Battery pack and vehicle

Abstract

The present application provides a battery pack and a vehicle. The battery pack comprises a case and a cross beam. The case is provided with an accommodating space and mounting holes in communication with the accommodating space. The cross beam is fixedly connected to the case and mounted in the accommodating space. Part of the cross beam is arranged in the mounting holes and configured to be connected to a vehicle frame, so as to mount the battery pack onto the vehicle frame.

Description

Battery packs and vehicles

[0001] This application claims priority to Chinese Patent Application No. 202423247364.8, filed with the Chinese Patent Office on December 26, 2024, the entire contents of which are incorporated herein by reference. Technical Field

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

[0003] The battery pack is one of the core components of a new energy vehicle. When the battery pack is mounted on the vehicle, uneven road surfaces or sudden changes in vehicle speed can transfer energy to the battery pack, which can easily affect the installation stability and safety of the battery pack.

[0004] In related technologies, conventional enclosure designs separate the crossbeams and mounting points. The force transmission path is usually: vehicle frame, mounting point, battery pack enclosure frame, module crossbeam, and cell module. Invention Overview

[0005] Such a long force transmission path can easily cause structural failure and reduced stiffness when the battery pack is subjected to vibration-related conditions. For example, the weld seam or body of the box may crack, and the overall mode of the pack may be too low, which may cause resonance in the vehicle. In addition, since the mounting points of the conventional box are located around the box, they usually need to be extended outside the box in the form of hanging ears or brackets to be connected to the vehicle, which greatly wastes the installation space of the battery and results in low space utilization.

[0006] This application provides a battery pack, which includes a housing and a crossbeam; the housing has a communicating receiving space and a mounting hole; the crossbeam is fixedly connected to the housing and installed in the receiving space, and a portion of the crossbeam is provided in the mounting hole for connection to the vehicle frame so as to load the battery pack onto the vehicle frame.

[0007] This application also provides a vehicle including a frame and the aforementioned battery pack, with a crossbeam connected to the frame to mount the battery pack on the frame. Beneficial effects

[0008] The battery pack provided in this application includes a housing and a crossbeam. The housing has a communicating receiving space and mounting holes. The crossbeam is fixedly connected to the housing and installed in the receiving space. A portion of the crossbeam is located in the mounting holes, configured to connect to the vehicle frame to mount the battery pack onto the frame. By connecting the crossbeam to the vehicle frame, the battery pack is mounted on the frame, meaning the mounting point is integrated into the crossbeam. This reduces the force transmission path, enhances the strength of the housing, and thus improves the battery pack's fatigue resistance.

[0009] The vehicle provided in this application mounts the battery pack onto the frame by connecting the crossbeam to the frame, meaning the mounting point is integrated into the crossbeam. This reduces the force transmission path, enhances the strength of the battery pack, and thus improves its fatigue resistance. Attached Figure Description

[0010] Figure 1 is a view of the battery pack from multiple perspectives provided by a possible implementation of this application.

[0011] Figure 2 is an exploded view of a portion of the battery pack structure provided by a possible implementation of this application.

[0012] Figure 3 is a structural schematic diagram from the first perspective of Figure 2.

[0013] Figure 4 is a bottom view of the battery pack provided by a possible implementation of this application.

[0014] Figure 5 is a cross-sectional view of Figure 4 along the AA direction.

[0015] Figure 6 is a magnified view of part B in Figure 5.

[0016] Figure 7 is a magnified view of point C in Figure 5.

[0017] Figure 8 is a structural schematic diagram from the second perspective of Figure 2.

[0018] Figure 9 is a framework diagram of a vehicle provided by a possible implementation of this application.

[0019] Explanation of reference numerals in the attached figures:

[0020] 10. Battery pack; 30. Frame; 31. Through hole; 50. Vehicle; 51. Fastener;

[0021] 100. Housing; 110. Bottom wall; 120. Accommodation space; 130. Side wall; 131. First sub-wall; 133. Second sub-wall; 111. Mounting hole; 112. Hole wall;

[0022] 200, crossbeam; 201, threaded hole; 210, protrusion; 230, main body; 240, solid part; 250, cavity part; 251, cavity. Embodiments of the present invention

[0023] The battery pack is one of the core components of a new energy vehicle. When the battery pack is mounted on the vehicle, uneven road surfaces or sudden changes in vehicle speed can transfer energy to the battery pack, potentially affecting its installation stability and safety. The main function of the mounting point is to securely fix the battery pack to the vehicle body, ensuring its stability under various driving conditions.

[0024] The crossbeam is a crucial structural component connecting the battery pack to the vehicle body. It significantly improves the overall rigidity of both the battery pack and the vehicle body, reducing vibration and deformation during driving. In the event of a collision, the crossbeam effectively disperses impact forces, protecting the battery pack from damage. Furthermore, the crossbeam serves as a fulcrum for mounting electrical connectors and thermal management systems, ensuring the stability and reliability of these systems.

[0025] In related technologies, conventional battery pack designs separate the crossbeams and mounting points. The force transmission path is usually: frame, mounting point, battery pack frame edge, module crossbeam, cell module. This force transmission path is too long, which can easily cause structural failure and reduced stiffness when the battery pack is subjected to vibration-related conditions. For example, the weld seams or body of the battery pack may crack, and the overall mode of the pack may be too low, making the vehicle more prone to resonance. Furthermore, since the mounting points of conventional battery pack designs are located on the side or around the battery pack, they usually need to extend outside the battery pack in the form of lugs or brackets to connect with the vehicle installation, which greatly wastes battery installation space and results in low space utilization.

[0026] In a first aspect, embodiments of this application provide a battery pack. Referring to Figures 1 and 2, the battery pack may include a housing 100 and a crossbeam 200, with the crossbeam 200 mounted on the housing 100. The crossbeam 200 and the housing 100 may be fixedly connected, for example, by welding or screwing.

[0027] The housing 100 has a communicating receiving space 120 and a mounting hole 111. In some examples, the housing 100 includes a bottom wall 110 and a side wall 130, which form the receiving space 120. The bottom wall 110 has a mounting hole 111. In other examples, the mounting hole may also be provided on the side wall.

[0028] Referring to Figures 3 and 4, the crossbeam 200 is fixedly connected to the box 100 and installed in the accommodating space 120. The connection between the crossbeam 200 and the box 100 can be by bolting, welding, etc.

[0029] A portion of the crossbeam 200 is provided in the mounting hole 111 for connection to the vehicle frame to mount the battery pack. For example, the mounting hole 111 allows a portion of the crossbeam 200 to be positioned opposite the vehicle frame, and a portion of the crossbeam 200 can be connected to the vehicle frame through the mounting hole 111. The crossbeam 200 passes through the mounting hole 111, enabling its connection to the vehicle frame. The crossbeam 200 and the vehicle frame can be connected by means of bolting, riveting, welding, etc. In some examples, the crossbeam 200 is bolted to the vehicle frame.

[0030] Thus, the battery pack is mounted on the frame by connecting the crossbeam 200 to the frame. In other words, the battery pack can be connected to the frame at least via the crossbeam 200.

[0031] In this embodiment, the battery pack is mounted on the vehicle frame by connecting the crossbeam 200 to the frame; that is, the mounting point is integrated into the crossbeam. This reduces the force transmission path, enhances the strength of the housing, and thus improves the fatigue resistance of the battery pack.

[0032] The battery pack is typically installed under the chassis in a vehicle. This is because a chassis-level installation minimizes the impact on passenger space and helps maintain a low center of gravity, improving driving stability. This not only allows the battery pack to occupy almost the entire chassis space, but also, through the protection of reinforcing ribs and a load-bearing frame, effectively reduces the risk of short-circuit spontaneous combustion in the event of a collision.

[0033] In some embodiments, the battery pack is located under the chassis, allowing the crossbeam 200 to be connected to the chassis of the vehicle frame.

[0034] In some embodiments, the battery pack may further include battery cells, which may be installed in the receiving space 120 between the crossbeam 200 and the housing.

[0035] As the skeleton structure of the battery pack, one of the main functions of the crossbeam is to provide physical support, ensuring that the entire battery pack can withstand forces from different directions, such as vibration and impact, during vehicle operation. Especially in the event of a collision, the crossbeam can effectively absorb and disperse energy, protecting the internal battery cells from direct damage.

[0036] In some embodiments, the housing 100 includes a bottom wall 110 and a side wall 130, the bottom wall 110 and the side wall 130 forming a receiving space 120, and the bottom wall 110 having a mounting hole 111.

[0037] In these embodiments, mounting holes 111 are provided in the bottom wall 110, and the crossbeam 200 is connected to the vehicle frame through the mounting holes 111 at the bottom. Compared with the related art, which provides hanging ears or brackets on the side of the battery pack housing and locks the battery pack to the vehicle frame through the hanging ears or brackets on the side of the battery pack housing, the battery pack in this embodiment is connected to the vehicle frame through the mounting holes 111 at the bottom. That is to say, the battery pack is in a bottom-locked state. This can save the width dimension of the battery. Within the same size range, this solution can accommodate more cells to obtain more power and extend the vehicle's driving range.

[0038] The side of the crossbeam 200 can be welded to the side wall 130, thereby enhancing the connection between the crossbeam 200 and the battery pack housing 100.

[0039] In some embodiments, the crossbeam 200 includes a protrusion 210 and a body 230. One end of the protrusion 210 is fixedly connected to the body 230, and the other end extends in a direction away from the body and is inserted into a mounting hole 111. The protrusion 210 is configured to connect to the vehicle frame. The mounting hole 111 has a hole wall surrounding the protrusion 210, and the hole wall is fixedly connected to the periphery of the protrusion 210. The protrusion 210 and the body 230 can be fixedly connected by means of screwing, welding, or integral molding.

[0040] In these embodiments, the crossbeam 200 is connected to the frame via the protrusion 210. During processing, the protrusion 210 can be first inserted into the mounting hole 111, and then the periphery of the protrusion 210 can be fixedly connected to the wall of the mounting hole 111. Since the wall of the mounting hole 111 is circumferentially arranged around the protrusion 210, the periphery of the protrusion 210 can be connected to the wall of the mounting hole 111, thereby enabling a tight connection between the protrusion 210 and the bottom wall 110, resulting in better force transmission.

[0041] In some embodiments, the hole wall and the protrusion 210 are connected by friction stir welding. In these embodiments, friction stir welding provides a uniform and tight weld between the hole wall and the protrusion 210, resulting in good weld quality and ensuring the airtightness and strength of the housing.

[0042] Friction stir welding (FSW) is a solid-state joining process that uses mechanical force and frictional heat to achieve a strong bond between two or more materials without melting the workpiece material. Because the temperature during FSW is relatively low, it avoids porosity and cracks that can occur in conventional fusion welding, resulting in higher weld quality. Compared to other welding methods, FSW reduces material waste and energy consumption, while also simplifying equipment structure to lower costs.

[0043] In friction stir welding, a rotating stirring head is inserted into the joint of the workpieces to be welded. This stirring head consists of two main parts: a shoulder at the top and a stirring pin extending into the joint. As the stirring head advances along a predetermined path, its rotational motion generates intense friction with the surface and internal materials of the workpiece, producing enough heat to bring the materials to a plastic state without completely melting them. At this point, the plasticized material flows from front to back under the pressure of the stirring head and is forced to re-solidify due to the pressure applied by the shoulder, forming a dense and defect-free weld.

[0044] Unlike traditional fusion welding methods, friction stir welding does not require the addition of welding wire or shielding gas, and it is less likely to generate pollution, fumes, or radiation throughout the process, making it more environmentally friendly.

[0045] In some embodiments, the mounting hole 111 is a circular hole, and the cross-section of the protrusion 210 is circular. For example, it may be a cylinder or a cone. In some examples, the protrusion 210 may be cylindrical. In these embodiments, the mounting hole 111 is a circular hole, and the cross-section of the protrusion 210 is circular. The protrusion 210 and the mounting hole 111 are adapted to each other in shape, and this allows for more uniform welding during friction stir welding. In some examples, the protrusion 210 and the mounting hole 111 may be coaxially arranged.

[0046] During processing, mounting holes 111 can be pre-drilled in the bottom wall 110 of the housing 100. Using a single-piece machining machine, the main body 230 and the protrusion 210 are machined. Then, the protrusion 210 is inserted into the mounting hole 111. The protrusion 210 and the mounting hole 111 can have a hole-shaft clearance fit. When there are multiple protrusions 210 on a crossbeam, multiple protrusions 210 are assembled with the mounting holes 111 one by one, so that the housing 100 and a single crossbeam are assembled through several hole-shaft fits. Afterwards, from the bottom surface of the housing 100, circular friction stir welding can be performed along the circular gap created by the hole-shaft fit, thereby achieving a rigid connection between the crossbeam and the housing 100. Because friction stir welding has good welding quality, the airtightness and strength of the housing are guaranteed.

[0047] In some embodiments, the sidewall 130 includes a first sub-wall 131 and a second sub-wall 133 arranged along the width direction of the box body, and the opposite ends of the main body 230 are respectively connected to the first sub-wall 131 and the second sub-wall 133.

[0048] In some examples, mounting holes 111 can be provided in the bottom wall 110, and the protrusion 210 of the crossbeam 200 is fixedly connected to the bottom wall 110. The crossbeam 200 is connected to the frame through the mounting holes 111 in the bottom wall 110. Simultaneously, the opposite ends of the main body 230 are connected to the first sub-wall 131 and the second sub-wall 133, respectively. That is, the bottom of the crossbeam 200 is fixedly connected to the bottom wall 110, and the bottom of the crossbeam 200 is connected to the frame. The sides of the crossbeam 200 are connected to the first sub-wall 131 and the second sub-wall 133. This makes the connection between the crossbeam 200 and the housing 100 more robust and reliable. The sides of the crossbeam 200 can be welded to the first sub-wall 131, for example, by arc welding. The sides of the crossbeam 200 can also be welded to the second sub-wall 133, for example, by arc welding.

[0049] In some embodiments, there are multiple protrusions 210, which are spaced apart along the width direction of the housing 100. There are also multiple mounting holes 111, and each protrusion 210 mates with one of the mounting holes 111. In this way, the battery pack is securely mounted on the vehicle frame by connecting to the vehicle frame through the multiple protrusions 210.

[0050] In some embodiments, there are multiple crossbeams 200.

[0051] In some examples, three crossbeams 200 are provided, with the three crossbeams 200 spaced apart along the length of the box.

[0052] In some examples, a crossbeam 200 includes a body 230 and four protrusions 210, which are spaced apart along the width of the housing 100. There are four mounting holes 111, and the protrusions 210 mate with the mounting holes 111 one by one.

[0053] Referring to Figure 9, in a second aspect, this application also provides a vehicle 50, which includes a frame 30 and the aforementioned battery pack 10. A crossbeam 200 is connected to the frame 30 to mount the battery pack 10 onto the frame 30. This vehicle 50 has all the beneficial effects of the aforementioned battery pack 10, which will not be repeated here.

[0054] The vehicle may be a gasoline-powered vehicle, a plug-in hybrid electric vehicle, or a new energy vehicle, etc., and this disclosure does not make any specific restrictions.

[0055] In the vehicle of this application, the battery pack is mounted on the frame by connecting the crossbeam 200 to the frame, that is, the mounting point is integrated into the crossbeam. This reduces the force transmission path, enhances the strength of the housing, and thus improves the fatigue resistance of the battery pack.

[0056] The battery pack can be installed under the chassis because this location minimizes the impact on passenger space and helps maintain a low center of gravity, improving driving stability. This not only allows the battery pack to occupy almost the entire chassis space, but also effectively reduces the risk of short-circuit combustion in the event of a collision through the protection of reinforcing ribs and a load-bearing frame.

[0057] The battery cells can be installed in the space 120 between the crossbeam 200 and the enclosure.

[0058] In the vehicle of this application, a mounting hole 111 is provided on the bottom wall 110 of the battery pack, and the crossbeam 200 is connected to the vehicle frame through the mounting hole 111 at the bottom. Compared with the related technology, which provides a hanging ear or bracket on the side of the battery pack housing and locks the battery pack to the vehicle frame through the hanging ear or bracket on the side of the battery pack housing, the battery pack in this embodiment is connected to the vehicle frame through the mounting hole 111 at the bottom. That is to say, the battery pack is in a bottom-locked state. This can save the width dimension of the battery. Within the same size range, this solution can accommodate more cells to obtain more power and extend the vehicle's driving range.

[0059] In some embodiments, the crossbeam 200 includes a protrusion 210 and a body 230. One end of the protrusion 210 is fixedly connected to the body 230, and the other end extends in a direction away from the body and is inserted into a mounting hole 111. The protrusion 210 is configured to connect to the vehicle frame. The mounting hole 111 has a hole wall 112 surrounding the protrusion 210, and the hole wall 112 is fixedly connected to the periphery of the protrusion 210. The protrusion 210 and the body 230 can be fixedly connected by means of screwing, welding, or integral molding.

[0060] In these embodiments, the crossbeam 200 is connected to the frame via a protrusion 210. During processing, the protrusion 210 can be first inserted into the mounting hole 111, and then the periphery of the protrusion 210 can be fixedly connected to the wall of the mounting hole 111. Since the wall 112 of the mounting hole 111 is circumferentially arranged around the protrusion 210, the periphery of the protrusion 210 can be connected to the wall 112 of the mounting hole 111, thereby enabling a tight connection between the protrusion 210 and the bottom wall 110, resulting in better force transmission.

[0061] In some embodiments, the hole wall and the protrusion 210 are connected by friction stir welding. In these embodiments, friction stir welding provides a uniform and tight weld between the hole wall and the protrusion 210, resulting in good weld quality and ensuring the airtightness and strength of the housing.

[0062] In some embodiments, the portion of the crossbeam 200 located in the mounting hole 111 is bolted to the vehicle frame.

[0063] In some embodiments, the portion of the crossbeam 200 located at the mounting hole 111 has a threaded hole 201, the frame 30 has a through hole 31, and the vehicle also includes a fastener 51, which passes through the through hole 31 and the threaded hole 201 to fasten the crossbeam 200 to the frame 30. The fastener 51 may be a screw.

[0064] Referring to Figure 8, in some examples, the crossbeam 200 includes a protrusion 210 and a main body 230. One end of the protrusion 210 is fixedly connected to the main body 230, and the other end extends in a direction away from the main body and is inserted into the mounting hole 111. The protrusion 210 is configured to connect to the vehicle frame. The mounting hole 111 has a hole wall surrounding the protrusion 210, and the hole wall is fixedly connected to the periphery of the protrusion 210. A threaded hole is provided at the end of the protrusion 210 away from the main body 230. The vehicle frame may have an opening, so that screws can be sequentially passed through the vehicle frame and the threaded hole of the protrusion 210. The screws engage with the threaded hole of the protrusion 210 to fasten the battery pack to the vehicle frame.

[0065] Referring to Figures 5, 6, and 7, in some embodiments, the crossbeam 200 includes a solid portion 240 and a cavity portion 250 connected together. The solid portion 240 is disposed near the mounting hole 111, and the cavity portion 250 is provided with a cavity 251. A threaded hole 201 is disposed in the solid portion 240.

[0066] In some examples, the threaded hole is formed along the height of the solid portion 240, and the height of the solid portion 240 needs to be greater than or equal to the depth of the threaded hole. This makes the connection tighter and the sealing better. By setting the solid portion 240 at the bottom of the crossbeam 200, the rigidity of the crossbeam can be enhanced.

Claims

1. A battery pack, comprising: The housing (100) has a connected receiving space (120) and mounting holes (111). as well as A crossbeam (200) is fixedly connected to the housing (100) and installed in the receiving space (120). Part of the crossbeam (200) is provided in the mounting hole (111) and is configured to be connected to the frame so as to load the battery pack (10) onto the frame (30).

2. The battery pack according to claim 1, wherein, The housing (100) includes a bottom wall (110) and a side wall (130), which together form the receiving space (120). The bottom wall (110) has the mounting hole (111).

3. The battery pack according to claim 1 or 2, wherein, The crossbeam (200) includes a protrusion (210) and a body (230). One end of the protrusion (210) is fixedly connected to the body (230), and the other end extends in a direction away from the body (230) and is inserted into the mounting hole (111). The protrusion (210) is configured to be connected to the frame (30). The mounting hole (111) has a hole wall (112) surrounding the protrusion (210), and the hole wall (112) is fixedly connected to the protrusion (210) around its periphery.

4. The battery pack according to claim 3, wherein, The hole wall (112) and the protrusion (210) are connected by friction stir welding.

5. The battery pack according to claim 4, wherein, The mounting hole (111) is a round hole, and the cross-section of the protrusion (210) is circular.

6. The battery pack according to claim 3, wherein, The sidewall (130) includes a first sub-wall (131) and a second sub-wall (133) arranged along the width direction of the box (100), and the opposite ends of the main body (230) are respectively connected to the first sub-wall (131) and the second sub-wall (133).

7. The battery pack according to claim 6, wherein, There are multiple protrusions (210), and the multiple protrusions (210) are spaced apart along the width direction of the housing (100). There are multiple mounting holes (111), and the protrusions (210) and mounting holes (111) are matched one by one.

8. A vehicle (50) comprising a frame (30) and a battery pack (10) as claimed in any one of claims 1-7, wherein the crossbeam (200) is connected to the frame (30) to mount the battery pack (10) on the frame (30).

9. The vehicle according to claim 8, wherein, The portion of the crossbeam (200) located in the mounting hole (111) is screwed to the frame (30).

10. The vehicle according to claim 8, wherein, The crossbeam (200) has a threaded hole (201) at the mounting hole (111), the frame (30) has a through hole (31), and the vehicle (50) also includes a fastener (51), which passes through the through hole (31) and the threaded hole (201) to fasten the crossbeam (200) and the frame (30).

11. The vehicle according to claim 10, wherein, The crossbeam (200) includes a solid part (240) and a cavity part (250) connected to each other. The solid part (240) is located near the mounting hole (111), and the cavity part (250) is provided with a cavity (251). The threaded hole is located in the solid part (240).

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