EP-4741198-A1 - BATTERY PACK CASE, CELL TO BODY AND ELECTRIC VEHICLE

EP4741198A1EP 4741198 A1EP4741198 A1EP 4741198A1EP-4741198-A1

Abstract

Provided are a battery pack box (10), a cell-integrated vehicle body, and an electric vehicle. The battery pack box (10) includes a housing (1), an upper cover (2), and a reinforcing structure (3). The housing (1) includes a bottom shell (11) and an enclosing frame (12), and the enclosing frame (12) is fastened to the bottom shell (11) and protrudes from the bottom shell (11) to form space for accommodating cells (30). The reinforcing structure (3) includes at least one longitudinal beam (31) and a plurality of transverse beam brackets (321). Each longitudinal beam (31) is fastened to the enclosing frame (12) in a length direction of the electric vehicle. Any one of the transverse beam brackets (321) is fastened between one longitudinal beam (31) and the enclosing frame (12) or between any two adjacent longitudinal beams (31) in a width direction of the electric vehicle. The transverse beam brackets (321) are arched and protrude away from the bottom shell (11). The upper cover (2) is sealingly fastened on a top that is of the enclosing frame (12) and that faces away from the bottom shell (11), the upper cover (2) is fixedly connected to the transverse beam brackets (321), and the upper cover (2) is configured to form at least a part of a floor of the frame (20).

Inventors

PAN, ZHIHONG
HE, Yande
XU, Chengmin
LI, JINGJING
LENG, Yuanyuan

Assignees

Shenzhen Yinwang Intelligent Technologies Co., Ltd.

Dates

Publication Date: 20260513
Application Date: 20240726

Claims (12)

A battery pack box (10), configured to be integrated into a frame (20) of an electric vehicle, wherein the battery pack box (10) comprises a housing (1), an upper cover (2), and a reinforcing structure (3); the housing (1) comprises a bottom shell (11) and an enclosing frame (12), and the enclosing frame (12) is fastened to the bottom shell (11) and protrudes from the bottom shell (11) to form space for accommodating cells (30); the reinforcing structure (3) comprises at least one longitudinal beam (31) and a plurality of transverse beam brackets (321); each longitudinal beam (31) is fastened to the enclosing frame (12) in a length direction of the electric vehicle; any one of the transverse beam brackets (321) is fastened between one longitudinal beam (31) and the enclosing frame (12) or between any two adjacent longitudinal beams (31) in a width direction of the electric vehicle; and in the width direction of the electric vehicle, the transverse beam brackets (321) are arched and protrude away from the bottom shell (11); and the upper cover (2) is sealingly fastened on a top that is of the enclosing frame (12) and that faces away from the bottom shell (11), the upper cover (2) is fixedly connected to the transverse beam brackets (321), and the upper cover (2) is configured to form at least a part of a floor of the frame.
The battery pack box (10) according to claim 1, wherein in the length direction of the electric vehicle, the transverse beam bracket (321) comprises at least one bent structure (3211), and the bent structure (3211) protrudes away from the bottom shell (11).
The battery pack box (10) according to claim 2, wherein the bent structure (3211) comprises a support surface (M) parallel to the bottom shell, and the upper cover (2) is at least partially fastened to the support surface (M).
The battery pack box (10) according to claim 3, wherein in the length direction of the electric vehicle, at least two bent structures (3211) are spaced apart, and support surfaces (M) of the bent structures (3211) are coplanar.
The battery pack box (10) according to any one of claims 1 to 4, wherein the battery pack box (10) is provided with a plurality of transverse beam assemblies (32) in the length direction of the electric vehicle; and the transverse beam assemblies (32) each comprise a plurality of transverse beam brackets (321), and the plurality of transverse beam brackets (321) are sequentially arranged from head to tail in the width direction of the electric vehicle.
The battery pack box (10) according to any one of claims 1 to 5, wherein all the transverse beam brackets (321) have a same size in the width direction of the electric vehicle.
A cell-integrated vehicle body, comprising a frame (20), cells (30), and the battery pack box (10) according to any one of claims 1 to 6, wherein the frame (20) comprises a front segment (201), a rear segment (202), and two threshold beams (203) connected between the front segment (201) and the rear segment (202); the front segment (201) and the rear segment (202) are fastened respectively at two ends of the enclosing frame (12) in the length direction of the electric vehicle, and the two threshold beams (203) are fastened respectively at two ends of the enclosing frame (12) in the width direction of the electric vehicle; and the upper cover (2) forms at least a part of a floor of the frame (20), and the cells (30) are accommodated between the housing (1) and the upper cover (2).
The cell-integrated vehicle body according to claim 7, wherein the battery pack box (10) is provided with a plurality of transverse beam assemblies (32) in the length direction of the electric vehicle; and the transverse beam assemblies (32) each comprise a plurality of transverse beam brackets (321), and the plurality of transverse beam brackets (321) are sequentially arranged from head to tail in the width direction of the electric vehicle.
The cell-integrated vehicle body according to claim 8, wherein in the length direction of the electric vehicle, the plurality of transverse beam assemblies (32) are grouped into three sets, each set of transverse beam assemblies (32) comprises at least one transverse beam assembly (32), and the three sets of transverse beam assemblies (32) are spaced apart in the length direction of the electric vehicle; the three sets of transverse beam assemblies (32) comprise a first set of transverse beam assemblies (32a), a second set of transverse beam assemblies (32b), and a third set of transverse beam assemblies (32c); the first set of transverse beam assemblies (32a) is disposed between two front-row transverse beams (204) of front-row seats of the frame; the second set of transverse beam assemblies (32b) is disposed in front of a first base point (P1) and located in front of a front front-row transverse beam (204) of the front-row seats of the frame (20), and the first base point (P1) is an orthographic projection of hips of a front-row passenger in a sitting posture on the bottom shell (11); and the third set of transverse beam assemblies (32c) is disposed between a second base point (P2) and a rear front-row transverse beam (204) of the front-row seats of the frame, and the second base point (P2) is an orthographic projection of hips of a rear-row passenger in a sitting posture on the bottom shell (11).
The cell-integrated vehicle body according to claim 9, wherein in the length direction of the electric vehicle, a size of a transverse beam bracket (321) in the first set of transverse beam assemblies (32a) is greater than a size of a transverse beam bracket (321) in the second set of transverse beam assemblies (32b).
The cell-integrated vehicle body according to claim 9 or 10, wherein in the length direction of the electric vehicle, the third set of transverse beam assemblies (32c) comprises a plurality of transverse beam assemblies (32), and the plurality of transverse beam assemblies (32) are arranged adjacently in the length direction of the electric vehicle.
An electric vehicle, comprising the cell-integrated vehicle body according to any one of claims 7 to 11.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to Chinese Patent Application No. 202310989995.8, filed with the China National Intellectual Property Administration on August 7, 2023 and entitled "BATTERY PACK BOX, CELL-INTEGRATED VEHICLE BODY, AND ELECTRIC VEHICLE", which is incorporated herein by reference in its entirety. TECHNICAL FIELD This application relates to the field of automobile technologies, and in particular, to a battery pack box, a cell-integrated vehicle body, and an electric vehicle. BACKGROUND With the continuous development of new-energy vehicles, a manner of integrating a battery into an electric vehicle is also continuously improved. Cell to body (cell to body, CTB) is a new technology for battery-body integration. Specifically, in the cell-to-body technology, an upper cover of a battery pack and a floor of a vehicle body can be integrated together to form one structure, so that battery integration and structure integration can be further implemented. In the conventional technology, a common cell-to-body solution is to use a sheet metal bottom plate of a body in white as an upper cover of a blade battery. The blade battery can be used as a structural member to bear a stepping force from a passenger, without affecting a side electrode tab, and therefore no failure, for example, a short circuit at a high voltage, is caused. However, this solution is applicable to only blade batteries. For a cell-to-body solution for a prismatic battery, balancing battery sealing and stepping stiffness is a current technical difficulty. SUMMARY Embodiments of this application provide a battery pack box, a cell-integrated vehicle body, and an electric vehicle. The battery pack box can be integrated with a frame. A top portion of the battery pack box can form at least a part of a bottom plate of the frame and provide sufficient stepping stiffness, meeting a strength requirement of the frame. According to a first aspect, a battery pack box is provided. The battery pack box may be configured to be integrated with a frame of an electric vehicle, to implement integration of cells and the frame. The battery pack box includes a housing, an upper cover, and a reinforcing structure. The housing includes a bottom shell and an enclosing frame. The enclosing frame is fastened to the bottom shell and protrudes from the bottom shell to form space for accommodating cells. The enclosing frame and the bottom shell may be in a shape of an open case, which helps accommodate the cells. The reinforcing structure is fastened to the enclosing frame to increase strength of the housing. The reinforcing structure includes at least one longitudinal beam and a plurality of transverse beam brackets. Each longitudinal beam is fastened to the enclosing frame in a length direction of the electric vehicle. The longitudinal beam can provide support in the length direction of the electric vehicle. Any one of the transverse beam brackets is fastened between one longitudinal beam and the enclosing frame or between any two adjacent longitudinal beams in a width direction of the electric vehicle. The transverse beam bracket can provide support in the width direction of the electric vehicle. Specifically, the transverse beam bracket is in two possible connection states: one is that the transverse beam bracket is connected between the enclosing frame and one longitudinal beam, and the other is that the transverse beam bracket is connected between two longitudinal beams when there are at least two longitudinal beams. In the width direction of the electric vehicle, the transverse beam brackets are arched and protrude away from the bottom shell. The transverse beam bracket, when receiving a force, can transfer the force to two lower ends and then to the longitudinal beam and the enclosing frame, thereby increasing a support force. The upper cover is sealingly fastened on a top that is of the enclosing frame and that faces away from the bottom shell, the upper cover is fixedly connected to the transverse beam brackets, and the upper cover is configured to form at least a part of a floor of the frame. The upper cover of the battery pack box provided in this application can be used as the floor of the frame. The reinforcing structure fastened to the enclosing frame has sufficient structural strength, so that a load-bearing capability of the housing can be improved. In this case, the upper cover has sufficient stepping stiffness, meeting a strength requirement of the floor of the frame. The integration of the battery pack box and the frame can free up space that is originally for a multi-layer structure between the battery pack and the floor, and can improve volume utilization of a battery system, so that more batteries can be placed in the same space. In addition, the sealed connection between the upper cover and the housing of the battery pack box can ensure safety of the battery pack. In a possible implementation, in the wid