Wiring structure, battery pack tray, battery pack and vehicle

Abstract

The present application discloses a wiring structure, a battery pack tray, a battery pack and a vehicle. The wiring structure comprises: a longitudinal beam, wherein the longitudinal beam is arranged on a battery pack tray in the front-back direction of a vehicle, a wiring cavity is formed in the longitudinal beam, the wiring cavity is arranged in the length direction of the longitudinal beam and used for laying wires, and two ends of the longitudinal beam in the length direction are used for allowing the wires to enter and exit the wiring cavity. In the present application, a profile having two communicated ends is used as the longitudinal beam, and the wiring cavity is arranged in the longitudinal beam and is used for laying the wires, so that the structural strength is higher, the extrusion resistance and the impact resistance are better, and the safety of a battery pack structure is significantly improved.

Description

Wiring structure, battery pack tray, battery pack, vehicle

[0001] The present application claims priority to the Chinese patent application No. 202421238097.5, filed on May 31, 2024, and entitled "Wiring structure, battery pack tray, battery pack, vehicle", the whole content of which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present application relates generally to the field of battery technology, and more particularly to a wiring structure, a battery pack tray, a battery pack, and a vehicle. BACKGROUND

[0003] The existing power battery pack electrical connection wiring scheme mainly uses a "mountain" type bracket to insulate and separate the copper bars by opening a receiving groove on the beam. This technical solution saves the space for arranging copper bars, but due to the opening at the upper end of the beam, the structural strength of the beam is reduced, and in the event of thermal runaway, the beam is difficult to resist the expansion force of the battery cell, increasing the risk of failure.

[0004] Therefore, it is necessary to provide a wiring structure, a battery pack tray, a battery pack, and a vehicle to at least partially solve the above problems.

[0005] SUMMARY

[0006] In the summary section of the application, a series of simplified concepts are introduced, which will be further described in detail in the detailed description section. The summary section of the present application does not mean to attempt to limit the key features and necessary technical features of the claimed technical solution, nor to determine the protection scope of the claimed technical solution.

[0007] To at least partially solve the above problems, the first aspect of the present application provides a wiring structure, comprising:

[0008] a longitudinal beam, the longitudinal beam is arranged on the battery pack tray along the front-rear direction of the vehicle, and the inside of the longitudinal beam is formed with a wiring cavity, the wiring cavity is arranged along the length direction of the longitudinal beam for laying wires;

[0009] both ends of the length direction of the longitudinal beam are used for the wires to enter and exit the wiring cavity.

[0010] Optionally, the wiring structure further comprises:

[0011] an insulating protective shell module, the insulating protective shell module is arranged inside the wiring cavity, and the insulating protective shell module is used for insulating and protecting the wires.

[0012] Optionally, the wiring cavity comprises:

[0013] a web plate connecting opposite two side walls of the wiring cavity;

[0014] a first cavity provided at a first side of the web plate, the insulation protection shell module being provided in the first cavity;

[0015] a second cavity provided at a second side of the web plate.

[0016] Optionally, the insulation protection shell module comprises:

[0017] a first insulation protection shell;

[0018] a second insulation protection shell;

[0019] the first insulation protection shell and the second insulation protection shell are arranged in a stacking manner along a height direction of the longitudinal beam to form an insulation protection cavity.

[0020] Optionally, the wiring structure further comprises:

[0021] a wire harness clamp module arranged in the insulation protection cavity, the wire harness clamp module comprising a plurality of limiting grooves for fixing the conductive wires.

[0022] Optionally, the wire harness clamp module comprises:

[0023] a first wire harness clamp;

[0024] a second wire harness clamp, the first wire harness clamp and the second wire harness clamp being combined by clamping to fix the conductive wires.

[0025] Optionally, the second wire harness clamp is fixedly connected with a bottom of the first insulation protection shell or a top of the second insulation protection shell, the bottom of the first insulation protection shell or the top of the second insulation protection shell being provided with a clamping hole, and the second wire harness clamp being correspondingly provided with a clamping protrusion fixedly connected with the clamping hole.

[0026] Optionally, the wiring structure further comprises:

[0027] a longitudinal beam embedding block arranged at a top of the longitudinal beam, the longitudinal beam embedding block being used for connecting other components.

[0028] Optionally, a side wall of the insulation protection shell module is provided with a clamping opening, and the insulation protection shell module is limited in the wiring cavity through the clamping opening.

[0029] Optionally, a side wall of the wiring cavity is provided with a guide protrusion, and a side wall of the insulation protection shell module is correspondingly provided with a guide groove, the insulation protection shell module being inserted into the wiring cavity, and the guide protrusion being inserted into the guide groove.

[0030] The second aspect of the present application provides a battery pack tray, comprising the wiring structure in any one of the above technical solutions.

[0031] Optionally, the battery pack tray further comprises:

[0032] a frame, the frame comprising:

[0033] a first end beam arranged on a first side of the frame along a left-right direction of the vehicle;

[0034] a second end beam arranged on a third side of the frame along the left-right direction of the vehicle,

[0035] a first side beam arranged on a second side of the frame along a front-rear direction of the vehicle, a first end of the first side beam being fixedly connected to the first end beam, and a second end of the first side beam being fixedly connected to the second end beam;

[0036] a second side beam arranged on a fourth side of the frame along the front-rear direction of the vehicle, a first end of the second side beam being fixedly connected to the first end beam, and a second end of the second side beam being fixedly connected to the second end beam.

[0037] Optionally, the longitudinal beam is arranged inside the frame along the front-rear direction of the vehicle, and a first end of the longitudinal beam is fixedly connected to the first end beam.

[0038] Optionally, the battery pack tray further comprises:

[0039] a middle cross beam arranged inside the frame along the left-right direction of the vehicle, and a second end of the longitudinal beam being fixedly connected to the middle cross beam.

[0040] Optionally, the middle cross beam is provided with a mounting groove corresponding to the longitudinal beam, the second end of the longitudinal beam being connected to the mounting groove and fixedly connected to the middle cross beam.

[0041] Optionally, a top of the mounting groove is provided with a middle cross beam embedding block, and the middle cross beam embedding block covers a slot of the mounting groove.

[0042] Optionally, the battery pack tray further comprises:

[0043] a first rear longitudinal beam arranged inside the frame along the front-rear direction of the vehicle, a first end of the first rear longitudinal beam being fixedly connected to the middle cross beam, and a second end of the first rear longitudinal beam being fixedly connected to the second end beam;

[0044] The second rear longitudinal beam is disposed inside the frame along the front-rear direction of the vehicle. The first end of the second rear longitudinal beam is connected and fixed to the middle cross beam, and the second end of the second rear longitudinal beam is connected and fixed to the second end beam.

[0045] The space between the first rear longitudinal beam and the second rear longitudinal beam constitutes a power distribution installation area. The second end of the longitudinal beam is connected to the power distribution installation area, so that the conductor can enter the power distribution installation area.

[0046] A third aspect of this application provides a battery pack, including the battery pack tray described in any of the above technical solutions.

[0047] A fourth aspect of this application provides a vehicle comprising the battery pack described in any of the above technical solutions.

[0048] According to the wiring structure and vehicle disclosed in this application, the wiring structure uses a profile connected at both ends as a longitudinal beam. The longitudinal beam has a wiring cavity inside for laying wires, which improves the structural strength of the longitudinal beam and achieves smoke and thermal isolation between the power distribution installation area, high and low voltage wiring harnesses, and the battery module. Compared with the existing open-beam structure, this structure has higher strength, better resistance to compression and impact, and significantly improves the safety of the battery pack structure. Attached Figure Description

[0049] The following drawings, illustrating embodiments of this application, are incorporated herein by reference and are used to understand this application. The drawings illustrate embodiments of this application and their descriptions, serving to explain the principles of this application. In the drawings,

[0050] Figure 1 is a perspective view of a battery pack tray according to a preferred embodiment of this application;

[0051] Figure 2 is a partial enlarged view of Figure 1;

[0052] Figure 3 is an exploded view of a battery pack tray according to a preferred embodiment of this application;

[0053] Figure 4 is a perspective view of a longitudinal beam according to a preferred embodiment of this application;

[0054] Figure 5 is an exploded view of a wire harness clip according to a preferred embodiment of this application;

[0055] Figure 6 is a transverse sectional view of a longitudinal beam according to a preferred embodiment of this application;

[0056] Figure 7 is a partial enlarged view of Figure 5;

[0057] Figure 8 is a longitudinal sectional view of a longitudinal beam according to a preferred embodiment of the present application.

[0058] Explanation of reference numerals in the attached drawings: 1: Battery pack tray; 2: Longitudinal beam; 3: First side beam; 4: Middle crossbeam; 5: Bottom guard plate; 6: First rear longitudinal beam; 7: Second end beam; 8: Second rear longitudinal beam; 9: Second side beam; 10: First end beam; 11: Middle crossbeam insert; 12: Connection channel; 13: High-voltage harness; 14: Low-voltage harness; 15: Port protection plate; 16: Welding surface; 17: Nut; 18: Insulation protection shell module; 19: Longitudinal beam insert; 20: First insulation protection shell; 21: First harness clip; 22: Second harness clip; 23: Second insulation protection shell; 24: Second cavity; 25: Guide protrusion; 26: First cavity; 27: Bayonet; 28: Harness clip module; 29: Snap-in hole; 30: Wiring cavity; 31: Rib plate; 32: Snap-in protrusion; 33: Guide groove; 34: Insulation protection cavity. Detailed Implementation

[0059] The following description provides numerous specific details to offer a more thorough understanding of this application. However, it will be apparent to those skilled in the art that this application can be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described to avoid confusion with this application.

[0060] To fully understand this application, a detailed description will be provided in the following description. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. Obviously, the implementation of the embodiments of this application is not limited to the specific details familiar to those skilled in the art. Preferred embodiments of this application are described in detail below; however, in addition to these detailed descriptions, this application may have other embodiments.

[0061] Ordinal numbers such as “first” and “second” used in this application are merely identifiers and have no other meaning, such as a specific order. Moreover, for example, the term “first component” does not imply the existence of a “second component”, and the term “second component” does not imply the existence of a “first component”.

[0062] It should be noted that the terms “upper,” “lower,” “front,” “back,” “left,” “right,” “inner,” “outer,” and similar expressions used in this application are for illustrative purposes only and are not intended to be limiting.

[0063] This application discloses a wiring structure, a battery pack tray, a battery pack, and a vehicle.

[0064] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings.

[0065] As shown in Figures 1, 2, 3, and 4, in a preferred embodiment, a wiring structure includes: a longitudinal beam 2; the longitudinal beam 2 is disposed on the battery pack tray 1 along the front-rear direction of the vehicle;

[0066] The interior of the longitudinal beam 2 is formed with a wiring cavity 30, which is arranged along the length of the longitudinal beam 2 for laying wires; there can be multiple wires, such as high voltage wire harness 13 and low voltage wire harness 14.

[0067] The wiring cavity 30 is a closed cavity with side walls, and the two ends of the longitudinal beam 2 along its length are used for the wires to enter and exit the wiring cavity 30.

[0068] The longitudinal beam 2 can be made of stainless steel or aluminum alloy and other metal materials. It is manufactured using the profile extrusion molding process. During the manufacturing process, the side wall of the longitudinal beam 2 is integral and there are no gaps. The wiring cavity 30 is a closed cavity with a side wall.

[0069] In this embodiment, the wiring structure uses a closed-section profile connected at both ends as the longitudinal beam 2. The longitudinal beam 2 has a wiring cavity 30 inside for laying wires, which improves the structural strength of the longitudinal beam 2 and achieves smoke and heat isolation between the power distribution installation area, high and low voltage wiring harnesses, and the battery module. Compared with the existing open-beam structure, this structure has higher strength, better resistance to compression and impact, and significantly improves the safety of the battery pack structure.

[0070] In one embodiment, as shown in Figures 2 and 4, the wiring structure further includes:

[0071] An insulating protective shell module 18 is disposed inside the wiring cavity 30 and is used to provide insulation protection for the wires.

[0072] The insulating protective shell module 18 protects the wires from friction with the interior of the metal longitudinal beam 2. The insulating protective shell module 18 is typically made of plastic using injection molding or vacuum forming processes, offering low cost, good insulation, and the ability to be fabricated into complex structures. The insulating protective shell module 18 isolates the high-voltage harness 13 and low-voltage harness 14 from the inner wall of the metal longitudinal beam 2, preventing damage to the outer sheath caused by friction between the harnesses and the metal inner wall of the longitudinal beam 2 during vehicle operation, thus avoiding the risk of leakage or arcing.

[0073] In one embodiment, as shown in Figures 4 and 6, the wiring cavity 30 includes:

[0074] Rib plate 31, rib plate 31 connects the two opposite side walls of wiring cavity 30;

[0075] The first cavity 26 is disposed on the first side of the stiffener 31, and the insulating protective shell module 18 is disposed in the first cavity 26.

[0076] The second cavity 24 is located on the second side of the stiffening plate 31.

[0077] The stiffening rib 31 can be integrally formed with the side wall of the longitudinal beam 2. By setting the stiffening rib 31, the strength of the longitudinal beam 2 can be improved. The number of stiffening ribs 31 can also be varied, for example, more than two stiffening ribs 31 can be set. The internal space of the longitudinal beam 2 can be flexibly arranged by changing the position and number of stiffening ribs 31 in the wiring cavity 30. In addition, when it is necessary to withstand greater expansion force, increasing the number of stiffening ribs 31 in the wiring cavity 30 can further improve the strength of the longitudinal beam 2. At the same time, the enclosed space outside the wire harness can also be designed as an exhaust channel in case of thermal runaway. For example, the second cavity 24 can be used as an exhaust channel in case of thermal runaway, or it can be used to set up a coolant pipe. The coolant pipe connects to the power distribution integrated module in the power distribution installation area to provide coolant to the power distribution integrated module.

[0078] In one embodiment, as shown in FIG2, a port protection plate 15 is provided at the cavity opening of the first cavity 26 near the power distribution installation area. The port protection plate 15 is welded and fixed to the longitudinal beam 2. The port protection plate 15 can be used to close part of the first cavity 26.

[0079] In one embodiment, as shown in Figures 4, 5, and 6, the insulating protective shell module 18 includes:

[0080] The first insulating protective shell 20 is disposed in the wiring cavity 30;

[0081] The second insulating protective shell 23 is disposed in the wiring cavity 30;

[0082] The first insulating protective shell 20 and the second insulating protective shell 23 are stacked along the height direction of the longitudinal beam 2 to form an insulating protective cavity 34.

[0083] By setting the insulating protective shell module 18 as a split structure, it is convenient to set the wires and wire harness clamp module 28 inside the insulating protective shell module 18. When the insulating protective shell module 18 is installed into the wiring cavity 30, the first insulating protective shell 20 and the second insulating protective shell 23 can also be installed into the wiring cavity 30 in different orders. The first insulating protective shell 20 and the second insulating protective shell 23 are superimposed and combined in the wiring cavity 30.

[0084] In one embodiment, as shown in Figures 6, 7, and 8, the wiring structure further includes:

[0085] The wire harness clamp module 28 is disposed in the insulation protection cavity 34, that is, between the first insulation protection shell 20 and the second insulation protection shell 23. The wire harness clamp module 28 includes multiple limiting grooves, which are used to fix the wires.

[0086] By setting up the wire harness clamp module 28, the high and low voltage wire harnesses are fixed inside the insulation protection shell module 18, which facilitates the installation of high and low voltage wire harnesses; it can also install the high and low voltage wire harnesses and the insulation protection shell module 18 into the wiring cavity 30 simultaneously.

[0087] In one embodiment, as shown in Figures 6, 7, and 8, the wire harness clip module 28 includes:

[0088] First wire harness clip 21;

[0089] The second wire harness clamp 22 is snapped together with the first wire harness clamp 21 and the second wire harness clamp 22 to hold and fix the wires, limit the position of each wire harness, and prevent the wire harnesses from moving around and interfering with each other during vehicle operation.

[0090] By designing the wire harness clamp module 28 as a split structure, it is convenient to install wires inside the wire harness clamp module 28. The first wire harness clamp 21 and the second wire harness clamp 22 are each provided with multiple limiting slots, and each limiting slot can hold one wire. The wire can be snapped into the limiting slot, providing temporary fixation. As shown in Figures 2 and 7, the high-voltage wire harness 13 can be fixed in the limiting slot of the first wire harness clamp 21, and the low-voltage wire harness 14 can be fixed in the limiting slot of the second wire harness clamp 22.

[0091] In one embodiment, as shown in Figures 6, 7, and 8, the second wire harness clip 22 is connected and fixed to the bottom of the first insulating protective shell 20 or the top of the second insulating protective shell 23. The bottom of the first insulating protective shell 20 or the top of the second insulating protective shell 23 is provided with a snap-fit ​​hole 29, and the second wire harness clip 22 is correspondingly provided with a snap-fit ​​protrusion 32, which is connected and fixed to the snap-fit ​​hole 29.

[0092] The snap-fit ​​protrusion 32 in Figure 7 is equipped with a spring arm structure. Squeezing the spring arm structure inserts the snap-fit ​​protrusion 32 into the snap-fit ​​hole 29. Releasing the spring arm structure allows it to be connected and fixed to the snap-fit ​​hole 29, which is convenient for installation. Moreover, the snap-fit ​​protrusion 32 will not easily detach from the snap-fit ​​hole 29, ensuring that the wire harness clamp module 28 can be stably fixed inside the insulating protective shell module 18.

[0093] In one embodiment, the upper and lower surfaces of the metal longitudinal beam 2 can be thickened to allow for the addition of adhesive grooves or bolted structures. In the battery pack tray 1, the adhesive grooves or bolted structures can enhance the connection strength between the longitudinal beam 2 and the bottom plate or top cover of the battery pack tray 1. As shown in Figures 6 and 8, the wiring structure also includes:

[0094] The longitudinal beam insert 19 is located on the top of the longitudinal beam 2 and is used to connect other components. The metal longitudinal beam insert 19 is welded to the top of the metal longitudinal beam 2 by slotting it, and the thread structure is machined on the metal longitudinal beam insert 19 to cooperate with the nut 17 to achieve bolting.

[0095] The top of the longitudinal beam 2 has a large thickness, which also allows for slotting on the top of the longitudinal beam 2 to provide a channel for the bridging of wire harnesses or copper busbars between battery modules.

[0096] In one embodiment, as shown in Figures 5 and 8, the side wall of the insulating protective shell module 18 is provided with a latch 27, which limits the insulating protective shell module 18 within the wiring cavity 30. The side wall of the wiring cavity 30 may be provided with an inwardly protruding tenon. During the insertion of the insulating protective shell module 18 into the wiring cavity 30, when the latch 27 engages with the tenon, the insulating protective shell module 18 is inserted into the predetermined position, and at this time, the insulating protective shell module 18 does not need to be moved further.

[0097] In one embodiment, as shown in Figures 4, 5, and 6, the sidewall of the wiring cavity 30 is provided with a guide protrusion 25, and the sidewall of the insulating protective shell module 18 is provided with a corresponding guide groove 33. The insulating protective shell module 18 is inserted into the wiring cavity 30, and the guide protrusion 25 is inserted into the guide groove 33.

[0098] The sidewalls of the first insulating protective shell 20 and the second insulating protective shell 23 are provided with guide grooves 33, and the sidewalls of the wiring cavity 30 are provided with two sets of upper and lower guide protrusions 25. During the process of inserting the insulating protective shell module 18 into the wiring cavity 30, the guide protrusions 25 are inserted into the guide grooves 33, and the first insulating protective shell 20 and the second insulating protective shell 23 can move along the guide protrusions 25.

[0099] By setting the guide protrusion 25 and the guide groove 33, the first insulating protective shell 20 and the second insulating protective shell 23 can be limited, so that the first insulating protective shell 20 and the second insulating protective shell 23 maintain a relative combined position in the wiring cavity 30.

[0100] During wiring installation, a tooling fixture can be used to fix the second insulating protective shell 23. The second wire harness clamp 22 is then pressed into the snap-fit ​​hole 29 on the second insulating protective shell 23 via its built-in bayonet protrusion 32 to complete the installation with the second insulating protective shell 23. After installing five low-voltage wire harnesses 14 above the second wire harness clamp 22, it is inverted with the first wire harness clamp 21. The low-voltage wire harnesses 14 on the second wire harness clamp 22 are then installed with the three high-voltage wire harnesses 13 in the upper limiting groove of the first wire harness clamp 21 using a tooling fixture. The wire harness clamp module is then assembled using the snap-fit ​​at both ends of the second wire harness clamp 22. Finally, after reversing the orientation, the installed protective shell and wire harness clamp are pushed together into the wiring cavity 30. The wire harness installation in this scheme can be completed from top to bottom by a robotic arm, achieving automation and significantly improving assembly efficiency. When replacing wire harnesses, the insulating protective shell module 18 can be pulled out entirely from the port connecting the longitudinal beam 2 to the outside of the battery pack for replacement. Wire harness maintenance within the longitudinal beam 2 is also more convenient.

[0101] As shown in Figures 1 and 3, an embodiment of this application also provides a battery pack tray 1, which includes the wiring structure described in any of the above embodiments.

[0102] The battery pack tray 1 includes a top cover, a frame, and a bottom cover 5. The frame is located at the edge of the battery pack tray 1 and can be designed as a rectangle or other suitable shape. The frame, combined with the bottom cover 5 and the top cover, constitutes the main structure of the battery pack tray 1.

[0103] The bottom protective plate 5 supports the battery cell module on one hand, and can also form a cooling mechanism for the battery cell module on the other hand.

[0104] The top cover seals the cell mounting area and the power distribution mounting area. After assembling the power distribution integration module and cell modules in battery pack tray 1, the top cover is then assembled to complete the sealing of the battery pack.

[0105] In one embodiment, as shown in Figures 1 and 3, the border includes:

[0106] The first end beam 10 is disposed on the first side of the frame along the left-right direction of the vehicle.

[0107] The second end beam 7 is located on the third side of the frame along the left-right direction of the vehicle.

[0108] The first side beam 3 is set on the second side of the frame along the front-rear direction of the vehicle. The first end of the first side beam 3 is connected and fixed to the first end beam 10, and the second end of the first side beam 3 is connected and fixed to the second end beam 7.

[0109] The second side beam 9 is located on the fourth side of the frame along the front-rear direction of the vehicle. The first end of the second side beam 9 is connected and fixed to the first end beam 10, and the second end of the second side beam 9 is connected and fixed to the second end beam 7.

[0110] The first end beam 10, the first side beam 3, the second end beam 7, and the second side beam 9 are connected end to end to form a rectangular frame, which forms the main load-bearing structure of the battery pack tray 1. This can strengthen the external strength of the battery pack tray 1 and improve its impact resistance.

[0111] In one embodiment, the longitudinal beam 2 is disposed inside the frame along the front-rear direction of the vehicle, and the first end of the longitudinal beam 2 is connected and fixed to the first end beam 10.

[0112] In one embodiment, the battery pack tray 1 further includes:

[0113] The middle crossbeam 4 is located inside the frame along the left-right direction of the vehicle and is located at the second end of the longitudinal beam 2. The second end of the longitudinal beam 2 is connected and fixed to the middle crossbeam 4, which can be fixed by welding.

[0114] The two ends of the middle crossbeam 4 can be welded and fixed to the first side beam 3 and the second side beam 9 respectively.

[0115] Connectors can be installed on the first end beam 10. The wiring harness connects from the power distribution installation area to the connector on the first end beam 10 through the wiring cavity 30 inside the longitudinal beam 2, saving space for wiring harness arrangement and improving the space utilization rate within the battery pack. The longitudinal beam 2 is connected to the intermediate crossbeam 4 and the first end beam 10 by welding, providing sealing and thermal isolation for the wiring harness and improving the safety of the power distribution installation area in the event of thermal runaway of the battery module.

[0116] In one embodiment, as shown in Figures 1 and 2, the intermediate crossbeam 4 is provided with an installation groove corresponding to the longitudinal beam 2. The second end of the longitudinal beam 2 is connected to the installation groove and fixed to the intermediate crossbeam 4. Specifically, it can be fixed by welding. As shown in Figure 2, the welding surface 16 is the welding position. The welding surface 16 is located inside the power distribution installation area, which can ensure both the connection strength between the longitudinal beam 2 and the intermediate crossbeam 4 and the sealing of the connection.

[0117] The end of the longitudinal beam 2 can be placed in the mounting groove, or a small portion of it can protrude from the mounting groove.

[0118] In one embodiment, as shown in Figures 1 and 2, a middle crossbeam insert 11 is provided at the top of the mounting groove, and the middle crossbeam insert 11 covers the opening of the mounting groove. The middle crossbeam insert 11 can be welded and fixed to the middle crossbeam 4 and the longitudinal beam 2.

[0119] When a vehicle is subjected to a side impact, the side impact force is transmitted along the direction of the intermediate crossbeam 4. The intermediate crossbeam insert 11 and the metal longitudinal beam 2, as rigid materials, provide support, significantly reducing the risk of bending in the middle of the intermediate crossbeam 4 during a side collision. This allows the metal longitudinal beam 2 to connect to the power distribution installation area while passing through the intermediate crossbeam 4, without causing significant damage to the structural strength of the intermediate crossbeam 4. It should be noted that the connection channel 12 below the intermediate crossbeam insert 11 can be used for the passage of connecting wires between the battery module and the power distribution installation area. A sealing device in the connection channel 12 can achieve smoke isolation between the battery module and the power distribution installation area.

[0120] Optionally, as shown in Figures 1 and 3, the battery pack tray 1 further includes:

[0121] The first rear longitudinal beam 6 is set inside the frame along the front-rear direction of the vehicle. The first end of the first rear longitudinal beam 6 is connected and fixed to the middle cross beam 4, and the second end of the first rear longitudinal beam 6 is connected and fixed to the second end beam 7. Specifically, it can be fixed by welding.

[0122] The second rear longitudinal beam 8 is set inside the frame along the front-rear direction of the vehicle. The first end of the second rear longitudinal beam 8 is connected and fixed to the middle cross beam 4, and the second end of the second rear longitudinal beam 8 is connected and fixed to the second end beam 7. Specifically, it can be fixed by welding.

[0123] The space between the first rear longitudinal beam 6 and the second rear longitudinal beam 8 constitutes the power distribution installation area. The second end of the longitudinal beam 2 is connected to the power distribution installation area, allowing the conductors to enter the power distribution installation area.

[0124] The power distribution installation area is used to accommodate the power distribution integrated module, which can integrate, but is not limited to, battery control module, electronic control module, compressor control module and power supply module, thereby improving the integration of the battery pack. The high integration can realize the integrated control of multiple modules, which facilitates the installation and use of the power distribution integrated module and realizes the cost reduction and weight reduction of the vehicle.

[0125] Embodiments of this application also provide a battery pack, including the battery pack tray 1 described in any of the above embodiments.

[0126] Figure 1 only shows the battery pack tray 1. The battery pack also includes components such as the power distribution integration module and the cell module, which are not shown in the figure.

[0127] An embodiment of this application also includes a vehicle comprising the battery pack described in any of the above embodiments.

[0128] The wiring structure, battery pack tray, battery pack, and vehicle disclosed in this application have the following features:

[0129] 1. The extruded longitudinal beam 2 forms a closed cavity structure inside, which is stronger than the open beam structure at the top, and has better resistance to extrusion and impact, making the battery pack structure safer.

[0130] 2. The cavity of the metal longitudinal beam 2 completely encloses the wire harness, avoiding direct contact between the insulation structure and the module. In the event of thermal runaway, it can effectively prevent the fire from spreading to the wire harness and isolate the smoke.

[0131] 3. The longitudinal beam 2 can be connected to the power distribution installation area by welding, which effectively retards flames and provides better airtightness, thus preventing electrolyte gas from entering the power distribution installation area and causing arcing in the event of thermal runaway.

[0132] 4. The spatial arrangement of profiles can be made more flexible by changing the structural position of stiffener 31. The use of insulating protective shell and wire harness clamp can not only arrange copper busbars, but also arrange high and low voltage wire harnesses.

[0133] 5. Through the insulating protective shell module 18 and wire harness clamp module 28 designed in this application, high and low voltage wire harnesses can be isolated when arranging wire harnesses, and the risk of insulation failure caused by the high voltage wire harness 13 moving around during vehicle operation and friction with the inner wall of the metal longitudinal beam 2 can be effectively avoided.

[0134] 6. The longitudinal beam 2 cavity can be reinforced with stiffening plates 31 to improve structural strength, depending on the application scenario.

[0135] 7. The top and bottom surfaces of longitudinal beam 2 can be thickened to allow for the addition of fasteners such as glue grooves or bolts to enhance the connection with the base plate, top cover, etc.

[0136] 8. Wiring harness replacement within longitudinal beam 2 is more convenient. Since the enclosed metal beam prevents wiring harness installation from top to bottom, this solution involves pre-inserting the wiring harness into the wiring harness clamp and then securing the clamp within the insulating protective shell. During installation, the protective shell is pushed into the profile cavity to complete the process. When replacing the wiring harness, simply pull out the entire protective shell from the port connecting the longitudinal beam to the battery pack perimeter to replace the harness.

[0137] 9. The separate insulating protective shell module 18 and the separate wire harness clamp module 28 designed in this application can realize the automation of the installation of insulating protective shell, wire harness clamp, and high and low voltage wire harness, thereby improving work efficiency.

[0138] 10. The split-type insulating protective shell module 18 and the wire harness clamp module 28 can be processed by extrusion and injection molding respectively. The technology is mature and the processing cost is low.

[0139] The processes and steps described in all the preferred embodiments above are merely examples. Unless adverse effects occur, various processing operations can be performed in a different order than those described above. The order of steps in the above process can also be added, combined, or deleted according to actual needs.

[0140] In understanding the scope of this application, the term "comprising" and its derivatives, as used herein, are intended to be open-ended terms that specify the presence of a described feature, element, component, group, whole, and / or step, but do not exclude the presence of other undescribed features, elements, components, groups, wholes, and / or steps. This concept also applies to words with similar meanings, such as the terms "comprising," "having," and their derivatives.

[0141] The term "attached" or "joined" as used herein includes: a construction in which one element is directly fixed to another element by fixing it directly to another element; a construction in which one element is indirectly fixed to another element by fixing it to an intermediate member, which in turn is fixed to another element; and a construction in which one element is integral with another element, that is, one element is substantially part of another element. This definition also applies to words with similar meanings, such as "connect," "joint," "couple," "install," "adhere," "fix," and their derivatives. Finally, degree terms such as "substantially," "approximately," and "approximately" as used herein indicate the amount of deviation from which modifications to the terminology do not significantly alter the final result.

[0142] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for descriptive purposes only and is not intended to limit the scope of this application. Features described in one embodiment may be applied, alone or in combination with other features, to another embodiment, unless that feature is not applicable in that other embodiment or is otherwise stated.

[0143] This application has been described through the above embodiments. However, it should be understood that the above embodiments are for illustrative purposes only and are not intended to limit this application to the described embodiments. Furthermore, those skilled in the art will understand that this application is not limited to the above embodiments, and many more variations and modifications can be made based on the teachings of this application, all of which fall within the scope of protection claimed in this application.

Claims

A wiring structure, wherein, Comprising: a longitudinal beam (2) arranged on a battery pack tray (1) along the front-rear direction of a vehicle, an inside of the longitudinal beam (2) being formed with a wiring cavity (30) arranged along the length direction of the longitudinal beam (2) for laying a wire; two ends of the length direction of the longitudinal beam (2) being used for the wire to enter and exit the wiring cavity (30). The wiring structure according to claim 1, wherein Further comprising: an insulation protection shell module (18) arranged inside the wiring cavity (30), the insulation protection shell module (18) being used for insulating and protecting the wire. The wiring structure according to claim 2, wherein The wiring cavity (30) comprises: a rib plate (31) connecting two opposite side walls of the wiring cavity (30); a first type cavity (26) arranged on a first side of the rib plate (31), the insulation protection shell module (18) being arranged in the first type cavity (26); a second type cavity (24) arranged on a second side of the rib plate (31). The wiring structure according to claim 2, wherein The insulation protection shell module (18) comprises: a first insulation protection shell (20); a second insulation protection shell (23); the first insulation protection shell (20) and the second insulation protection shell (23) being arranged in a stacking manner along the height direction of the longitudinal beam (2) to form an insulation protection cavity (34). The wiring structure according to claim 4, wherein Further comprising: a wire harness clamp module (28) arranged in the insulation protection cavity (34), the wire harness clamp module (28) comprising a plurality of limiting grooves for fixing the wire. The wiring structure according to claim 5, wherein The wire harness clamp module (28) comprises: a first wire harness clamp (21); a second wire harness clamp (22), the first wire harness clamp (21) and the second wire harness clamp (22) being clamped and combined to clamp and fix the wire. The wiring structure according to claim 6, wherein The second wire harness clamp (22) is connected and fixed with the bottom of the first insulation protection shell (20) or the top of the second insulation protection shell (23), the bottom of the first insulation protection shell (20) or the top of the second insulation protection shell (23) being provided with a buckle hole (29), the second wire harness clamp (22) being correspondingly provided with a clamping protrusion (32), the clamping protrusion (32) being connected and fixed with the buckle hole (29). The wiring structure according to claim 7, wherein Further comprising: a longitudinal beam embedding block (19) arranged on the top of the longitudinal beam (2), the longitudinal beam embedding block (19) being used for connecting other components. The wiring structure according to claim 2, wherein A side wall of the insulation protection shell module (18) is provided with a bayonet (27), the insulation protection shell module (18) being limited in the wiring cavity (30) through the bayonet (27). The wiring structure according to claim 9, wherein A side wall of the wiring cavity (30) is provided with a guide protrusion (25), a side wall of the insulation protection shell module (18) being correspondingly provided with a guide groove (33), the insulation protection shell module (18) being inserted into the wiring cavity (30), the guide protrusion (25) being inserted into the guide groove (33). A battery pack tray, wherein, Comprising the wiring structure according to any one of claims 1-10. The battery pack tray of claim 11, wherein, Further comprising: a frame, the frame comprising: A first end beam (10) is arranged on a first side of the frame in the left-right direction of the vehicle; A second end beam (7) is arranged on a third side of the frame in the left-right direction of the vehicle, A first side beam (3) is arranged on a second side of the frame in the front-rear direction of the vehicle, a first end of the first side beam (3) is fixedly connected with the first end beam (10), and a second end of the first side beam (3) is fixedly connected with the second end beam (7); A second side beam (9) is arranged on a fourth side of the frame in the front-rear direction of the vehicle, a first end of the second side beam (9) is fixedly connected with the first end beam (10), and a second end of the second side beam (9) is fixedly connected with the second end beam (7). The battery pack tray of claim 12, wherein, The longitudinal beam (2) is arranged inside the frame in the front-rear direction of the vehicle, and a first end of the longitudinal beam (2) is fixedly connected with the first end beam (10). The battery pack tray of claim 12, wherein, Further comprising: A middle cross beam (4) is arranged inside the frame in the left-right direction of the vehicle, and a second end of the longitudinal beam (2) is fixedly connected with the middle cross beam (4). The battery pack tray of claim 14, wherein, The middle cross beam (4) is provided with a mounting groove corresponding to the longitudinal beam (2), the second end of the longitudinal beam (2) is connected with the mounting groove and fixedly connected with the middle cross beam (4). The battery pack tray of claim 15, wherein, A top of the mounting groove is provided with a middle cross beam embedding block (11) covering the slot of the mounting groove. The battery pack tray of claim 14, wherein, Further comprising: A first rear longitudinal beam (6) is arranged inside the frame in the front-rear direction of the vehicle, a first end of the first rear longitudinal beam (6) is fixedly connected with the middle cross beam (4), and a second end of the first rear longitudinal beam (6) is fixedly connected with the second end beam (7); A second rear longitudinal beam (8) is arranged inside the frame in the front-rear direction of the vehicle, a first end of the second rear longitudinal beam (8) is fixedly connected with the middle cross beam (4), and a second end of the second rear longitudinal beam (8) is fixedly connected with the second end beam (7); A space between the first rear longitudinal beam (6) and the second rear longitudinal beam (8) constitutes a power distribution mounting area, and the second end of the longitudinal beam (2) is in communication with the power distribution mounting area, so that the wire can enter the power distribution mounting area. A battery pack, wherein, The battery pack tray (1) according to any one of claims 11-17. A vehicle, wherein, The battery pack according to claim 18.

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