Battery pack frame and battery pack

Abstract

A battery pack frame and a battery pack. The battery pack frame comprises a front frame (11), a first connecting frame (12), a rear frame (13) and a second connecting frame (14), which are sequentially connected end to end, wherein the first connecting frame (12) and the second connecting frame (14) are configured to be fixedly connected to an external assembly; both the front frame (11) and the rear frame (13) are of an integrally stamping-formed structure; and both the first connecting frame (12) and the second connecting frame (14) are of an integrally rolling-formed structure.

Description

Battery pack frame and battery pack

[0001] This application claims priority to Chinese Patent Application No. 202421228979.3, filed with the Chinese Patent Office on May 30, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of battery pack frame technology, specifically to a battery pack frame and a battery pack. Background Technology

[0003] Currently, the mainstream battery box frame usually adopts aluminum extrusion combined with welding process. Although the aluminum profile solution has a high degree of maturity, the profile shape design is free and varied, and the overall weight is light, the aluminum extrusion process is a high energy consumption process. Therefore, the processing cost of the above solution is high. At the same time, aluminum is a non-ferrous metal, and the material cost is also high. Invention Overview

[0004] To address the aforementioned production drawbacks of aluminum profile enclosures, many companies have begun designing roll-formed steel enclosures. Roll-formed steel enclosures, due to their lower material cost, mature welding process, and relatively less machining, can be about 30% cheaper than aluminum profile enclosures. However, all-steel enclosures are heavier, making them inconvenient to transport. Furthermore, the development cost of roll forming molds is high, thus increasing production costs.

[0005] Therefore, there is an urgent need to design a battery pack frame and battery pack to address potential technical risks.

[0006] In a first aspect, this application provides a battery pack frame. It includes: a front frame, a first connecting frame, a rear frame, and a second connecting frame connected sequentially end-to-end. The front frame is provided with multiple electrical components, and the first and second connecting frames are used for fixed connection with external components. The front and rear frames are both integrally stamped structures, and the first and second connecting frames are both integrally roll-formed structures.

[0007] Secondly, this application also provides a battery pack. The battery system includes a battery pack frame; a base plate connected to the front frame, first connecting frame, rear frame and bottom of the second connecting frame of the battery pack frame, the base plate and the battery pack frame cooperating to form a receiving cavity; and a battery module disposed within the receiving cavity. Beneficial effects

[0008] The battery pack frame provided in this application has a front and rear frame integrally stamped and formed, and a first connecting frame and a second connecting frame integrally rolled and formed. Since the stamped structure has the advantages of light weight and low processing cost, it can reduce the overall weight of the battery pack frame to a certain extent, reduce production costs, and facilitate the transportation of the battery pack frame. Since the rolled structure has the advantage of high strength, and since the first and second connecting frames need to be fixedly connected to external components, it can ensure the stability of the battery pack frame after being connected to the external components, thereby reducing the risk of the battery pack frame falling off the external components to a certain extent and ensuring the safety of the battery pack frame during use.

[0009] The battery pack provided in this application ensures the stability of the battery module during operation by placing the battery module inside the receiving cavity of the battery pack frame. Attached Figure Description

[0010] Figure 1 is a perspective view of the battery pack frame provided in the embodiment;

[0011] Figure 2 is a structural schematic diagram of the first connecting frame and the second connecting frame provided in the embodiment;

[0012] Figure 3 is a cross-sectional schematic diagram of the first connecting frame and the second connecting frame provided in the embodiment;

[0013] Figure 4 is a perspective view of the separator provided in the embodiment;

[0014] Figure 5 is an enlarged view of point A in Figure 4;

[0015] Figure 6 is an enlarged view of point B in Figure 4;

[0016] Figure 7 is an assembly diagram of the battery pack frame provided in the embodiment;

[0017] Figure 8 is an enlarged view of point C in Figure 7.

[0018] Explanation of reference numerals in the attached figures:

[0019] 11. Front border; 12. First connecting frame; 13. Back border; 14. Second connecting frame;

[0020] 21. Top wall; 22. Bottom wall; 23. Inner wall; 24. Outer wall; 25. Reinforcing section;

[0021] 30. Divider; 31. Connector; 32. First partition; 33. Second partition; 34. Third partition;

[0022] 40. Fastener; 41. First through hole; 42. Second through hole;

[0023] 50. Supporting component; 60. Buffer component; 70. Mounting beam. Embodiments of the present invention

[0024] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] As shown in Figure 1, an embodiment of this application provides a battery pack frame, which includes a front frame 11, a first connecting frame 12, a rear frame 13, and a second connecting frame 14 connected in sequence. The first connecting frame 12 and the second connecting frame 14 are used for fixed connection with external components. The front frame 11 and the rear frame 13 are both integrally stamped structures, and the first connecting frame 12 and the second connecting frame 14 are both integrally rolled structures.

[0026] By applying the technical solution of this application, the front frame 11 and the rear frame 13 are set as an integral stamping structure, and the first connecting frame 12 and the second connecting frame 14 are integral roll forming structures. Since the stamped structure has the advantages of light weight and low processing cost, it can reduce the overall weight of the battery pack frame to a certain extent, reduce production costs, and facilitate the transportation of the battery pack frame. Since the roll forming structure has the advantage of high strength, and the first connecting frame 12 and the second connecting frame 14 need to be fixedly connected to the external components, the stability of the battery pack frame after being connected to the external components can be guaranteed, thereby reducing the risk of the battery pack frame falling off the external components to a certain extent and ensuring the safety of the battery pack frame during use.

[0027] Stamping is a forming process that uses a press and dies to apply external force to sheet metal, strip, tube, and profiles, causing plastic deformation or separation to obtain the desired shape and size. Stamped parts are typically thin, uniform, lightweight, and strong. Roll forming, on the other hand, relies on the plastic movement of materials to roll them into various shapes. Roll forming deformation is a line-contact, continuous, and gradual process, requiring less deformation force. Roll-formed parts have high strength and stable quality.

[0028] As shown in Figures 2 and 3, in this application, the first connecting frame 12 and the second connecting frame 14 have the same shape. Of course, in other embodiments of this application, the structure of the first connecting frame 12 and the second connecting frame 14 can also be set to different shapes. The specific setting should be selected according to the usage environment of the device, so as to improve the applicability and scope of application of the device.

[0029] Meanwhile, the front frame 11, the first connecting frame 12, the rear frame 13, and the second connecting frame 14 in this application undergo surface treatment using electrophoresis, and after electrophoresis, they are connected to the separator 30 in this application to form a box. Electrophoresis is a technique that utilizes the different speeds of charged particles moving in an electric field to separate charged particles. During electrophoresis, charged particles move towards the electrode with the opposite charge under the influence of an electric field. In industrial production, electrophoresis technology is mainly used for coating. Electrophoretic coating is a common coating process that uses an electric field to deposit charged particles onto the surface of a conductive material. This coating method has advantages such as uniform coating thickness, strong adhesion, and good coating quality, and is particularly suitable for coating complex-shaped workpieces. This avoids corrosion of the steel frame, ensuring not only the integrity of the frame's appearance but also extending its service life.

[0030] Specifically, the frame in this application is made of high-strength steel, such as 780DP or higher strength steel, thus ensuring the structural strength of the frame as much as possible. At the same time, the front frame 11, the first connecting frame 12, the rear frame 13 and the second connecting frame 14 are connected by resistance spot welding, laser welding or sealant.

[0031] Furthermore, both the first connecting frame 12 and the second connecting frame 14 include a top wall 21, an outer wall 24, a bottom wall 22, and an inner wall 23 that are sequentially formed and connected to each other by roll forming. The top wall 21, bottom wall 22, inner wall 23, and outer wall 24 cooperate to form a cavity. Since the cavity has a relatively simple structure, high strength, good rigidity, and is not easily deformed, it can improve the structural strength of the first connecting frame 12 and the second connecting frame 14 and ensure the structural stability of the first connecting frame 12 and the second connecting frame 14.

[0032] Furthermore, the portion of the outer sidewall 24 near the bottom wall 22 protrudes toward the side away from the inner sidewall 23 to form a boss structure.

[0033] Specifically, the thickness of the top wall 21, bottom wall 22, inner side wall 23, and outer side wall 24 is H, where 1mm ≤ H ≤ 2mm. When H < 1mm, the thickness of the top wall 21, bottom wall 22, inner side wall 23, and outer side wall 24 is too thin, resulting in low structural strength of the component and failing to meet the usage requirements of the device. When H > 2mm, the thickness of the top wall 21, bottom wall 22, inner side wall 23, and outer side wall 24 is too thick, which not only increases the material required for production, leading to increased production costs, but also increases the overall weight of the component, making assembly and transportation difficult. Therefore, setting the thickness to 1mm ≤ H ≤ 2mm not only ensures the structural strength of the component to meet user requirements but also avoids the disadvantages of excessive production costs and excessive overall weight.

[0034] In this application, H can be set to other values such as 1 mm, 1.5 mm or 2 mm, as long as it can meet the usage requirements of the device.

[0035] Furthermore, there is a reinforcing portion 25 between the inner wall 23 and the outer wall 24. Both ends of the reinforcing portion 25 are respectively connected to one side of the inner wall 23 close to the outer wall 24 and one side of the outer wall 24 close to the inner wall 23. The extending direction of the reinforcing portion 25 is the same as the extending direction of the top wall 21. With this setting, not only is the space between the inner wall 23 and the outer wall 24 reasonably utilized, but also during the use of the device, the inner wall 23 and the outer wall 24 can be supported by the reinforcing rib, and the structural strength between the inner wall 23 and the outer wall 24 can also be improved to ensure the stability during the use of the device.

[0036] In this application, the width of the reinforcing portion 25 is the same as the width of the top wall 21. Of course, in other embodiments of this application, the width of the reinforcing portion 25 can also be adjusted according to strength requirements. At the same time, the cross-sectional shapes of the first connecting frame 12 and the second connecting frame 14 are L-shaped. Optionally, the cross-sectional shapes of the first connecting frame 12 and the second connecting frame 14 can also be set to other shapes such as a square shape with a vertical bar in the middle, a rectangular shape with a horizontal bar in the middle or a T-shaped, as long as it can meet the usage requirements of the device.

[0037] As shown in FIGS. 4 to 6, furthermore, the battery pack frame further includes a separator 30. The front frame 11, the first connecting frame 12, the rear frame 13 and the second connecting frame 14 together enclose a receiving portion. The separator 30 is disposed in the receiving portion and divides the receiving portion into multiple receiving sub-portions for receiving battery modules. With this setting, it can prevent the battery modules in multiple receiving sub-portions from interfering with other battery modules when expanding, so the stability during the operation of the device can be ensured.

[0038] Among them, the material of the separator 30 includes aluminum.

[0039] Furthermore, the separator 30 includes a connecting member 31 extending along the length direction of the first connecting frame 12; a first blocking portion 32 disposed at one end of the connecting member 31 and extending along the length direction of the rear frame 13; a second blocking portion 33 disposed at the other end of the connecting member 31 and extending along the length direction of the rear frame 13; a third blocking portion 34 disposed in the middle of the connecting member 31 and extending along the length direction of the rear frame 13. Among them, both ends of the first blocking portion 32, the second blocking portion 33 and the third blocking portion 34 are fixedly connected to the first connecting frame 12 and the second connecting frame 14 respectively.

[0040] In the present application, the separator 30 has a "king" - shaped structure, and the third partition portion 34 is a split structure and is symmetrically arranged on both sides of the connecting member 31 along the length direction of the rear frame 13. This not only facilitates the disassembly and assembly of the components but also meets the installation requirements of the battery module. Of course, in other embodiments of the present application, the separator 30 can also be set to other shapes, such as a "field" - shaped structure, as long as it can meet the usage requirements of the device.

[0041] Furthermore, the separator 30 further includes a fixing member 40. The first partition portion 32 and the connecting member 31 and the second partition portion 33 and the connecting member 31 are fixedly connected through the fixing member 40. In the application, the fixing member 40 is a T - shaped connection terminal. After the above - mentioned structure fixes the first partition portion 32 and the connecting member 31 and the second partition portion 33 and the connecting member 31, the T - shaped connection terminal will overlap on the side walls of the first partition portion 32 and the second partition portion 33. Therefore, it can increase the contact area between the two and improve the connection strength after fixation.

[0042] Of course, in other embodiments of the present application, the fixing member 40 can also be set as a fastening bolt, etc., as long as it can meet the fixing requirements of the device.

[0043] Furthermore, one side of the first partition portion 32 and / or the second partition portion 33 facing the front frame 11 has a first through - hole 41. The first through - hole 41 extends along the length direction of the first connection frame 12. The connecting member 31 has a second through - hole 42 arranged in alignment with the first through - hole 41. The fixing member 40 is穿设连接(这里中文原文可能有误,推测是“穿设连接”,英文可表述为“passes through and connects with”) with the first through - hole 41 and the second through - hole 42 to fixedly connect the first partition portion 32 and / or the second partition portion 33 and the connecting member 31.

[0044] As shown in FIGS. 7 and 8, furthermore, the battery pack frame further includes a receiving member 50. The first partition portion 32, the second partition portion 33, and the third partition portion 34 and the first connection frame 12 and the second connection frame 14 are fixedly connected through the receiving member 50. With this setting, it can ensure the stability when the first partition portion 32, the second partition portion 33, and the third partition portion 34 are connected to the first connection frame 12 and the second connection frame 14, thereby尽可能地提高(这里中文原文可能有误,推测是“尽可能地提高”,英文可表述为“maximally improve”) the connection strength between the components.

[0045] In the present application, the cross - section of the receiving member 50 in the height direction of the rear frame 13 is U - shaped, and the opening of the receiving member 50 faces the top of the first connection frame set. The receiving member 50 has mounting holes, and the first partition portion 32, the second partition portion 33, and the third partition portion 34 have through - holes at the positions corresponding to the mounting holes of their respective receiving members 50. This facilitates the external fixing member 40 to fixedly connect the two. In the present application, the external fixing member 40 is a bolt. The above - mentioned structure is simple and easy to process. It can not only reduce the production cost of the device but also facilitate disassembly and assembly, thereby improving the disassembly and assembly efficiency of the device.

[0046] Furthermore, the battery pack frame also includes a buffer 60. The first partition 32, the second partition 33 and the third partition 34 are all provided with buffers 60 between the first partition 32, the second partition 33 and the third partition 34 and the receiving member 50 [a1]. The buffers 60 are used to fill the gaps between the first partition 32, the second partition 33 and the third partition 34 and the receiving member 50.

[0047] In this application, the buffer 60 is specifically a structural adhesive. Because structural adhesive has very high strength, it possesses good peel resistance and impact resistance. Its compressive strength can reach 65 MPa, its steel-to-steel tensile bond strength is 30 MPa, and its shear strength is 18 MPa. These properties enable the structural adhesive to withstand large loads and maintain stable performance throughout its expected lifespan.

[0048] Meanwhile, structural adhesives have good fatigue resistance and corrosion resistance, so they can be used as a barrier layer to reduce or even eliminate electrochemical corrosion problems between different metals. In addition, the application process of structural adhesives is simple, which can improve the installation efficiency of components.

[0049] Secondly, embodiments of this application provide a battery pack, which further includes: the aforementioned battery pack frame; a base plate connected to the bottom of the front frame 11, the first connecting frame 12, the rear frame 13, and the second connecting frame 14, wherein the base plate and the battery pack frame cooperate to form a receiving cavity; and a battery module disposed within the receiving cavity.

[0050] By applying the technical solution of this application, the front frame 11 and the rear frame 13 are set as an integral stamping structure, and the first connecting frame 12 and the second connecting frame 14 are integral roll forming structures. Since the stamped structure has the advantages of light weight and low processing cost, it can reduce the overall weight of the battery pack frame to a certain extent, reduce production costs, and facilitate the transportation of the battery pack frame. Since the roll forming structure has the advantage of high strength, and since the first connecting frame 12 and the second connecting frame 14 need to be fixedly connected to the external components, the stability of the battery pack frame after being connected to the external components can be guaranteed, thereby reducing the risk of the battery pack frame falling off the external components to a certain extent and ensuring the safety of the battery pack frame during use.

[0051] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0052] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of this application. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0053] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0054] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0055] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be construed as limiting the scope of protection of this application.

[0056] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A battery pack frame, the battery pack frame comprising a front frame, a first connecting frame, a rear frame, and a second connecting frame connected sequentially from end to end; in, Both the front frame and the rear frame are integrally stamped structures, and both the first connecting frame and the second connecting frame are integrally rolled structures.

2. The battery pack frame according to claim 1, wherein, The first connecting frame and / or the second connecting frame includes a top wall, a bottom wall, an inner side wall, and an outer side wall that are connected to each other. The outer side wall is connected to the external component. The top wall, the bottom wall, the inner side wall, and the outer side wall cooperate to form a cavity.

3. The battery pack frame according to any one of claims 1-2, wherein, The portion of the outer sidewall near the bottom wall protrudes toward the side away from the inner sidewall to form a boss structure.

4. The battery pack frame according to any one of claims 1-2, wherein, The thickness of the top wall, the bottom wall, the inner side wall, and the outer side wall is all H, where 1mm ≤ H ≤ 2mm.

5. The battery pack frame according to any one of claims 1-2, wherein, A reinforcing portion is provided between the inner sidewall and the outer sidewall. One end of the reinforcing portion is connected to the side of the inner sidewall near the outer sidewall, and the other end of the reinforcing portion is connected to the side of the outer sidewall near the inner sidewall. The extending direction of the reinforcing portion is the same as the extending direction of the top wall.

6. The battery pack frame according to any one of claims 1-5, wherein, The battery pack frame also includes a separator. The front frame, the first connecting frame, the rear frame, and the second connecting frame together enclose a receiving portion. The separator is disposed within the receiving portion and divides the receiving portion into multiple receiving sub-parts. The receiving sub-parts are used to receive the battery module.

7. The battery pack frame according to claim 6, wherein, The separator includes: The connector extends along the length of the first connecting frame; A first partition is provided at one end of the connector near the front frame, and the first partition extends along the length direction of the rear frame. The second partition is disposed at one end of the connector near the rear frame, and the second partition extends along the length direction of the rear frame; A third partition is provided in the middle of the connector, and the third partition extends along the length direction of the rear frame. The first partition, the second partition, and the third partition are respectively fixedly connected to the first connecting frame and the second connecting frame at both ends.

8. The battery pack frame according to claim 7, wherein, The separator also includes a fixing member, wherein the first partition portion is fixedly connected to the connecting member and / or the second partition portion is fixedly connected to the connecting member through the fixing member.

9. The battery pack frame according to claim 7, wherein, The third partition is a split structure and is symmetrically arranged on both sides of the connector along the length direction of the rear frame.

10. The battery pack frame according to claim 8, wherein, The first partition and / or the second partition have a first through hole on the side facing the front frame. The first through hole extends along the length direction of the first connecting frame. The connector has a second through hole that is aligned with the first through hole. The fastener passes through and connects to the first through hole and the second through hole to fix the first partition and / or the second partition to the connector.

11. The battery pack frame according to claim 7, wherein, The battery pack frame also includes a support member, and the first partition, the second partition and the third partition are fixedly connected to the first connecting frame and the second connecting frame through the support member.

12. The battery pack frame according to claim 11, wherein, The receiving component has a U-shaped cross-section in the height direction of the rear frame, and the opening of the receiving component is positioned facing the top of the first connecting frame.

13. The battery pack frame according to claim 11, wherein, The battery pack frame also includes a buffer member. The first partition, the second partition, and the third partition, as well as the receiving member, are all provided with the buffer member. The buffer member is used to fill the gap between the first partition, the second partition, and the third partition and the receiving member.

14. The battery pack frame according to claim 6, wherein, The separator is made of aluminum, and the battery pack frame is made of 780DP steel.

15. The battery pack frame according to any one of claims 1-14, wherein, The surfaces of the front frame, the first connecting frame, the rear frame, and the second connecting frame are treated with an electrophoretic process.

16. The battery pack frame according to any one of claims 1-14, wherein, The width of the reinforcing part is the same as the width of the top wall.

17. The battery pack frame according to any one of claims 1-14, wherein, The cross-sectional shape of the first connecting frame and the second connecting frame is L-shaped.

18. The battery pack frame according to any one of claims 1-14, wherein, The third partition is a split structure and is symmetrically arranged on both sides of the connector along the length direction of the rear frame.

19. The battery pack frame according to any one of claims 1-14, wherein, The buffer component is specifically structural adhesive.

20. A battery pack, the battery pack comprising: Battery pack frame as described in any one of claims 1-19; The bottom plate is connected to the bottom of the front frame, the first connecting frame, the rear frame, and the second connecting frame. The bottom plate and the battery pack frame cooperate to form a receiving cavity. The battery module is disposed within the receiving cavity.

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