclosure, a battery pack assembly for a vehicle includes a plurality of sub-pack assemblies, each of which includes a box frame. An inner frame assembly is disposed within the box frame. The box frame includes a front wall, a rear wall, and a pair of side walls, one of the front wall and the rear wall including a first plurality of vertically spaced mounting flanges, and each of the pair of side walls including a second plurality of vertically spaced mounting flanges. The inner frame assembly includes a plurality of first cooling plate structures directly mounted to at least one of the first and second plurality of mounting flanges. A heat hose assembly is connected to each of the plurality of first cooling plate structures, and a plurality of battery modules are supported by the plurality of first cooling plate structures.

[0014] In a further aspect, the inner frame assembly further includes a plurality of front vertical support brackets extending along a front wall, a plurality of rear vertical support brackets extending along a rear wall of the box frame, and a plurality of support beams extending between each of the plurality of front vertical support brackets and the plurality of rear vertical support brackets.

[0015] In a further aspect, the plurality of first cooling plate structures are connected to at least one of the plurality of support beams.

[0016] In a further aspect, the inner frame comprises a top plate mounted on top of the box frame.

[0017] In a further aspect, a plurality of second cooling plate structures are arranged on the top plate.

[0018] In a further aspect, a second plurality of battery modules are arranged on a plurality of second cooling plate structures.

[0019] In a further aspect, a plurality of covers are disposed on a second plurality of battery modules.

[0020] According to a further aspect, the plurality of first cooling plate structures include a structural plate and a cooling plate fixed to the structural plate.

[0021] In a further aspect, the structural plate includes a plurality of alignment pins, and the cooling plate includes a plurality of openings for receiving the alignment pins.

[0022] In a further aspect, the structural plate includes a plurality of mounting features for mounting to the first plurality of mounting flanges and the second plurality of mounting flanges.

[0023] In another aspect, the vehicle may be equipped with a vehicle battery pack assembly mounted on a pair of frame rails of the vehicle's frame structure.

[0024] Additional scope of application will become apparent from the description provided herein. The descriptions and specific examples in this overview are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0025] The drawings described herein are intended to be illustrative only of selected embodiments, do not illustrate every possible implementation, and are not intended to limit the scope of the present disclosure.

[0026] FIG. 1 is a plan view of a large truck frame and battery pack assembly according to the principles of the present disclosure.

[0027] FIG. 2 is a perspective view of a battery pack assembly according to the principle of the present disclosure.

[0028] FIG. 3 is a front plan view of an example sub-pack of a battery pack assembly according to the principles of the present disclosure with the front panel removed.

[0029] Fig. 4 is a perspective view of a box frame of a sub-pack according to the principle of the present disclosure.

[0030] Figure 5 is a perspective view of the inner frame of a sub-pack according to the principle of the present disclosure.

[0031] Figure 6 is an exploded perspective view of an exemplary sub-pack according to the principles of the present disclosure.

[0032] FIGS. 7A through 7P illustrate step-by-step assembly processes for a sub-pack of an example of a rechargeable energy storage system for a large vehicle according to the principles of the present disclosure.

[0033] FIG. 8 is an exploded perspective view of a cooling plate structure assembly of a sub-pack of a rechargeable energy storage system for a large vehicle according to the principles of the present disclosure.

[0034] Figure 9 is an exploded perspective view of a cooling plate structure assembly according to the principle of the present disclosure.

[0035] FIG. 10 is a perspective view of a pair of cooling plate structure assemblies according to the principles of the present disclosure.

[0036] FIG. 11 is a perspective view of a pair of cooling plate structural assemblies and a structural beam according to the principles of the present disclosure.

[0037] FIG. 12 is a detailed perspective view of a pair of cooling plate structural assemblies and structural beams according to the principles of the present disclosure.

[0038] Fig. 13 is a perspective view of a heat hose assembly according to the principle of the present disclosure.

[0039] FIG. 14 is a perspective view of a top plate assembly and a mounting beam assembly according to the principles of the present disclosure.

[0040] Figure 15 is a perspective view of an end of a mounting beam having mounting bolts for a mounting plate.

[0041] Figure 16 is a perspective view of the mounting plate and mounting bolts assembled to the mounting beam.

[0042] Figure 17 is a schematic drawing of a sub-pack showing details of a mounting beam assembly for mounting the sub-pack to a vehicle frame rail.

[0043] The reference number identifies the corresponding part through multiple views of the drawing.

[0044] An exemplary embodiment will now be described in more detail with reference to the attached drawings.

[0045] Exemplary embodiments are provided to ensure that the disclosure is thorough and fully conveys its scope to those skilled in the art. Numerous specific details, such as examples of specific components, devices, and methods, are provided to facilitate a thorough understanding of the embodiments of the disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that the exemplary embodiments may be implemented in many different forms, and that none of these should be construed as limiting the scope of the disclosure. Some exemplary embodiments do not describe in detail well-known processes, well-known device structures, and well-known techniques.

[0046] The terminology used herein is for the purpose of describing particular exemplary embodiments and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural as well unless the context clearly dictates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive, meaning that they specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring the particular order of performance discussed or illustrated, unless such order is specifically specified. It is also to be understood that additional or alternative steps may be employed.

[0047] When a particular element or layer is referred to as being "on," "engaged with," "connected to," or "joined to" another element or layer, it may be directly on, engaged with, connected to, or joined to the other element or layer, or there may be intermediate elements or layers present. Conversely, when a particular element is referred to as being "on," "engaged with," "connected to," or "joined to," there may not be intermediate elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0048] Although terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited to these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless the context clearly indicates otherwise. Thus, a first element, component, region, layer, or section discussed below could also be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0049] For convenience of explanation, spatially relative terms such as “inside,” “outside,” “below,” “bottom,” “above,” “upper,” “front,” “back,” “left,” “right,” etc. may be used herein to describe the relationship between an element or mechanism depicted in the drawings and another (or multiple) elements or mechanisms. Spatially relative terms may be intended to encompass various orientations of the device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is turned over, an element described as “below” or “directly below” another element or mechanism is positioned “above” the other element or mechanism. Thus, the exemplary term “below” may encompass both the above and below orientations. The device may be positioned in other orientations (rotated 90 degrees or otherwise) and the spatially relative descriptors used herein may be interpreted accordingly.

[0050] Referring to FIG. 1, a vehicle frame structure (10) of a vehicle (8) is illustrated as including a pair of frame rails (12a, 12b). A pair of wheels (14a, 14b) are illustrated as being mounted on a pair of suspension arms (16a, 16b) that are rotatably mounted to the frame structure (10). An electric motor may be supported to drive selected wheels of the vehicle, as is known in the art. The electric motor may drive the wheels directly or through a transmission of the vehicle. The vehicle drivetrain may include a hybrid drive system that allows the wheels to be driven by an engine and / or an electric motor. The frame structure (10) may include cross support structures (18) respectively connected to the frame rails (12a, 12b).

[0051] A rechargeable energy storage system in the form of a battery pack (20) may be supported by a frame structure (10). In particular, the battery pack may include a plurality of sub-packs (22a-22d) each mounted on a pair of frame rails (12a, 12b). In the illustrated embodiment, four sub-packs are installed, but more or fewer sub-packs may be used. The battery pack (20) supplies electricity to the electric motor of the vehicle. The sub-packs (22a-22d) are mounted longitudinally side by side along a pair of frame rails (12a, 12b). The sub-packs may be identical to each other or may have different arrangements depending on the specific application.

[0052] Referring to FIG. 2, a battery pack (20) is illustrated separately from a frame structure (10). The battery pack (20) includes four sub-packs (22a-22d) aligned longitudinally with respect to the direction of travel of the vehicle as illustrated. Referring to FIGS. 3 and 4, each sub-pack (22a-22d) includes a box frame (24) having a front wall (26), a rear wall (28), a pair of side walls (30a, 30b), and a base (32). FIG. 3 illustrates the box frame (24) with the front wall (26) removed to show the inner frame assembly (34) supporting the battery module (36). The front wall (26) is illustrated in an exploded perspective view of FIG. 6.

[0053] In some cases, each sub-pack (22a, 22b, 22c, 22d) may include additional components. For example, a battery control unit (42) may be mounted on the upper portion of the box frame (24). The battery pack (20) may also include one or more additional battery modules (136) positioned on the upper portion of the box frame (24). For example, as illustrated in FIG. 4, the additional battery modules (136) are stacked on the upper portion of the box frame (24), with two battery modules (136) shown on the right side and three battery modules (136) stacked in the center. It should be understood that the location and number of the additional battery modules (136) may vary depending on the desired application. In addition, the location of the battery control unit (42) may also vary depending on the desired application. The battery pack (20) may additionally include a plurality of covers to protect and enclose the various components. In some cases, these covers may include a side cover (44a), a center cover (44b), and another cover (44c). The covers (44a, 44b, 44c) may be positioned on the additional battery module (136) and the battery control unit (42).

[0054] The heat hose assembly (38) (best illustrated in FIG. 13) is connected to a cooling plate structure (40) that forms part of the inner frame assembly (34), as described in more detail herein. Additional battery modules (136) on the upper portion of the box frame (24) are each supported by an additional cooling plate structure (140). The heat hose assembly (38) is also connected to the additional cooling plate structure (140) on the upper portion of the box frame (24). As illustrated in FIG. 3, the heat hose assembly (38) has an inlet fitting (38a) and an outlet fitting (38b) that extend and are positioned within the cover (44b) at the center of the sub-pack (22). Figure 13 is a detailed perspective view of an exemplary heat hose assembly (38) having inlet and outlet fittings (38a, 38b), an additional fitting (38c) for connecting to the inlet fitting of a cooling plate structure assembly (40, 140), and a fitting (38d) for connecting to the outlet fitting of a cooling plate structure assembly (40, 140). The heat hose assembly (38) may further include an additional degassing valve (38e) installed to discharge air from the heat hose assembly (38). The heat hose assembly (38) may have other shapes or configurations.

[0055] Referring to FIG. 5, the inner frame assembly (34) is illustrated with the box frame (24) and the battery module (36) removed. The inner frame assembly (34) includes three cooling plate structures (40a) on one side, three middle cooling plate structures (40b) and three cooling plate structures (40c) on the other side. It should be understood that the number of cooling plate structures (40a, 40b, 40c) may vary in other embodiments. Front and rear vertical support brackets (46a-46c) are installed to connect to the front and rear of the central edge portions of each cooling plate structure (40a-40c), respectively. Additional vertical front support brackets (48a, 48b) are installed between the central cooling plate (40b) and the outer cooling plates (40a, 40c), respectively. Front-rear support beams (50a-50c) extend between and connect to the front-rear support brackets (48a, 48b). The front and rear beams (50a, 50b) can be connected to the support brackets (48a, 48b) by mutual coupling mechanisms, fasteners or other known fastening techniques.

[0056] A top plate assembly (52) is installed on top of the inner frame assembly (34). An additional cooling plate structure (140) is installed on top of the top plate assembly (52) at one end, and a pair of laminated cooling plate structures (140) are laminated on the central portion of the top plate assembly (52). Each cooling plate structure (40a-40c, 140) can accommodate one or more battery modules (36, 136). FIG. 8 illustrates the cooling plate structures (40a-40c) and the additional cooling plate structure (140) to which the heat hose assembly (38) is connected. FIG. 11 illustrates the interface between the front and rear support beams (50a, 50b) and the cooling plate structure assemblies (40a, 40b). FIG. 12 is a detailed perspective view of an assembly of a cooling plate structure assembly (40a, 40b) and front and rear support beams (50a, 50b) according to the principle of the present disclosure.

[0057] Referring to FIG. 6, the rear wall (28) and a pair of side walls (30a, 30b) each include mounting flanges (54) spaced vertically apart, with mounting openings for mounting cooling plate structures (40a-40c). As illustrated in FIG. 6, three cooling plate structures (40a) are mounted on vertically spaced mounting flanges (54) of the rear wall (28) and one side wall (30a) and front and rear support beams (50a-50c) on one side of the box frame (24), three central cooling plate structures (40b) are mounted on vertically spaced mounting flanges 54 of the rear wall and front and rear support beams (50a-50c), and three cooling plate structures (40c) are mounted on vertically spaced mounting flanges (54) of the rear wall (28) and the other side wall (30b) and front and rear support beams (50a-50c) on the other side of the box frame (24) using screws or other fasteners (55). The cooling plate structures (40a-40c) are also respectively connected to front vertical support brackets (46a-46c). The top plate assembly (52) is mounted along the upper perimeter of the box frame (24) using screws or other fasteners (55).

[0058] The front wall (26) of the box frame (24) may include a rectangular frame structure (26a) and a wall panel (26b) detachably mounted to the frame structure (26a). Upon assembly, the wall panel (26b) is removed to allow the cooling plate structures (40a-40c) to be connected to the support brackets (46a-46c) and to install a heat hose assembly (38) for connecting to the cooling plate structures (40a-40c). Two of the additional cooling plate structures (140) are mounted to the top plate assembly and additional battery modules (136) are stacked on the two additional cooling plate structures (140). Optionally, an additional stacked upper cooling plate structure (140) is positioned above the additional battery module (136) in the center of the top plate assembly (52), and at least one additional battery module (136) is positioned on the additional upper cooling plate structure (140). A battery control unit (42) is mounted on a top plate assembly (52). Covers (44a-44c) are mounted on the top plate assembly (52) over the additional battery module (136) and the battery control unit (42). A pair of mounting beam assemblies (56) are installed to mount the sub-pack (22) to frame rails (12a, 12b) of the vehicle (8). The pair of mounting beam assemblies (56) are mounted on the box frame (24) and include mounting bolts (58) for mounting to the frame rails (12a, 12b). FIG. 14 is a perspective view of a top plate assembly and a mounting beam assembly according to the principles of the present disclosure.

[0059] Fig. 15 is a perspective view of an end of a mounting beam assembly (56) having mounting bolts for a mounting plate. Fig. 16 is a perspective view of a mounting plate (57) and mounting bolts (58) assembled to the mounting beam assembly (56) by means of nut and bolt assemblies (59a, 59b). Fig. 17 is a schematic drawing of a sub-pack showing details of a mounting beam assembly (56) and mounting bolts (58) for mounting the sub-pack (20) to a vehicle frame rail (12a, 12b).

[0060] Referring to FIGS. 7A to 7P, a step-by-step assembly of a sub-pack (22) according to the principles of the present disclosure will be described. FIG. 7A illustrates a box frame assembly (24) with the front panel (26b) removed from the front frame (26a). Mounting flanges (54) are shown spaced vertically from the rear wall (28) and side walls (30a, 30b).

[0061] Figure 7B shows that a single-layer cooling plate structure (40a-40c) is inserted into a box frame (24) together with two front and rear support beams (50a), three front support brackets (46a-46c) and two rear support brackets (48b).

[0062] Figure 7C illustrates a first layer battery module (36) being inserted into a box frame (24) on top of a first layer cooling plate structure (40a-40c). While nine battery modules are shown, more or fewer battery modules may be used.

[0063] FIG. 7D illustrates that the cooling plate structure (40a-40c) of the second layer is inserted into the box frame (24) together with two front and rear support beams (50a) of the second layer.

[0064] Figure 7E illustrates a second layer of battery modules (36) being inserted into a box frame (24) on top of the second layer of cooling plate structures (40a-40c). While nine battery modules (36) are shown, more or fewer battery modules (36) may be used.

[0065] FIG. 7F illustrates that the cooling plate structure (40a-40c) of the third layer is inserted into the box frame (24) together with the two front and rear support beams (50a) of the third layer.

[0066] FIG. 7G illustrates five battery modules (36) being inserted on top of the third layer cooling plate structure (40a-40c).

[0067] Figure 7H illustrates the mounting of the mounting reinforcement (60) of the mounting beam assembly (56). Also shown is a heat hose assembly for connection to the cooling plate structures (40a-40c) within the box frame.

[0068] FIG. 7I illustrates mounting two front support brackets (48a) to the front wall frame (26a), mounting four additional battery modules (36) within the box frame, and mounting the front panel (26b) to the front wall frame (26a).

[0069] FIG. 7J illustrates mounting a top plate assembly (52) and a mounting beam assembly (56) to a box frame (24).

[0070] FIG. 7K illustrates mounting a battery control unit (42) and two additional cooling plate structures (140) to a top plate assembly (52).

[0071] FIG. 7L illustrates mounting four additional battery modules (136) on an additional cooling plate structure (140).

[0072] FIG. 7M illustrates mounting an upper shelf assembly (62) including an additional cooling plate structure (140) to a top plate assembly (52).

[0073] FIG. 7N illustrates mounting an additional battery module (136) to the cooling plate structure (140) of the upper shelf assembly (62). While one battery module (136) is shown, more battery modules may be mounted to the upper shelf assembly (62).

[0074] Figure 7O illustrates mounting three cover assemblies (44a-44c) on a top plate assembly (52).

[0075] Figure 7P illustrates a fully assembled sub-pack (22) according to the principles of the present disclosure.

[0076] FIG. 9 is an exploded perspective view of an exemplary cooling plate structural assembly (40) according to the principles of the present disclosure. The cooling plate structural assembly (40) includes a structural plate (68) and a cooling plate (70) secured to the structural plate (68). Optionally, the cooling plate (70) may be secured to the structural plate (68) using adhesive tape. The structural plate (68) includes a plurality of alignment pins (72), and the cooling plate (70) includes a plurality of openings (74) for receiving the alignment pins (72). Optionally, the alignment pins (72) may be received by the openings (74) to ensure proper positioning of the cooling plate (70) on the structural plate (68). The structural plate (68) includes a plurality of mounting mechanisms (76) for mounting to a mounting flange (54) within the box frame (24). The cooling plate (68) may include a diagonal cooling water flow path connected between an inlet fitting (78) and an outlet fitting (80). FIG. 10 is a perspective view of a pair of cooling plate structure assemblies (40) according to the principles of the present disclosure.

[0077] The foregoing description of the embodiments is provided for illustrative and explanatory purposes. It is not intended to be comprehensive or limiting of the present disclosure. Individual elements or mechanisms of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment even if not specifically illustrated or described. Likewise, various modifications may be made. Such modifications should not be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A vehicle battery pack assembly comprising a plurality of sub-pack assemblies, Each sub pack has box frame; an inner frame assembly disposed within the above box frame; and A plurality of first battery modules supported by an inner frame assembly within the box frame; The box frame comprises a front wall, a rear wall, and a pair of side walls, one of the front wall and the rear wall comprises a first plurality of mounting flanges spaced vertically apart, and each of the pair of side walls comprises a second plurality of mounting flanges spaced vertically apart, The inner frame assembly includes a plurality of first cooling plate structures directly mounted on at least one of the first and second plurality of mounting flanges; and The above heat hose assembly is connected to each of the plurality of first cooling plate structures, and the plurality of battery modules are supported on the plurality of first cooling plate structures. Battery pack assembly for vehicles.

2. A vehicle battery pack assembly according to claim 1, wherein the inner frame assembly further includes a plurality of front vertical support brackets extending along the front wall, a plurality of rear vertical support brackets extending along the rear wall of the box frame, and a plurality of support beams extending between each of the plurality of front vertical support brackets and the plurality of rear vertical support brackets.

3. A vehicle battery pack assembly according to claim 2, wherein the plurality of first cooling plate structures are connected to at least one of the plurality of support beams.

4. A battery pack assembly for a vehicle according to claim 1, wherein the inner frame includes a top plate mounted on the upper portion of the box frame.

5. A vehicle battery pack assembly according to claim 4, further comprising a plurality of second cooling plate structures arranged on the top plate.

6. A vehicle battery pack assembly according to claim 5, further comprising a second plurality of battery modules arranged on the second plurality of cooling plate structures.

7. A vehicle battery pack assembly according to claim 6, further comprising a plurality of covers covering the second plurality of battery modules.

8. A battery pack assembly for a vehicle according to claim 1, wherein the plurality of first cooling plate structures include a structural plate and a cooling plate fixed to the structural plate.

9. A battery pack assembly for a vehicle according to claim 8, wherein the structural plate includes a plurality of alignment pins, and the cooling plate includes a plurality of openings for receiving the alignment pins.

10. A battery pack assembly for a vehicle according to claim 9, wherein the structural plate includes a plurality of mounting mechanisms for mounting to a first plurality of mounting flanges and a second plurality of mounting flanges.

11. As an electric vehicle, A vehicle frame structure comprising a pair of frame rails; A plurality of sub-pack assemblies each mounted on a pair of frame rails, wherein each sub-pack comprises: box frame; an inner frame assembly disposed within the above box frame; and A plurality of first battery modules supported within a box frame by the inner frame assembly; The box frame comprises a front wall, a rear wall, and a pair of side walls, one of the front wall and the rear wall comprises a first plurality of mounting flanges spaced vertically apart, and each of the pair of side walls comprises a second plurality of mounting flanges spaced vertically apart, The inner frame assembly includes a plurality of first cooling plate structures directly mounted to at least one of the first and second plurality of mounting flanges; and The above heat hose assembly is connected to each of the plurality of first cooling plate structures, and the plurality of battery modules are supported on the plurality of first cooling plate structures. Electric vehicles.

12. An electric vehicle according to claim 11, wherein the inner frame assembly further comprises a plurality of front vertical support brackets extending along the front wall, a plurality of rear vertical support brackets extending along the rear wall of the box frame, and a plurality of support beams extending between each of the plurality of front vertical support brackets and the plurality of rear vertical support brackets.

13. An electric vehicle according to claim 12, wherein the plurality of first cooling plate structures are connected to at least one of the plurality of support beams.

14. An electric vehicle according to claim 11, wherein the inner frame includes a top plate mounted on the upper portion of the box frame.

15. An electric vehicle according to claim 14, further comprising a plurality of second cooling plate structures arranged on the top plate.

16. An electric vehicle according to claim 15, further comprising a second plurality of battery modules arranged on the second plurality of cooling plate structures.

17. An electric vehicle according to claim 16, further comprising a plurality of covers covering the second plurality of battery modules.

18. An electric vehicle according to claim 11, wherein the plurality of first cooling plate structures include a structural plate and a cooling plate fixed to the structural plate.

19. An electric vehicle according to claim 18, wherein the structural plate includes a plurality of alignment pins, and the cooling plate includes a plurality of openings for receiving the alignment pins.

20. An electric vehicle according to claim 19, wherein the structural plate includes a plurality of mounting mechanisms for mounting to the first plurality of mounting flanges and the second plurality of mounting flanges.

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