Battery pack mounting structure and method for vehicle

Abstract

A battery pack mounting structure for a vehicle, the battery pack mounting structure comprising a first battery mounting unit (10). The first battery mounting unit (10) comprises: square frames (101), the square frames (101) including a first square frame, a second square frame and a third square frame, which are arranged in sequence and spaced apart from each other in the direction of longitudinal beams (30); longitudinal support rods (102), the longitudinal support rods (102) including a first longitudinal support rod and a second longitudinal support rod arranged in parallel, and a third longitudinal support rod and a fourth longitudinal support rod arranged in parallel; a first protective plate support (104); vertical rods (103), the vertical rods (103) including a first vertical rod, a second vertical rod, a third vertical rod and a fourth vertical rod; a plurality of rubber bushings or elastic connectors (105); a plurality of mounting supports (40); first connectors (106) arranged on the first square frame, the second square frame and the third square frame; and second connectors arranged on the first square frame, the second square frame and the third square frame. The first battery mounting unit (10) and a battery pack can be pre-assembled in a factory, and on site, it is only necessary to connect the first battery mounting unit (10) and the battery pack to the mounting supports (40) on the longitudinal beams (30) by means of the rubber bushings or the elastic connectors (105). The length is adjustable, and a light weight is achieved. Further provided is a battery pack mounting method for a vehicle.

Description

Battery Pack Installation Structure and Method for Vehicles

[0001] This application claims priority to Chinese Patent Application No. ZL 202411889954.2, entitled “Battery Pack Installation Structure and Method for Vehicles”, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This invention relates to the field of new energy vehicle components, and in particular to a battery pack installation structure and method for vehicles. Background Technology

[0003] The domestic heavy-duty commercial truck market is gradually becoming electrified. Most models on the market adopt the battery pack bracket structure shown in Figure 7. This bracket structure includes end frames at both ends, an L-shaped frame between the end frames, and a rectangular frame. The lower battery is housed and fixed within the rectangular frame, while the upper battery is fixed to the top of the rectangular frame. The end frames, L-shaped frame, and rectangular frame, as well as the various components of the rectangular frame, are all rigidly welded together. During vehicle travel, the battery pack is susceptible to significant impacts. Furthermore, on-site welding and installation of the bracket is time-consuming, labor-intensive, and inefficient, and the bracket structure is complex.

[0004] In addition, Chinese patent ZL202421720085.6 discloses a battery pack bracket for new energy vehicles, as shown in Figure 8, which includes a first battery mounting unit, comprising:

[0005] The first and second suspension brackets, arranged at intervals, are horizontally installed on the outside of the longitudinal beam 6 of the vehicle frame;

[0006] Battery frame 3 is used to house and secure the first battery pack located on the upper layer and the second battery pack located on the lower layer;

[0007] The first side bracket and the second side bracket 2 are disposed at the first end of the battery frame 3;

[0008] The third and fourth side brackets are disposed at the second end of the battery frame 3; and

[0009] The first side bracket and the second side bracket 2 are respectively connected to the first suspension bracket via rubber bushings or elastic connectors 5; the third side bracket and the fourth side bracket are respectively connected to the second suspension bracket via rubber bushings or elastic connectors.

[0010] However, this battery pack bracket is heavy, weighing approximately 800 kg. The first and second suspension brackets at both ends limit the length of the battery pack, making it unsuitable for battery packs of different lengths and increasing the vehicle's wheelbase. Improving compatibility with different battery models, reducing vehicle wheelbase, and achieving lightweight battery pack brackets are urgent problems to be solved.

[0011] Therefore, it is necessary to study a battery pack mounting structure and method for vehicles to solve one or more of the above-mentioned technical problems. Summary of the Invention

[0012] To solve at least one of the above-mentioned technical problems, according to one aspect of the present invention, a battery pack mounting structure for a vehicle is provided, characterized in that it includes a first battery mounting unit, the first battery mounting unit being disposed between two longitudinal beams of a new energy vehicle and comprising:

[0013] The first square frame, the second square frame, and the third square frame are arranged at intervals along the longitudinal beam direction;

[0014] The first and second longitudinal support rods, arranged in parallel, are connected between the bottoms of the first square frame, the second square frame, and the third square frame, and together with the first square frame, the second square frame, and the third square frame, define the first lower battery pack installation space.

[0015] The third and fourth longitudinal support rods, arranged in parallel, are connected between the tops of the first square frame, the second square frame, and the third square frame.

[0016] The first guard plate bracket is arranged parallel above the third longitudinal support rod and the fourth longitudinal support rod;

[0017] The first upright, the second upright, the third upright, and the fourth upright are respectively connected to the two ends of the first longitudinal support rod and the third longitudinal support rod, the two ends of the second longitudinal support rod and the fourth longitudinal support rod, and the four ends of the first protective plate bracket; the first protective plate bracket, the third longitudinal support rod and the fourth longitudinal support rod, as well as the first upright, the second upright, the third upright, and the fourth upright together define the installation space of the first upper battery pack;

[0018] Multiple rubber bushings or elastic connectors are respectively disposed on the first square frame, the second square frame and the third square frame;

[0019] Multiple mounting brackets are spaced apart and connected to the outside of the two longitudinal beams, and are connected one-to-one with the multiple rubber bushings or elastic connectors;

[0020] A first connector is disposed on the first square frame, the second square frame, and the third square frame; and

[0021] The second connector is provided on the first square frame, the second square frame, and the third square frame;

[0022] The second battery mounting unit is connected to the first battery mounting unit via the first connector and the second connector.

[0023] According to another aspect of the present invention, the second battery mounting unit is disposed on the outer side of the two longitudinal beams of the new energy vehicle and includes:

[0024] The fourth, fifth, and sixth square frames are arranged at intervals along the longitudinal beam direction;

[0025] The fifth and sixth longitudinal support rods, arranged in parallel, are connected between the bottoms of the fourth, fifth, and sixth square frames and together with the fourth, fifth, and sixth square frames, define the installation space for the second lower battery pack.

[0026] The seventh and eighth longitudinal support rods, arranged in parallel, are connected between the tops of the fourth, fifth, and sixth square frames.

[0027] The second guard plate bracket is arranged parallel above the seventh longitudinal support rod and the eighth longitudinal support rod;

[0028] The fifth, sixth, and seventh uprights are respectively connected to the sides of the fifth and seventh longitudinal support rods and the first side of the second guard plate bracket;

[0029] The eighth, ninth, and tenth uprights are respectively connected to the top surfaces of the fourth, fifth, and sixth square frames and the second side surface of the second protective plate bracket; the second protective plate bracket, the third and fourth longitudinal support rods, and the fifth to tenth uprights together define the installation space of the second upper battery pack;

[0030] The third connector is located on one side of the fourth, fifth, and sixth square frames, immediately adjacent to the longitudinal beam; and

[0031] The fourth connector is located on one side of the fourth square frame, the fifth square frame, and the sixth square frame, immediately adjacent to the longitudinal beam.

[0032] The third connector is connected to the first connector, and the fourth connector is connected to the second connector to connect the second battery mounting unit to the first battery mounting unit.

[0033] According to another aspect of the present invention, the second square frame of the first battery mounting unit and the fifth square frame, sixth upright and ninth upright of the second battery mounting unit are omitted.

[0034] This invention can achieve one or more of the following technical effects:

[0035] 1. Rubber bushings or elastic connectors can buffer and / or absorb the impact of vehicle bumps on the battery pack, improving safety.

[0036] 2. The first battery installation unit and battery pack can be pre-installed in the factory. On-site installation only requires hoisting the whole unit and connecting it to the mounting bracket on the longitudinal beam through rubber bushings or elastic connectors. The installation is simple and efficient.

[0037] 3. The second battery mounting unit and battery pack can be pre-installed in the factory. On-site, the entire assembly only needs to be hoisted and connected to the first battery mounting unit. The battery pack mounting structure for this vehicle is simpler than the existing technology structure. Compared with the weight of about 800kg in Chinese patent ZL202421720085.6, it can be reduced to about 400kg, achieving lightweighting.

[0038] 4. The overall weight is lighter and occupies less space in the vehicle's length direction, which can shorten the vehicle's wheelbase. It can also be adapted to different models and lengths of battery packs by adjusting the bracket mounting position and the length of the longitudinal support rod. Attached Figure Description

[0039] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0040] Figure 1 is a perspective view of a vehicle battery pack mounting structure according to a preferred embodiment of the present invention.

[0041] Figure 2 is a schematic diagram of the vehicle battery pack mounting structure and the overall battery pack according to a preferred embodiment of the present invention.

[0042] Figure 3 is a schematic diagram of the first battery mounting unit of a vehicle battery pack mounting structure according to a preferred embodiment of the present invention.

[0043] Figure 4 is a schematic diagram of the first battery mounting unit in Figure 3, which is equipped with a battery pack (for on-site hoisting).

[0044] Figure 5 is a schematic diagram of the second battery mounting unit of a vehicle battery pack mounting structure according to a preferred embodiment of the present invention.

[0045] Figure 6 is another perspective view of a vehicle battery pack mounting structure according to a preferred embodiment of the present invention (with longitudinal beams, cross beams and other related components hidden).

[0046] Figure 7 is a schematic diagram of the first type of battery pack support structure in the prior art.

[0047] Figure 8 is a schematic diagram of the second type of battery pack support structure in the prior art. Detailed Implementation

[0048] The preferred embodiments of the present invention will now be described with reference to the accompanying drawings. These specific embodiments are intended to illustrate the present invention in detail, but should not be construed as limiting the present invention. Various modifications and variations can be made without departing from the spirit and scope of the present invention, and all of these should be included within the protection scope of the present invention.

[0049] Example 1

[0050] According to a preferred embodiment of the present invention, referring to Figures 1-6, a battery pack mounting structure for a vehicle is provided, characterized in that it includes a first battery mounting unit 10, which is disposed between two longitudinal beams 30 of a new energy vehicle, referring to Figures 3-4, and includes:

[0051] A first square frame 101, a second square frame 101, and a third square frame 101 are arranged at intervals along the longitudinal beam direction;

[0052] The first longitudinal support rod 102 and the second longitudinal support rod 102 arranged in parallel are connected between the bottom of the first square frame, the second square frame and the third square frame, and together with the first square frame, the second square frame and the third square frame, define the first lower battery pack installation space.

[0053] The third longitudinal support rod 102 and the fourth longitudinal support rod 102, which are arranged in parallel, are connected between the tops of the first square frame, the second square frame and the third square frame.

[0054] The first guard plate bracket 104 is arranged parallel above the third longitudinal support rod and the fourth longitudinal support rod;

[0055] The first upright 103, the second upright 103, the third upright 103, and the fourth upright 103 are respectively connected to the two ends of the first longitudinal support rod and the third longitudinal support rod, the two ends of the second longitudinal support rod and the fourth longitudinal support rod, and the four ends of the first protective plate bracket; the first protective plate bracket, the third longitudinal support rod and the fourth longitudinal support rod, as well as the first upright, the second upright, the third upright and the fourth upright, together define the first upper battery pack installation space;

[0056] Multiple rubber bushings or elastic connectors 105 are respectively disposed on the first square frame, the second square frame and the third square frame;

[0057] Multiple mounting brackets 40 are spaced apart and connected to the outside of the two longitudinal beams 30, and are connected one-to-one with the multiple rubber bushings or elastic connectors 105;

[0058] A first connector 106 is disposed on the first square frame, the second square frame, and the third square frame; and

[0059] The second connector is provided on the first square frame, the second square frame, and the third square frame;

[0060] The second battery mounting unit is connected to the first battery mounting unit via the first connector and the second connector.

[0061] Preferably, the first connector 106 and the second connector are threaded holes. The connecting holes (threaded holes) of the square frame casting are not limited to the form shown in Figure 3. The connection direction of the threaded hole bolts can be adjusted, or alternative connection methods can be used.

[0062] According to another preferred embodiment of the present invention, the lengths of the first longitudinal support rod and the second longitudinal support rod are adjustable to accommodate battery packs of different lengths, and the lengths of the third longitudinal support rod and the fourth longitudinal support rod are adjustable to accommodate battery packs of different lengths.

[0063] According to another preferred embodiment of the present invention, the first battery mounting unit and the battery pack housed in the first battery mounting unit are prefabricated in the factory and hoisted or lifted on site as a whole to be connected to a plurality of mounting brackets provided on the longitudinal beam.

[0064] According to another preferred embodiment of the present invention, the first guard plate support includes a square frame and longitudinal beams, transverse beams and / or diagonal beams disposed within the square frame.

[0065] According to another preferred embodiment of the present invention, the first and second longitudinal support rods are L-shaped and supported on the upper surfaces of the bottom beams of the first, second, and third square frames. The third and fourth longitudinal support rods are L-shaped and supported on the upper surfaces of the top beams of the first, second, and third square frames. Supporting pads are also spaced apart on the upper surfaces of the bottom and top beams. Advantageously, the supporting pads are used for fixed connection and auxiliary support of the bottom of the battery pack.

[0066] According to another preferred embodiment of the present invention, the second battery mounting unit 20 is disposed on the outer side of the two longitudinal beams of the new energy vehicle and includes:

[0067] The fourth square frame 201, the fifth square frame 201 and the sixth square frame 201 are arranged at intervals along the longitudinal beam direction;

[0068] The fifth longitudinal support rod 202 and the sixth longitudinal support rod 202, which are arranged in parallel, are connected between the bottoms of the fourth square frame, the fifth square frame and the sixth square frame, and together with the fourth square frame, the fifth square frame and the sixth square frame, define the second lower battery pack installation space.

[0069] The seventh longitudinal support rod 202 and the eighth longitudinal support rod 202, which are arranged in parallel, are connected between the tops of the fourth square frame, the fifth square frame and the sixth square frame;

[0070] The second guard plate bracket 205 is arranged parallel above the seventh longitudinal support rod and the eighth longitudinal support rod;

[0071] The fifth upright 203, the sixth upright 203 and the seventh upright 203 are respectively connected to the sides of the fifth longitudinal support rod and the seventh longitudinal support rod, as well as the first side (outer side in Figure 5) of the second guard plate bracket 205.

[0072] The eighth, ninth, and tenth uprights 204 are respectively connected to the top surfaces of the fourth, fifth, and sixth square frames and the second side surface of the second protective plate bracket; the second protective plate bracket 205, the third and fourth longitudinal support rods, and the fifth to tenth uprights together define the installation space of the second upper battery pack.

[0073] The third connector 207 is disposed on one side of the fourth, fifth, and sixth square frames immediately adjacent to the longitudinal beams; and

[0074] The fourth connector 207 is located on one side of the fourth square frame, the fifth square frame and the sixth square frame adjacent to the longitudinal beam;

[0075] The third connector is connected to the first connector, and the fourth connector is connected to the second connector to connect the second battery mounting unit to the first battery mounting unit.

[0076] Preferably, the third connector and the fourth connector 207 are threaded holes, and the third connector and the first connector are mated and can be fixed by screws / bolts.

[0077] According to another preferred embodiment of the present invention, the lengths of the fifth to eighth longitudinal support rods are adjustable to accommodate battery packs of different lengths. Preferably, referring to FIG5, there are no obstructions / blockages at both ends of the fifth to eighth longitudinal support rods.

[0078] According to another preferred embodiment of the present invention, the second battery mounting unit and the battery pack housed in the second battery mounting unit are prefabricated in the factory and hoisted onto the left and right sides of the first battery mounting unit as a whole on site.

[0079] According to another preferred embodiment of the present invention, the second guard plate support includes a square frame and longitudinal beams, transverse beams and / or diagonal beams disposed within the square frame.

[0080] According to another preferred embodiment of the present invention, the fifth and sixth longitudinal support rods are L-shaped and supported on the upper surfaces of the bottom beams of the fourth, fifth, and sixth square frames. The seventh and eighth longitudinal support rods are L-shaped and supported on the upper surfaces of the top beams of the fourth, fifth, and sixth square frames. Support pads are also spaced apart on the upper surfaces of the bottom and top beams of the fourth, fifth, and sixth square frames (as shown in Figure 5). Preferably, the second battery mounting unit is further provided with a lifting hole 206 and a battery pack protective plate on its outer side. Preferably, the first and second protective plate brackets can be omitted according to customer requirements and installed by the customer later.

[0081] According to another preferred embodiment of the present invention, the second square frame of the first battery mounting unit and the fifth square frame, sixth upright, and ninth upright of the second battery mounting unit are omitted. That is, when a small-capacity battery pack is selected, the length is much shorter, and two square frames are used to form a support. Preferably, the number of square frames can be adjusted according to the length of the battery pack, for example, two, three, or more.

[0082] According to another preferred embodiment of the present invention, a method for mounting a battery pack to a vehicle using the aforementioned vehicle battery pack mounting structure is characterized by comprising the following steps:

[0083] The first battery mounting unit, which houses the battery pack, and the second battery mounting unit, which houses the battery pack, are prefabricated in the factory.

[0084] Install multiple mounting brackets on the outside of the two longitudinal beams;

[0085] The first battery mounting unit, which contains the battery pack, is hoisted from bottom to top, and multiple rubber bushings or elastic connectors are correspondingly connected to multiple mounting brackets;

[0086] The second battery mounting unit, which contains the battery pack, is hoisted and connected to both sides of the first battery mounting unit.

[0087] This invention can achieve one or more of the following technical effects:

[0088] 1. Rubber bushings or elastic connectors can buffer and / or absorb the impact of vehicle bumps on the battery pack, improving safety.

[0089] 2. The first battery installation unit and battery pack can be pre-installed in the factory. On-site installation only requires hoisting the whole unit and connecting it to the mounting bracket on the longitudinal beam through rubber bushings or elastic connectors. The installation is simple and efficient.

[0090] 3. The second battery mounting unit and battery pack can be pre-installed in the factory. On-site, the entire assembly only needs to be hoisted and connected to the first battery mounting unit. The battery pack mounting structure for this vehicle is simpler than the existing technology structure. Compared with the weight of about 800kg in Chinese patent ZL202421720085.6, it can be reduced to about 400kg, achieving lightweighting.

[0091] 4. The overall weight is lighter and occupies less space in the vehicle's length direction, which can shorten the vehicle's wheelbase. It can also be adapted to different models and lengths of battery packs by adjusting the bracket mounting position and the length of the longitudinal support rod.

[0092] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A battery pack mounting structure for a vehicle, characterized in that... The first battery mounting unit is disposed between two longitudinal beams of the new energy vehicle and includes: The first square frame, the second square frame, and the third square frame are arranged at intervals along the longitudinal beam direction; The first and second longitudinal support rods, arranged in parallel, are connected between the bottoms of the first square frame, the second square frame, and the third square frame, and together with the first square frame, the second square frame, and the third square frame, define the first lower battery pack installation space. The third and fourth longitudinal support rods, arranged in parallel, are connected between the tops of the first square frame, the second square frame, and the third square frame. The first guard plate bracket is arranged parallel above the third longitudinal support rod and the fourth longitudinal support rod; The first upright, the second upright, the third upright, and the fourth upright are respectively connected to the two ends of the first longitudinal support rod and the third longitudinal support rod, the two ends of the second longitudinal support rod and the fourth longitudinal support rod, and the four ends of the first protective plate bracket; the first protective plate bracket, the third longitudinal support rod and the fourth longitudinal support rod, as well as the first upright, the second upright, the third upright, and the fourth upright together define the installation space of the first upper battery pack; Multiple rubber bushings or elastic connectors are respectively disposed on the first square frame, the second square frame and the third square frame; Multiple mounting brackets are spaced apart and connected to the outside of the two longitudinal beams, and are connected one-to-one with the multiple rubber bushings or elastic connectors; The first connector is disposed on the first square frame, the second square frame, and the third square frame; A second connector is disposed on the first square frame, the second square frame, and the third square frame; and The second battery mounting unit is connected to the first battery mounting unit via the first connector and the second connector.

2. The vehicle battery pack mounting structure according to claim 1, characterized in that... The lengths of the first and second longitudinal support rods are adjustable to accommodate battery packs of different lengths, and the lengths of the third and fourth longitudinal support rods are also adjustable to accommodate battery packs of different lengths.

3. The vehicle battery pack mounting structure according to claim 1 or 2, characterized in that... The first battery mounting unit and the battery pack housed within the first battery mounting unit are prefabricated in the factory and assembled on-site as a whole from bottom to top, connected to multiple mounting brackets set on the longitudinal beam.

4. The vehicle battery pack mounting structure according to claim 3, characterized in that... The first guard plate support includes a square frame and longitudinal beams, transverse beams and / or diagonal beams disposed within the square frame.

5. The vehicle battery pack mounting structure according to claim 4, characterized in that... The first and second longitudinal support rods are L-shaped and support the upper surfaces of the bottom beams of the first square frame, the second square frame and the third square frame. The third and fourth longitudinal support rods are L-shaped and support the upper surfaces of the top beams of the first square frame, the second square frame and the third square frame. Support pads are also provided at intervals on the upper surfaces of the bottom beams and the top beams.

6. The vehicle battery pack mounting structure according to claim 1 or 2, characterized in that... The second battery mounting unit is disposed on the outer side of the two longitudinal beams of the new energy vehicle and includes: The fourth, fifth, and sixth square frames are arranged at intervals along the longitudinal beam direction; The fifth and sixth longitudinal support rods, arranged in parallel, are connected between the bottoms of the fourth, fifth, and sixth square frames and together with the fourth, fifth, and sixth square frames, define the installation space for the second lower battery pack. The seventh and eighth longitudinal support rods, arranged in parallel, are connected between the tops of the fourth, fifth, and sixth square frames. The second guard plate bracket is arranged parallel above the seventh longitudinal support rod and the eighth longitudinal support rod; The fifth, sixth, and seventh uprights are respectively connected to the sides of the fifth and seventh longitudinal support rods and the first side of the second guard plate bracket; The eighth, ninth, and tenth uprights are respectively connected to the top surfaces of the fourth, fifth, and sixth square frames and the second side surface of the second protective plate bracket; the second protective plate bracket, the third and fourth longitudinal support rods, and the fifth to tenth uprights together define the installation space of the second upper battery pack; The third connector is located on one side of the fourth, fifth, and sixth square frames, immediately adjacent to the longitudinal beam; and The fourth connector is located on one side of the fourth square frame, the fifth square frame, and the sixth square frame, immediately adjacent to the longitudinal beam. The third connector is connected to the first connector, and the fourth connector is connected to the second connector to connect the second battery mounting unit to the first battery mounting unit.

7. The vehicle battery pack mounting structure according to claim 6, characterized in that... The lengths of the fifth to eighth longitudinal support rods are adjustable to accommodate battery packs of different lengths.

8. The vehicle battery pack mounting structure according to claim 7, characterized in that... The second battery mounting unit and the battery pack housed within the second battery mounting unit are prefabricated in the factory and hoisted onto the left and right sides of the first battery mounting unit as a whole on site.

9. The vehicle battery pack mounting structure according to claim 6, characterized in that... The second protective plate bracket includes a square frame and longitudinal beams, transverse beams, and / or diagonal beams disposed within the square frame; the fifth and sixth longitudinal support rods are L-shaped and support the upper surfaces of the bottom beams of the fourth, fifth, and sixth square frames; the seventh and eighth longitudinal support rods are L-shaped and support the upper surfaces of the top beams of the fourth, fifth, and sixth square frames; support pads are also spaced apart on the upper surfaces of the bottom and top beams of the fourth, fifth, and sixth square frames; the second battery mounting unit is also provided with a lifting hole and a battery pack protective plate is provided on the outside.

10. The vehicle battery pack mounting structure according to claim 1, characterized in that... The second square frame of the first battery mounting unit is omitted.

11. The vehicle battery pack mounting structure according to claim 6, characterized in that... The fifth square frame, sixth upright, and ninth upright of the second battery mounting unit are omitted.

12. A method for mounting a battery pack in a vehicle using the vehicle battery pack mounting structure according to any one of claims 1-11, characterized in that... Includes the following steps: The first battery mounting unit, which houses the battery pack, and the second battery mounting unit, which houses the battery pack, are prefabricated in the factory. Install multiple mounting brackets on the outside of the two longitudinal beams; The first battery mounting unit, which contains the battery pack, is hoisted from bottom to top, and multiple rubber bushings or elastic connectors are correspondingly connected to multiple mounting brackets; The second battery mounting unit, which contains the battery pack, is hoisted and connected to both sides of the first battery mounting unit.

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