Battery pack structure

Abstract

A battery pack structure. The battery pack structure comprises: a housing, wherein the housing has a first cavity configured for mounting a battery module, and a second cavity provided on one side of the first cavity in a first direction; and a BMS and a BDU, wherein the BDU is provided in the second cavity, and the BMS is provided on the outer side of the second cavity and is connected to a bottom plate of the housing. In the battery pack structure, the BMS is provided on the outer bottom surface of the housing, so that when the BMS requires maintenance, the battery pack structure does not need to be disassembled, and the BMS on the outside of the housing can be directly maintained, thereby simplifying the overall maintenance operation, saving time and labor, and improving the maintenance efficiency.

Description

Battery pack structure

[0001] This application claims priority to Chinese Patent Application No. 2024221073196, filed with the Chinese Patent Office on August 28, 2024, the entire contents of which are incorporated herein by reference. Technical Field

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

[0003] The Battery Management System (BMS) and Battery Distribution Unit (BDU) are crucial components of the battery system in new energy electric vehicles. Within the battery system, the BMS and BDU work collaboratively. The BMS monitors the battery status and issues control commands, while the BDU, based on these commands, rationally distributes and controls power to ensure the stable and safe operation of the entire battery system. The BMS also requires rigorous testing to ensure its quality and integrity, including simulating battery behavior and testing responses under different conditions. Technical issues

[0004] Traditional BMS repair designs typically require disassembling the battery pack and opening its cover to access the internal BMS. However, disassembling the battery pack is a complex process, especially when it is mounted on the vehicle body. The battery pack itself is quite heavy, making this method of disassembling the battery pack for BMS repair complicated, time-consuming, and labor-intensive.

[0005] As can be seen from the above, the current battery packs have the problem of inconvenience in operation due to the need to disassemble the battery pack during BMS maintenance. Technical solutions

[0006] In a first aspect, this application provides a battery pack structure, the battery pack structure including a housing, the housing having a first cavity configured to install a battery module, and a second cavity disposed along a first direction on one side of the first cavity; a BMS and a BDU, the BDU being disposed inside the second cavity, and the BMS being disposed outside the second cavity and connected to the bottom plate of the housing. Beneficial effects

[0007] The beneficial effects provided by this application are as follows: By applying the technical solution of this application, the battery pack structure of this application adopts a configuration where the BMS is placed on the bottom surface of the outer casing. This allows for direct maintenance of the externally mounted BMS without disassembling the battery pack structure, simplifying the overall maintenance operation, saving time and effort, and improving maintenance efficiency. The externally mounted BMS structure of this application avoids the complex operations associated with related technologies that require disassembling the battery pack to maintain the internal BMS. Attached Figure Description

[0008] Figure 1 shows a three-dimensional structural schematic diagram of one of the battery pack structures of this application;

[0009] Figure 2 shows another three-dimensional structural diagram of the battery pack structure of this application;

[0010] Figure 3 shows a three-dimensional structural diagram of the battery pack structure of this application without a cover plate;

[0011] Figure 4 shows an enlarged view of point A in Figure 3;

[0012] Figure 5 shows a schematic diagram of the first cavity and the second cavity of the battery pack structure of this application;

[0013] Figure 6 shows an enlarged view of point B in Figure 5;

[0014] Figure 7 shows a three-dimensional structural diagram of the BMS mounted on the mounting plate of this application;

[0015] Figure 8 shows an enlarged view of point C in Figure 7;

[0016] Figure 9 shows a schematic diagram of the mounting structure of the mounting plate of this application;

[0017] Figure 10 shows an enlarged view of point D in Figure 9;

[0018] Figure 11 shows a schematic diagram of the mating structure of the connector and seal of this application.

[0019] In the picture:

[0020] 10. Outer shell; 101. First cavity; 102. Second cavity; 103. Mounting slot; 104. Wiring hole; 110. Outer frame; 120. Cover plate; 130. Mounting plate; 131. Mounting channel; 140. Partition plate; 150. Back plate; 20. BMS; 30. BDU; 40. Connector; 50. Protective plate; 60. Maintenance plate; 70. Reinforcing beam; 80. Wiring harness; 90. Seal.

[0021] Implementation methods of this application

[0022] To address the inconvenience caused by the need to disassemble the battery pack during BMS maintenance in related technologies, this application provides a battery pack structure.

[0023] The battery pack structure in this embodiment includes a housing 10, a battery module, a battery management system (BMS20), and a battery pack circuit breaker (BDU30). The battery pack structure utilizes the collaborative operation of BMS20 and BDU30. BMS20 monitors the battery status and issues control commands, while BDU30 allocates and controls power according to these commands to ensure the stable and safe operation of the entire battery system.

[0024] In this embodiment, the battery pack structure can be installed on the vehicle body to provide power to the vehicle body.

[0025] As shown in Figures 1 to 11, the battery pack structure includes a housing 10, a BMS 20, and a BDU 30. The housing 10 has a first cavity 101 configured to install a battery module, and a second cavity 102 disposed on one side of the first cavity 101 along a first direction. The BDU 30 is disposed inside the second cavity 102, and the BMS 20 is disposed outside the second cavity 102 and connected to the bottom plate of the housing 10.

[0026] The battery module, BMS20, and BDU30 are housed inside the same housing 10. Both BMS20 and BDU30 are connected to the battery module to facilitate monitoring and control of the battery module and ensure its stable and safe operation.

[0027] In this embodiment, the outer casing 10 is a metal casing to protect the battery module, BMS20 and BDU30 inside the outer casing 10, and also to facilitate installation at the installation location, such as installation on a vehicle body.

[0028] Specifically, the interior of the outer casing 10 is divided into two cavities arranged along the first direction, which are respectively used to install the battery module and to connect the battery module to the BDU30. The two cavities are configured to separate the battery module and the BDU30 to facilitate later maintenance and improve the safety of use.

[0029] In this embodiment, the battery pack structure features the BMS20 mounted on the bottom surface of the outer casing 10. This eliminates the need to disassemble the battery pack structure when the BMS20 requires maintenance; the externally mounted BMS20 can be directly repaired, simplifying the overall maintenance process, saving time and effort, and improving maintenance efficiency. The externally mounted BMS20 structure of this application avoids the complexities of repairing the internal BMS20 after disassembling the battery pack, as is often the case in related technologies.

[0030] The first direction is the length direction of the outer shell 10 as shown in Figure 1, the second direction is the width direction of the outer shell 10 as shown in Figure 1, and the third direction is the height direction of the outer shell 10 as shown in Figure 1.

[0031] As shown in Figures 3 to 6, the bottom plate of the second cavity 102 is a mounting plate 130, and BDU30 and BMS20 are respectively arranged on two opposite sides of the mounting plate 130 along the height direction of the outer shell 10.

[0032] Specifically, by placing the BMS20 on the lower side of the BDU30, the structure with control functions is placed on the same side of the battery module, which facilitates the overall structure layout and improves the structural layout of the battery pack. At the same time, placing the BMS20 on one side of the battery module also helps to improve the safety of use.

[0033] In this embodiment, the BMS20 is detachably mounted on the mounting plate 130. Specifically, the mounting plate 130 has mounting holes, and the BMS20 has through holes. Fasteners pass through the through holes on the BMS20 and extend into the mounting holes to clamp and fix the BMS20. The BMS20 is detachably fixed to the mounting plate 130 by the locking engagement of the fasteners with the mounting holes. The mounting holes are threaded holes, and the fasteners are screws. The fasteners fix the BMS20 by the threaded engagement of the screws with the threaded holes.

[0034] In this embodiment, the BMS20 includes at least a motherboard and a slave board, both of which are mounted on the mounting plate 130 and are connected to the connector 40 via a wiring harness 80.

[0035] Optionally, multiple mounting holes are provided, which are configured to cooperate with vias on the BMS20 to improve the stability of the connection between the BMS20 and the mounting plate 130.

[0036] As shown in Figures 3 to 6, a reinforcing beam 70 is provided on the top surface of the mounting plate 130, and the BDU30 is installed on the reinforcing beam 70. By providing the reinforcing beam 70 on the mounting plate 130, not only is the installation of the BDU30 provided, but the strength of the installation is also improved, thereby enhancing the stability of the battery pack structure.

[0037] The reinforcing beam 70 is disposed inside the second cavity 102 and extends along the second direction to improve the strength of the mounting plate 130 in the second direction and prevent deformation of the bottom of the second cavity 102 in the second direction.

[0038] To further improve the strength of the mounting plate 130 and the stability of the BDU30 installation, multiple reinforcing beams 70 are spaced apart along the first direction. These multiple reinforcing beams 70 are fixed between the BDU30 and the mounting plate 130 to increase the number of mounting positions, thereby improving the stability of the BDU30 installation.

[0039] In this embodiment, the reinforcing beam 70 is welded to the mounting plate 130. Welding is used to fix the reinforcing beam 70 to the reinforcing plate, which is convenient to operate and helps to improve the stability of the reinforcing beam 70.

[0040] Optionally, the reinforcing beam 70 and the mounting plate 130 are welded together by friction welding.

[0041] As shown in Figures 9 and 10, the mounting plate 130 is provided with a mounting channel 131 extending along the height direction of the housing 10, and the mounting channel 131 provides mounting space.

[0042] Specifically, the battery pack structure also includes a connector 40 and a wiring harness 80. The connector 40 is inserted into the interior of the mounting channel 131. One end of the connector 40 exposed outside the housing 10 is connected to the BMS 20 via the wiring harness 80. The other end of the connector 40 located inside the housing 10 is configured to connect to the battery module.

[0043] In this embodiment, along the height direction of the housing 10, one end of the connector 40 is exposed outside the housing 10, and the other end of the connector 40 is located inside the second cavity 102. The connector 40 is placed upright inside the mounting channel 131. The connector 40 is electrically connected to the BMS 20 through the wire harness 80. The other end of the connector 40, that is, the end located inside the second cavity 102, is electrically connected to the battery module.

[0044] As shown in Figure 11, the battery pack structure also includes a seal 90, at least a portion of which is disposed between the mounting channel 131 and the connector 40.

[0045] Specifically, by setting a seal 90, the gap between the installation channel 131 and the connection is sealed, thereby achieving the effect of waterproofing and dustproofing, so as to prevent water and dust from entering the interior of the housing 10 through the installation channel 131.

[0046] Optionally, the sealing element 90 is a plastic strip. The sealing element 90 is connected to the mounting plate 130, and the connector is fixedly connected to the mounting plate 130 by fasteners. The sealing strip not only achieves the sealing effect, but also has the function of limiting and fixing the connector 40.

[0047] In this embodiment, the mounting plate 130 has an inner raised bend facing the second cavity 102, and the bend along the height direction of the outer shell 10 forms a mounting groove 103 with the opening facing away from the BDU30. The BMS20 and the wire harness 80 are disposed inside the mounting groove 103.

[0048] As shown in Figures 7 to 10, the mounting plate 130 forms a mounting groove 103. The BMS20 and the wire harness 80 are disposed inside the mounting groove 103 to achieve the protective effect of the BMS20 and the wire harness 80 being built inside the mounting groove 103, thus preventing the BMS20 and the wire harness 80 from protruding out of the mounting groove 103 and thus avoiding the situation where the BMS20 and the wire harness 80 are easily damaged by collision.

[0049] Specifically, the battery pack structure also includes a maintenance plate 60, which is detachably connected to the mounting plate 130. The maintenance plate 60 covers the opening of the mounting slot 103. By positioning the maintenance plate 60 at the opening of the mounting slot 103, the BMS20 inside the mounting slot 103 is protected. When maintenance of the BMS20 is required, only the maintenance plate 60 needs to be removed to expose the BMS20, making operation convenient and simple, saving time and effort, and improving maintenance efficiency.

[0050] Optionally, the battery pack structure also includes a protective plate 50, which is detachably disposed outside the first cavity 101 and connected to the bottom surface of the outer casing 10. The bottom surface of the maintenance plate 60 is coplanar with that of the protective plate 50.

[0051] In this embodiment, the protective plate 50 is used to protect the bottom of the outer casing 10, preventing damage to the outer casing 10 from impacts or other external forces, which could affect the installation and use of internal components, such as the battery module. The protective plate 50's coplanar design with the maintenance plate 60 improves installation convenience and overall aesthetics; the coplanar structure of the protective plate 50 and maintenance plate 60 also prevents uneven surfaces on the bottom of the outer casing 10 from causing easy damage.

[0052] In this embodiment, the battery pack structure also includes a sealing strip, which is disposed between the maintenance plate 60 and the mounting plate 130. By disposing of the sealing strip between the maintenance plate 60 and the mounting plate 130, a seal is formed between the maintenance plate 60 and the mounting plate 130 when the maintenance plate 60 is mounted on the mounting plate 130. The sealing strip prevents water and dust from entering the interior of the mounting groove 103 and improves the stability of the maintenance plate 60 during installation. At the same time, the sealing strip is disposed between the protective plate 50 and the outer shell 10. By disposing of the sealing strip between the protective plate 50 and the mounting plate 130, a sealed connection is achieved between the protective plate 50 and the outer shell 10, thereby improving the stability of the protective plate 50 during installation.

[0053] Specifically, the maintenance plate 60 and the sealing element 90 are connected to the mounting plate 130 by bolts or other structural components. That is, the bolts or other structural components pass through the maintenance plate 60 and the sealing strip and are connected to the mounting plate 130, so as to facilitate disassembly when the BMS20 needs to be maintained and to facilitate installation after maintenance, thereby improving the efficiency of maintenance operations. Similarly, the protective plate 50 and the sealing strip are connected to the outer shell 10 by bolts or other structural components. That is, the bolts or other structural components pass through the protective plate 50 and the sealing strip and are connected to the outer shell 10, so as to facilitate disassembly when needed.

[0054] In this application, the maintenance board 60 is configured to correspond with the mounting board 130, so that when the BMS20 needs to be maintained, only the maintenance board 60 needs to be removed to maintain the BMS20.

[0055] As shown in Figures 1 to 11, the housing 10 in this embodiment includes an outer frame 110, a back plate 150, a mounting plate 130, and a cover plate 120. The back plate 150 and the mounting plate 130 are disposed at the bottom opening of the outer frame 110. The back plate 150 is configured to support the battery module. The BMS20 and BDU30 are disposed on the mounting plate 130. The cover plate 120 is disposed at the top opening of the outer frame 110.

[0056] Specifically, the outer frame 110 is formed by frames connected end to end in sequence, and the back plate 150 is welded and fixed to the bottom opening of the outer frame 110 to support the battery module and realize the installation of the battery module, thereby increasing the installation space of the battery module; at the same time, the BMS20 and BDU30 are installed on the mounting plate 130 to facilitate maintenance of the BMS20 from the bottom.

[0057] Optionally, the cover plate 120 is installed over the top opening of the outer frame 110 to cover the battery module and BDU30. The cover plate 120, outer frame 110, back plate 150 and mounting plate 130 cooperate to enclose the inner cavity of the outer casing 10.

[0058] In order to ensure the airtightness of the area covered by the cover plate 120, a sealing ring is provided between the top surface of the cover plate 120 and the outer frame 110. The sealing ring helps to achieve the effect of waterproofing and dustproofing in the contact area between the cover plate 120 and the outer frame 110, and also enhances the stability of the cover plate 120 installation.

[0059] In this embodiment, the cover plate 120 is connected to the outer frame 110 by bolts to achieve a detachable connection.

[0060] In this embodiment, the back plate 150 and the outer frame 110, and the mounting plate 130 and the outer frame 110 may be friction welded.

[0061] In this embodiment, to facilitate wiring, the outer frame 110 has a wiring hole 104 that communicates with the second cavity 102, so as to connect the wiring harness 80 inside the outer shell 10 to the outside of the outer shell 10. Of course, to prevent water and dust from entering the interior of the second cavity 102 through the wiring hole 104, this embodiment is provided with a sealing ring and a cover corresponding to the wiring hole 104. The sealing ring is set on the inner wall of the wiring hole 104, and the cover is detachably set at the wiring hole 104 so that it can be sealed when wiring is not needed.

[0062] As shown in Figures 3 to 6, the outer shell 10 also includes a partition 140 connected to the outer frame 110. The partition 140 is disposed between the mounting plate 130 and the back plate 150 along the first direction. The partition 140 extends toward the cover plate 120 and divides the inner cavity of the outer shell 10 into a first cavity 101 and a second cavity 102 disposed on both sides of the partition 140 along the first direction.

[0063] Specifically, by setting the partition 140, the inner cavity of the outer casing 10 is divided into a first cavity 101 and a second cavity 102, thereby partitioning the battery module and BDU30.

[0064] In this embodiment, during the assembly process, the mounting plate 130 is first fixed to the outer frame 110 by friction welding, so that the mounting plate 130 is formed into the bottom plate of the second cavity 102. Then, a reinforcing beam 70 is welded and fixed on the top surface of the mounting plate 130 to install the BDU 30 and strengthen the mounting plate 130. Then, the connector 40 and the seal 90 are connected and installed at the mounting channel 131. The seal 90 is fixed by bolts to clamp and fix the connector 40 and seal the mounting channel 131. Then, the BMS 20 is installed on the bottom surface of the mounting plate 130, and the BMS 20 and the connector 40 are electrically connected by display. Then, the connector 40 is electrically connected to the battery module by another wire harness 80. Finally, the BMS 20 is covered by the maintenance plate 60 to cover the slot of the mounting groove 103, so that the BMS 20 can be exposed for maintenance when maintenance is required.

[0065] As can be seen from the above description, the embodiments of this application achieve the following technical effects:

[0066] The battery pack structure of this application features the BMS20 mounted on the bottom surface of the outer casing 10. This eliminates the need to disassemble the battery pack structure when the BMS20 needs maintenance; the externally mounted BMS20 can be directly repaired, simplifying the overall maintenance operation, saving time and effort, and improving maintenance efficiency. The externally mounted BMS20 structure of this application avoids the complex operations associated with related technologies that require disassembling the battery pack to repair the internal BMS20.

Claims

1. A battery pack structure, comprising: The housing (10) has a first cavity (101) configured to install a battery module, and a second cavity (102) disposed on one side of the first cavity (101) along a first direction. BMS (20) and BDU (30), wherein the BDU (30) is disposed inside the second cavity (102) and the BMS (20) is disposed outside the second cavity (102) and connected to the bottom plate of the outer shell (10).

2. The battery pack structure according to claim 1, wherein, The bottom plate of the second cavity (102) is a mounting plate (130), and the BDU (30) and the BMS (20) are respectively disposed on two opposite sides of the mounting plate (130) along the height direction of the outer shell (10).

3. The battery pack structure according to claim 2, wherein, The first direction is the length direction of the outer shell (10); and / or The mounting plate (130) has mounting holes, and the BMS (20) is locked into the mounting holes by fasteners.

4. The battery pack structure according to claim 2, wherein, A reinforcing beam (70) is provided on the top surface of the mounting plate (130), and the BDU (30) is provided on the reinforcing beam (70).

5. The battery pack structure according to claim 4, wherein, The reinforcing beam (70) is welded to the mounting plate (130); and / or The reinforcing beam (70) extends along a second direction perpendicular to the first direction; and / or Multiple reinforcing beams (70) are provided, and the multiple reinforcing beams (70) are spaced apart along the first direction.

6. The battery pack structure according to claim 2, wherein, The mounting plate (130) is provided with a mounting channel (131) extending along the height direction of the outer casing (10), and the battery pack structure further includes: A connector (40) is inserted into the interior of the mounting channel (131); The wiring harness (80) has one end of the connector (40) exposed outside the housing (10) connected to the BMS (20) via the wiring harness (80), and the other end of the connector (40) located inside the housing (10) is configured to connect to the battery module.

7. The battery pack structure according to claim 6, wherein, The battery pack structure also includes a seal (90), at least a portion of which is disposed between the mounting channel (131) and the connector (40).

8. The battery pack structure according to claim 7, wherein, The mounting plate (130) has an inner raised bend facing the second cavity (102), and the bend is formed with a mounting groove (103) with the opening facing away from the BDU (30) along the height direction of the outer shell (10). The BMS (20) and the wire harness (80) are disposed inside the mounting groove (103).

9. The battery pack structure according to claim 8, wherein, The battery pack structure also includes: A protective plate (50) is detachably disposed outside the first cavity (101) and connected to the bottom surface of the outer shell (10); The maintenance plate (60) is detachably connected to the mounting plate (130), the maintenance plate (60) covers the opening of the mounting groove (103), and the bottom surfaces of the maintenance plate (60) and the protective plate (50) are coplanar.

10. The battery pack structure according to claim 9, wherein, The battery pack structure also includes a sealing strip. The sealing strip is disposed between the maintenance plate (60) and the mounting plate (130); and / or The sealing strip is disposed between the protective plate (50) and the outer shell (10).

11. The battery pack structure according to any one of claims 1 to 10, wherein, The outer casing (10) includes: Outer frame (110); A back plate (150) and a mounting plate (130) are provided at the bottom opening of the outer frame (110). The back plate (150) is configured to support the battery module. The BMS (20) and the BDU (30) are provided on the mounting plate (130). A cover plate (120) is disposed at the top opening of the outer frame (110).

12. The battery pack structure according to claim 11, wherein, The mounting plate (130) is welded and fixed to the outer frame (110); and / or The outer frame (110) has a wiring hole (104) that communicates with the second cavity (102).

13. The battery pack structure according to claim 11, wherein, The outer shell (10) also includes a partition (140) connected to the outer frame (110). The partition (140) is disposed between the mounting plate (130) and the back plate (150) along the first direction. The partition (140) extends toward the cover plate (120) and divides the inner cavity of the outer shell (10) into a first cavity (101) and a second cavity (102) disposed on both sides of the partition (140) along the first direction.

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