WO2023116733A1 - 电池箱的下箱体、电池箱、电池包及电动汽车 - Google Patents

电池箱的下箱体、电池箱、电池包及电动汽车 Download PDF

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Publication number
WO2023116733A1
WO2023116733A1 PCT/CN2022/140499 CN2022140499W WO2023116733A1 WO 2023116733 A1 WO2023116733 A1 WO 2023116733A1 CN 2022140499 W CN2022140499 W CN 2022140499W WO 2023116733 A1 WO2023116733 A1 WO 2023116733A1
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WO
WIPO (PCT)
Prior art keywords
battery
lower box
shell
reinforcing rib
box body
Prior art date
Application number
PCT/CN2022/140499
Other languages
English (en)
French (fr)
Inventor
张建平
黄春华
于新瑞
Original Assignee
奥动新能源汽车科技有限公司
上海电巴新能源科技有限公司
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Publication of WO2023116733A1 publication Critical patent/WO2023116733A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/615—Heating or keeping warm
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/231—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks having a layered structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H01M50/264—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks for cells or batteries, e.g. straps, tie rods or peripheral frames
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/282—Lids or covers for the racks or secondary casings characterised by the material having a layered structure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the invention relates to the field of electric vehicles, in particular to a lower box body of a battery box, a battery box, a battery pack and an electric vehicle.
  • Electric vehicles have the advantages of zero emission, low noise, and very economical operation and maintenance, and are increasingly favored by users.
  • the energy used by an electric vehicle is the electric energy provided by its own battery pack, and the electric vehicle needs to be charged after the electric energy is used up.
  • the battery pack installation methods of electric vehicles are generally divided into fixed type and replaceable type.
  • the fixed type battery pack is generally fixed on the vehicle, and the vehicle is directly used as the charging object when charging.
  • the replaceable battery pack is generally fixed on the bracket of the vehicle by means of movable installation, and the battery pack can be removed to perform replacement or charging operations separately. After the replaced battery pack is charged, it can be installed on the on the vehicle.
  • the shell of the existing battery box, especially the lower box, is usually made of metal materials, such as steel, aluminum, etc., based on strength considerations.
  • the thermal conductivity of the metal shell is generally relatively large, resulting in poor insulation effect of the battery pack, and the temperature of the battery pack is likely to change with the ambient temperature.
  • the improvement effect is limited. Especially when the battery pack is used in a cold area, when the ambient temperature is low, the temperature of the battery pack will drop faster, and the efficiency of the battery pack will decrease more obviously.
  • the technical problem to be solved by the present invention is to provide a lower box body of the battery box, a battery box, a battery pack and an electric vehicle in order to overcome the defect of poor heat preservation effect of the battery box in the prior art.
  • a lower box body of a battery box the lower box body has an accommodating cavity with an open upper end
  • the lower box body includes an outer shell, an inner shell and a supporting structure, and the supporting structure is arranged between the outer shell and the A chamber structure is formed between the inner shell and the outer shell and the inner shell, and both the outer shell and the inner shell are made of non-metallic composite material.
  • the lower box is composed of an outer shell and an inner shell, and a supporting structure is provided between the outer shell and the inner shell, so that the structure of the lower box made of non-metallic composite material is strengthened to meet the requirements of the battery. box strength requirements. Moreover, a cavity structure is formed between the outer shell and the inner shell to improve the heat insulation effect of the lower box.
  • the lower box is made of non-metallic composite material, which is better than the shell made of metal material. , to further enhance the thermal insulation performance, and the density of non-metallic composite materials is smaller than that of metal materials.
  • the lower box made of non-metallic composite material of the present application has better thermal insulation performance and is lighter than the box made of metal when meeting the strength requirements of the battery box.
  • the production process is simpler and the economic benefits are improved. .
  • the support structure is a reinforcing rib, and the reinforcing rib extends between the inner casing and the outer casing along the opposite surfaces and is spaced or interlaced, and the reinforcing rib connects the outer casing Several chambers are separated between the body and the inner casing to form the chamber structure.
  • the above-mentioned structural form is adopted, especially in the case of adopting staggered reinforcing ribs, so that the reinforcing ribs form a grid structure, which enhances and balances the strength of the bottom of the lower box.
  • the reinforcing rib is formed on the inner surface of the outer casing, and the reinforcing rib is connected with the inner casing;
  • the reinforcing rib is formed on the outer surface of the inner casing, and the reinforcing rib is connected to the outer casing.
  • the way of connecting the reinforcing rib to the inner casing or the outer casing includes adhesive connection or welding connection.
  • the connecting area of the outer casing for connecting with the reinforcing rib or the connecting area of the inner casing for connecting with the reinforcing rib is the opposite surface of the outer casing and the inner casing 10%-30% of the area.
  • the bonding area of the inner shell and the outer shell accounts for 20% of the plane area where the outer shell or the inner shell is bonded.
  • the cross-section of the reinforcing rib perpendicular to its extending direction is a continuous structure
  • the cross section of the reinforcing rib perpendicular to its extending direction is a split structure, and the split structure is composed of at least two sub-reinforcing ribs formed at intervals on or on the inner surface of the outer casing.
  • thicker ribs or ribs formed by several parallel narrower sub-ribs can be used to enhance the strength of the lower box, wherein the sub-rib structure can reduce the gap between the inner shell and the outer shell.
  • the contact area, the gap formed between the sub-reinforcing ribs is used for heat insulation, which can improve the heat preservation effect and also help reduce the weight of the lower box.
  • a glue-coating groove is provided on the connecting surface of the reinforcing rib, and the extending direction of the glue-coating groove is the same as the length direction of the reinforcing rib where it is located.
  • the gluing groove is used to accommodate the glue, prevent the glue from overflowing, ensure that there is a sufficient amount of glue on the bonding surface, and improve the bonding effect.
  • the cross-section where the reinforcing rib is perpendicular to its extending direction is a split structure
  • the split structure has at least two sub-reinforcing ribs arranged side by side with gaps between them, and the glue-coating groove spans each sub-reinforcing rib Connection face settings for ribs.
  • the glue-coated grooves on the connection surfaces of the staggered ribs are connected at the intersections of the ribs.
  • the above-mentioned structural form is adopted, so that the places with more glue can flow along the gluing grooves to the places with less glue, and evenly distribute in the gluing grooves, so as to improve the uniformity of glue distribution. In addition, it can also improve the continuity of the bonding surface and enhance the strength of the bonding connection.
  • the inner shell and the outer shell are stacked, and both the outer shell and the inner shell have a bottom plate and side plates surrounding the edge of the bottom plate, and the bottom plate of the outer shell Together with the bottom plate of the inner housing, the bottom wall of the lower box is formed, the side plates of the outer housing and the side plates of the inner housing form the side walls of the lower box, and the accommodating cavity Formed in the inner shell, the reinforcing rib includes a bottom reinforcing rib arranged between the bottom plate of the inner shell and the bottom plate of the outer shell, and a side plate set between the inner shell and the outer shell. Side ribs between the side panels of the outer shell.
  • the reinforcing ribs are arranged between the bottom plate of the inner shell and the bottom plate of the outer shell, and between the side plates of the inner shell and the side plates of the outer shell, at the opposite sides of the inner and outer shells of the entire lower box.
  • the adoption of the above structure facilitates the manufacture of the lower box body of non-metallic composite material and improves the overall strength of the lower box body. Since both the inner shell and the outer shell are made of non-metallic composite materials, the bottom wall and the side wall can be integrally formed (molding, injection molding, etc.), and the manufacturing process is simplified.
  • the side reinforcing rib is formed on the inner surface of the side plate of the outer casing, and the side reinforcing rib is connected with the inner casing;
  • the side reinforcing ribs include vertical reinforcing ribs arranged at intervals and extending along the vertical direction, and the vertical reinforcing ribs are connected with the bottom reinforcing ribs.
  • the vertical ribs are connected to the bottom ribs, which can improve the overall strength of the ribs.
  • the bottom of the vertical reinforcing rib extends to the bottom plate of the outer shell along the inner surface of the side plate of the outer shell, and the bottom reinforcing rib extends into the gluing recess of the vertical reinforcing rib Groove, and connected with the bottom of the vertical reinforcement;
  • the lower thickness of the vertical reinforcing rib is greater than the upper thickness
  • the top of the vertical reinforcing rib gradually shrinks toward the inner surface of the side plate of the outer shell along the height direction of the inner surface of the side plate of the outer shell.
  • the side wall of the battery box is the main stress-bearing part connected between the battery pack and the electric vehicle.
  • the glue-coating groove of the vertical rib is wider than that of the bottom rib, which can accommodate more structural glue, improve the bonding strength between the vertical rib and the side plate of the inner shell, and strengthen the side plates of the inner and outer shells The integrity of the body increases the overall strength.
  • the thickness of the lower part of the vertical rib is relatively large, which is not only beneficial to the separation of the product from the mold during the mold forming process; but also because the bottom of the vertical rib is located at the connection between the side plate and the bottom plate of the outer shell, which belongs to the place of stress concentration. Thickening to the lower part of the rib is conducive to enhancing the strength of the stress concentration.
  • the top of the vertical rib shrinks, preferably in the form of an R angle.
  • Such a structure is conducive to the smooth transition between the edge of the outer shell and the edge of the inner shell, and avoids stress concentration at the edges of the two.
  • a lightweight thermal insulation material is provided in the chamber structure, and the lightweight thermal insulation material includes polymer foam material or airgel felt.
  • polymer foaming material is based on polymer (plastic, rubber, elastomer or natural polymer material) and has a microporous material with numerous bubbles inside.
  • Typical foaming materials such as polyurethane (Polyurethane) foam, polystyrene (Polystyrene) foam, etc.
  • Airgel felt is made of silica airgel as the main material and compounded in reinforcing fibers. It has the characteristics of softness, easy cutting, low density, inorganic fire prevention, overall hydrophobicity, and environmental protection.
  • the height of the cavity structure between the outer shell and the inner shell is 1-15 mm or the thickness of the light heat insulating material is 1-15 mm;
  • the height of the chamber structure between the outer casing and the inner casing is 5mm or the thickness of the lightweight insulating material is 3-10mm; it is further preferred that the height of the chamber structure between the outer casing and the inner casing is 5mm or the thickness of the lightweight insulating material The thickness is 5mm.
  • the value of the height is a comprehensive consideration of many aspects.
  • the thickness of about 5mm can meet the thermal insulation requirements, and has little impact on the energy density of the battery.
  • the lightweight thermal insulation material is an airgel felt.
  • the airgel blanket can be bonded in the chamber structure with structural adhesive, or filled in the chamber structure. The airgel blanket is placed in the chamber structure in a non-compressed manner as far as possible, so as not to affect the thermal insulation performance of the airgel blanket.
  • a flange is provided on the edge of the inner housing, and the flange is fastened on the edge of the outer housing and matedly connected with the edge of the outer housing.
  • flanges are provided on the edge of the inner shell and fastened on the outer shell to improve the connection and fixation effect between the inner shell and the edge of the outer shell, further improve the integrity between the outer shell and the inner shell, and enhance The strength of the lower case.
  • the manner of fitting connection between the flange and the edge of the outer casing includes adhesive connection, welding connection or clip connection.
  • the non-metallic composite material includes a fiber-reinforced resin-based composite material; preferably, the fiber-reinforced resin-based composite material includes a glass fiber-reinforced resin-based composite material, and/or a carbon fiber-reinforced resin-based composite material, and/or resin Fiber-reinforced resin-based composite materials, and/or ceramic fiber-reinforced resin-based composite materials.
  • the fiber-reinforced resin-based composite material includes a glass fiber-reinforced resin-based composite material, and/or a carbon fiber-reinforced resin-based composite material, and/or resin Fiber-reinforced resin-based composite materials, and/or ceramic fiber-reinforced resin-based composite materials.
  • the non-metallic composite material can be a fiber-reinforced resin-based composite material, or other polymer composite materials with light weight, certain strength and high-temperature performance.
  • the non-metallic composite material is preferably a fiber-reinforced resin-based composite material. It has good strength and heat preservation performance, and it is easy to process and shape.
  • the non-metallic composite material is a glass fiber reinforced resin-based composite material, and it is further preferred that the non-metallic composite material is SMC (Sheet molding compound), also known as sheet molding compound, which is a polymer composite material, and the main raw material is SMC It is composed of special yarn, unsaturated resin, low shrinkage additive, filler and various auxiliary agents.
  • a reinforcement structure is provided around the outer periphery of the side of the outer casing, and the side of the outer casing extends outward to form the reinforcement structure.
  • the reinforcement structure can be used as a stress-bearing part to fix the quick-change unit on the reinforcement structure to achieve detachable connection with the electric vehicle, or to fix the battery pack using the lower box to the electric vehicle through the fixing unit. locking mechanism locking mechanism
  • At least the exposed surface of the outer bottom of the outer casing is covered with a polyurea layer.
  • the polyurea layer can improve the strength of the non-metallic composite material itself, and has the functions of wear resistance, heat insulation, and can improve the strength of the bottom of the box, and has a certain degree of softness, which can ensure stability under impact.
  • a battery box the battery box includes an upper cover and the above-mentioned lower box body, the upper cover is arranged on the lower box body and closes the accommodating cavity.
  • the battery box is covered on the lower box body by an upper cover to form a battery box shell with an inner cavity, which can protect the battery module installed in the cavity, and can also protect it. insulation.
  • a flange is provided on the edge of the inner shell, and a sealing groove with an opening facing the upper cover is provided on the edge of the outer shell, the flange is fastened in the sealing groove, and the upper
  • the cover is provided with a sealing vertical plate at a position corresponding to the sealing groove, and the gap between the upper cover and the lower box body is at least passed through the sealing groove, the sealing vertical plate and the sealing groove and the sealing vertical plate.
  • the sealing strip between the vertical plates realizes sealing, and the sealing strip at least abuts against the flange.
  • a battery pack includes the above-mentioned battery box and a battery unit arranged in the accommodating cavity, the battery unit includes a battery cell or a battery module formed by the battery cell, the lower box A quick-change unit or a fixing unit is installed on the outer side of the body, the quick-change unit is used to realize the detachable connection of the battery pack to the electric vehicle; the fixed unit is used to realize the fixed connection of the battery pack to the electric vehicle .
  • the battery pack seals the battery unit in the accommodation cavity surrounded by the upper cover and the lower box, which forms a protective barrier for the battery module and has a heat preservation effect.
  • the lower case of the battery pack is made of non-metallic composite material, which can reduce the weight compared with the metal case, and further improve the heat preservation effect and economic benefits.
  • the quick change unit includes but is not limited to: electric/liquid cooling connector, locking mechanism, etc.
  • the locking mechanism includes a threaded locking mechanism (a locking mechanism that fixes the battery box and the vehicle body through multiple bolts), locking pins, etc.
  • Locking mechanism a locking mechanism that fixes the battery box to the vehicle body by locking pins
  • a rotation locking mechanism a locking mechanism that fixes the battery box to the vehicle body by rotating and locking
  • a flipping locking mechanism The locking mechanism that fixes the battery box and the vehicle body by flipping and locking
  • the pressing locking mechanism the locking mechanism that fixes the battery box and the vehicle body by pressing the locking method
  • the staggered tooth locking mechanism The locking mechanism that fixes the battery box and the vehicle body through the staggered locking method
  • the latch locking mechanism the locking mechanism that fixes the battery box and the vehicle body through the latch locking method
  • the push-pull locking mechanism the The locking mechanism that fixes the battery box and the vehicle body by way of locking).
  • the fixing unit includes a bolt-type locking mechanism or other types of fixed connection mechanisms (including but not limited to mechanical, electrical or magnetic connections, etc.) and the like.
  • the quick change unit or the fixing unit is arranged at the joint of the lower box corresponding to the reinforcement rib of the lower box.
  • the quick-change unit or the fixed unit is the main stress-bearing part when the battery pack is connected to the electric vehicle, and it is easy to become a weak link in strength. It is arranged correspondingly to the reinforcing ribs of the lower box to enhance the strength and improve the battery pack. Reliability of electric vehicle connections.
  • An electric vehicle includes the above-mentioned battery pack.
  • the positive progress effect of the present invention is that the lower box is composed of an outer shell and an inner shell, and a supporting structure is arranged between the inner shell and the outer shell, so that the structure of the lower box is strengthened to meet the requirements of the battery box. strength requirements. Moreover, a cavity structure is formed between the outer shell and the inner shell to improve the heat insulation effect of the lower box.
  • the lower box is made of non-metallic composite material, which is better than the shell made of metal material. , to further enhance the thermal insulation performance, and the density of non-metallic composite materials is smaller than that of metal materials.
  • the lower box made of non-metallic composite material of the present application has better thermal insulation performance and is lighter than the box made of metal when meeting the strength requirements of the battery box.
  • the production process is simpler and the economic benefits are improved. .
  • FIG. 1 is a schematic structural view of the lower box body of the battery box in Example 1.
  • FIG. 1 is a schematic structural view of the lower box body of the battery box in Example 1.
  • FIG. 2 is a schematic structural view of the outer casing of Embodiment 1.
  • FIG. 2 is a schematic structural view of the outer casing of Embodiment 1.
  • FIG. 3 is a schematic diagram of a partial structure of the outer casing of Embodiment 1.
  • FIG. 3 is a schematic diagram of a partial structure of the outer casing of Embodiment 1.
  • FIG. 4 is a schematic perspective view of the three-dimensional structure of the battery box of Embodiment 1 at a first viewing angle.
  • FIG. 5 is a schematic perspective view of the three-dimensional structure of the battery box of Embodiment 1 at a second viewing angle.
  • Fig. 6 is a sectional view along line A-A in Fig. 5 .
  • FIG. 7 is an enlarged view of part B in FIG. 6 .
  • FIG. 8 is a schematic diagram of a partial structure of the outer casing of Embodiment 3.
  • FIG. 8 is a schematic diagram of a partial structure of the outer casing of Embodiment 3.
  • FIG. 9 is a schematic diagram of an exploded structure of the lower box body of the battery box in Example 4.
  • FIG. 9 is a schematic diagram of an exploded structure of the lower box body of the battery box in Example 4.
  • FIG. 10 is a partial cross-sectional structural schematic diagram of the battery box of Embodiment 4.
  • FIG. 10 is a partial cross-sectional structural schematic diagram of the battery box of Embodiment 4.
  • FIG. 11 is a schematic diagram of an exploded structure of the upper case cover of the battery case of Test Example 1.
  • FIG. 11 is a schematic diagram of an exploded structure of the upper case cover of the battery case of Test Example 1.
  • FIG. 12 is a schematic structural view of the battery box of Test Example 1.
  • FIG. 12 is a schematic structural view of the battery box of Test Example 1.
  • FIG. 13 is a plan view of the upper case cover of the battery case of Test Example 1.
  • Fig. 14 is a sectional view along line C-C in Fig. 13 .
  • FIG. 15 is a schematic structural view of the battery box of Test Example 2.
  • FIG. 15 is a schematic structural view of the battery box of Test Example 2.
  • FIG. 16 is a partial cross-sectional structural schematic view of the battery box of Test Example 2.
  • FIG. 17 is a schematic diagram of a partial structure of the lower box of Test Example 2.
  • Fig. 18 is a schematic cross-sectional structure diagram of the explosion-proof valve on the upper case cover of Test Example 2.
  • Insulation cover 11261a is Insulation cover 11261a
  • this embodiment discloses a lower box of a battery box, which can be combined with an upper cover to form a battery box, after placing batteries (and electrical components) and connecting necessary components, Form battery packs for use in electric vehicles.
  • the lower case 2 has an accommodating cavity with an open upper end.
  • the lower case 2 includes an outer case 21, an inner case 22 and a support structure 23.
  • the support structure 23 is arranged between the outer case 21 and the inner case 22, so that the lower case
  • the structure of the body 2 has been strengthened to meet the strength requirements of the battery box.
  • a chamber structure is formed between the outer shell 21 and the inner shell 22 to improve the heat insulation effect of the lower box 2 .
  • both the outer casing 21 and the inner casing 22 are made of non-metallic composite materials, which have better thermal insulation performance and lighter weight than metal casings compared with metal casings. Simpler and more economical.
  • the supporting structure 23 is a reinforcing rib 231, and the reinforcing rib 231 extends between the inner casing 22 and the outer casing 21 along the opposite surfaces of the two and is arranged in a staggered manner, and the reinforcing rib 231 connects the outer casing
  • the body 21 and the inner casing 22 are separated into several chambers to form a chamber structure, so that the reinforcing ribs 231 form a gridded chamber structure, which enhances and balances the strength and heat preservation effect of the bottom of the lower box body 2 .
  • the reinforcing ribs 231 adopt a staggered form that intersects vertically and horizontally.
  • the reinforcing rib 231 and the outer casing 21 are integrally formed on the inner surface of the outer casing 21 (that is, the surface of the outer casing 21 on the side opposite to the inner casing 22), and the outer casing 21 is connected to the inner casing 21 through the reinforcing rib 231.
  • the housing 22 is adhesively connected.
  • the scheme of integrally forming the reinforcing rib 231 and the outer shell 21 has a higher connection strength, which is conducive to enhancing the overall structural strength, and the reinforcing rib 231 and the outer shell 21 can be integrally molded (or injection molding and other non-metallic composite molding processes) forming, simplifying the manufacturing process, and at the same time, the connection mode between the reinforcing rib 231 and the outer shell 21 makes the connection surface between the reinforcing rib 231 and the inner shell 22 be located at the top of the reinforcing rib 231 , It is also convenient to apply glue on the reinforcing rib 231.
  • connection area of the inner shell 22 for connecting with the reinforcing rib 231 is 20% of the surface area of the outer shell 21 opposite to the inner shell 22 . It can better balance the insulation effect and the weight of the lower box.
  • the cross section where the reinforcing rib 231 is perpendicular to its extending direction is a continuous structure, so as to form a wider reinforcing rib 231 to enhance the strength of the lower box.
  • a glue-coating groove 2314 is provided on the connecting surface of the reinforcing rib 231 , and the extending direction of the glue-coating groove 2314 is the same as the length direction of the reinforcing rib 231 where it is located.
  • the gluing groove 2314 is formed on the top of the reinforcing rib 231, and is a depression positioned at the top of the gluing groove 2314.
  • the sectional shape of the gluing groove 2314 is a rectangle and has a certain depth, which is enough to accommodate the adhesive required for the bonding strength.
  • Glue, gluing groove 2314 is used for containing viscose, prevents glue from spilling out, and the viscose in gluing groove 2314 and the groove wall top contact of gluing groove 2314 are contacted simultaneously on the outer surface of inner shell 22, guarantees the adhesive surface There is a sufficient amount of glue on it to improve the bonding effect and ensure the connection strength.
  • the gluing grooves 2314 on the connection surfaces of the staggered reinforcing ribs 231 are connected at the intersections of the reinforcing ribs 231 , so that the glue can flow along the gluing grooves 2314 in many places.
  • the uniformity of the glue distribution and the uniformity of bonding with the inner shell 22 are improved, and the overflow of the glue is also avoided to a certain extent.
  • the glue used for bonding is structural glue.
  • the inner casing 22 and the outer casing 21 are stacked, and the outer casing 21 and the inner casing 22 both have a bottom plate and side plates surrounding the edge of the bottom plate, and the outer casing
  • the bottom plate of 21 and the bottom plate of the inner shell 22 jointly constitute the bottom wall of the lower box body 2
  • the side plates of the outer shell 21 and the side plates of the inner shell 22 form the side walls of the lower box body 2
  • the accommodating cavity is formed in the inner shell
  • the reinforcing rib 231 includes a bottom reinforcing rib 2311 disposed between the bottom plate of the inner shell 22 and the bottom plate of the outer shell 21 and a side rib 2311 disposed between the side plate of the inner shell 22 and the side plate of the outer shell 21.
  • the reinforcing ribs 231 can play a role of structural reinforcement and heat preservation on the entire side wall and bottom wall of the lower box body 2 , thereby improving the overall strength of the lower box body 2 .
  • this structural form, for the lower box body 2 of non-metallic composite material its fabrication and molding are realized very easily, because inner shell 22, outer shell 21 are all made of non-metallic composite material, are convenient to bottom wall and side
  • the wall is integrally formed (molding, injection molding, etc.), which simplifies the manufacturing process.
  • the outer casing 21 and the inner casing 22 are prepared by compression molding.
  • the side ribs 2312 are formed on the inner surface of the side plate of the outer shell 21 , and the side ribs 2312 are connected to the inner shell 22 .
  • the side reinforcing ribs 2312 include vertical reinforcing ribs arranged at intervals and extending along the vertical direction, and the vertical reinforcing ribs are connected with the bottom reinforcing ribs 2311 to enhance the overall strength of the reinforcing ribs 231 .
  • the side wall of the battery box is the main stress-bearing component connected between the battery pack and the electric vehicle.
  • the glue-coating groove 2314 of the vertical rib is wider than the bottom rib 2311, which can accommodate more structural glue, improve the bonding strength between the vertical rib and the side plate of the inner shell 22, and strengthen the inner shell 22 and the integrity of the outer shell 21 side plates, enhance the overall strength.
  • the bottom of the vertical rib extends to the bottom plate of the outer shell 21 along the inner surface of the side plate of the outer shell 21 (and the surface of the outer shell 21 facing the inner shell 22), and the bottom rib 2311 It extends into the glue-coating groove 2314 of the vertical reinforcing rib and is connected with the vertical reinforcing rib to form an integral body.
  • the thickness of the lower part of the vertical reinforcing rib is greater than that of the upper part, which is not only beneficial to the separation of the product from the mold during the mold forming process; And because the bottom of the vertical rib is located at the connection between the side plate and the bottom plate of the outer shell 21, which belongs to the place of stress concentration, thickening the lower part of the vertical rib is beneficial to enhance the strength of the stress concentration.
  • the top of the vertical rib gradually shrinks toward the inner surface of the side plate of the outer shell 21 along the height direction of the inner surface of the side plate of the outer shell 21 .
  • the top of the vertical rib shrinks, preferably in the form of an R angle.
  • the height of the chamber structure between the outer casing 21 and the inner casing 22 is 5mm.
  • the air in the cavity between the outer casing 21 and the inner casing 22 is used as a poor conductor of heat to play the role of heat insulation.
  • the structure is simpler and the weight is lighter.
  • the height of the chamber structure (that is, the distance between the opposing surfaces of the outer shell 21 and the inner shell 22) will affect the thickness of the inner and outer shells.
  • the height of the chamber structure will affect the volume of the space in which the battery box formed by the lower box 2 carries the battery units.
  • the chamber structure height of 5mm is a more balanced choice in all aspects. In the case of meeting the strength of the battery pack, it also meets the heat preservation requirements, and basically does not affect the energy density of the battery.
  • the non-metallic composite material used to make the outer casing 21 and the inner casing 22 is SMC (Sheet molding compound), also known as sheet molding compound.
  • SMC Sheet molding compound
  • This is a polymer composite material, and the main raw material is made of SMC special yarn , unsaturated resin, low shrinkage additives, fillers and various additives. Molded at high temperature once, it has high mechanical strength, light material weight, corrosion resistance, long service life, high insulation strength, arc resistance, flame retardancy, good sealing performance, and higher specific heat capacity than sheet metal materials, and the product design is flexible and easy to use.
  • Large-scale production and has the advantages of safety and beauty, with all-weather protection function, can meet the needs of various harsh environments and places in outdoor engineering projects, overcome the easy corrosion of metal material boxes, short life and poor heat insulation performance, etc. defect.
  • SMC as the material of the inner and outer shells not only has light weight and good thermal insulation performance, but also can bring a certain degree of flame retardant and heat insulation performance to the battery box, avoiding the burning of the box material caused by the battery cell inside the battery box. Can avoid open flame.
  • a flange 221 is provided at the edge of the inner casing 22, and a sealing groove with an opening facing the upper cover 1 is provided at the edge of the outer casing 21, and the flange 221 is fastened.
  • the upper cover 1 is provided with a sealing vertical plate 11 at a position corresponding to the sealing groove, and the upper cover 1 and the lower box body 2 pass through the sealing groove, the sealing vertical plate 11 and the The sealing strip 3 between 11 realizes sealing, and the sealing strip 3 abuts against the flange 221 .
  • the connection between the sealing groove and the flange 221 can not only improve the connection and fixation effect between the inner casing 22 and the outer casing 21, enhance the overall strength of the lower box body 2, but also improve the sealing effect.
  • a reinforcing structure 211 is provided around the outer periphery of the outer shell 21 , and the outer shell 21 extends outward to form the reinforcing structure 211 .
  • the reinforcement structure 211 reinforcement structure includes a first reinforcement part 201, a second reinforcement part 202 and a number of external reinforcement ribs 203, the first reinforcement part 201 and the second reinforcement part 202 are set up and down around the side wall at intervals, and a number of external reinforcement parts
  • the ribs 203 are arranged at intervals along the circumferential direction of the sidewall between the first reinforcement part 201 and the second reinforcement part 202 .
  • Both the first reinforcing part 201 and the second reinforcing part 202 are plate-shaped structures, which can strengthen the strength of the side wall of the lower box in the circumferential direction.
  • the external reinforcing rib 203 is provided between the first reinforcing part 201 and the second reinforcing part 202 to strengthen the strength of the side wall in the vertical direction.
  • the structural form of the first reinforcement part 201, the second reinforcement part 202 and several external reinforcement ribs 203 enhances the strength of the side wall of the lower box in the circumferential and vertical directions, and is beneficial to the lightweight of the lower box structure.
  • the reinforcement structure 211 is used as a force-receiving part, and the quick change unit can be fixed on the reinforcement structure 211 to achieve detachable connection with the electric vehicle.
  • an L-shaped connecting plate is installed on the reinforcement structure, and a staggered-tooth locking mechanism composed of a lock shaft 10 and a guide block 20 is installed on the L-shaped connecting plate (battery pack side) and electrical connectors for quick hook-up to quick-change electric vehicles.
  • connection of the quick change unit to the lower box body 2 is set correspondingly to the reinforcing rib 231 of the lower box body 2, so that the strength of the connection part between the quick change unit and the lower box body 2 is sufficiently large, and the reliability of the lower box body 2 is improved. sex. Furthermore, the deviation of the quick change unit at the joint of the lower box 2 and the reinforcing rib 231 of the lower box 2 is within ⁇ 5cm.
  • the exposed surface of the outer bottom of the outer casing 21 is covered with a polyurea layer.
  • the polyurea layer has a thickness of 0.8-1.2 mm.
  • the polyurea layer can improve the strength of the non-metallic composite material itself, and has the functions of wear resistance, heat insulation, and can improve the strength of the bottom of the box, and has a certain degree of softness, which can ensure stability under impact.
  • this embodiment also discloses a battery box, which includes an upper cover 1 and a lower box body 2 as above, the upper cover 1 is set on the lower box body 2 and accommodates Cavity closed.
  • the battery box is covered by the upper cover 1 on the lower box body 2 to form a shell of the battery box with an inner cavity.
  • the shell can protect the battery module installed in the cavity and also keep it warm.
  • This embodiment also discloses a battery pack, the battery pack includes the above battery box and a battery unit arranged in the accommodating cavity, the battery unit includes a battery module formed by batteries, and the outer surface of the lower box is installed with Quick change unit.
  • the quick change unit is used to realize the detachable connection of the battery pack to the electric vehicle.
  • the battery pack seals the battery unit in the accommodation cavity surrounded by the upper cover 1 and the lower box body 2, forming a protective barrier for the battery module and having the effect of heat preservation.
  • the lower box of the battery pack is made of non-metallic material, which can reduce the weight compared with the metal shell, and further improve the heat preservation effect and economic benefits.
  • This embodiment also discloses an electric vehicle, including the above-mentioned battery pack.
  • the electric vehicle is a quick-change electric vehicle (the battery pack is detachably connected to the body, which can be quickly separated from the vehicle and electricity).
  • Embodiment 2 is basically the same as Embodiment 1, the difference is that, in this embodiment, a light heat insulating material is arranged in the chamber structure.
  • Lightweight insulation uses airgel felt.
  • Airgel felt is made of silica airgel as the main material and compounded in reinforcing fibers. It has the characteristics of softness, easy cutting, low density, inorganic fire prevention, overall hydrophobicity, and environmental protection.
  • SMC as the material of the inner and outer shells
  • using it at the same time not only has light weight and good heat preservation performance, but also can bring a certain degree of flame retardant and heat insulation performance to the battery box, avoiding the fire caused by the battery inside the battery box. The burning of the box material can avoid the generation of open flames.
  • the airgel blanket is bonded to the airgel blanket in a form that is as full as possible and not compressed (to avoid affecting the thermal insulation performance of the airgel blanket) by means of structural adhesive bonding. in the chamber structure.
  • this embodiment is basically the same as Embodiment 1, the difference is that the cross-section where the reinforcing rib is perpendicular to its extending direction is a split structure, and the split structure is formed on the inner surface of the outer shell 21 by intervals
  • the three sub-ribs 2313 above are formed, and the structure of the sub-ribs 2313 can reduce the contact area between the inner shell (not shown in the figure) and the outer shell 21, and the air filled in the gap formed between the sub-ribs 2313 is used It is good for heat insulation, can improve the heat preservation effect, and is also conducive to reducing the weight of the lower box body 2.
  • only the bottom rib 2311 adopts a split structure, and the length direction of the sub-rib 2313 of the split structure is consistent with the transverse direction of the battery box, so as to increase the strength of the battery box in the longitudinal direction as much as possible.
  • a narrow reinforcing rib with a narrower width than the sub-reinforcing ribs is arranged in the lateral direction of the battery box under less force.
  • Glue-coating grooves 2314 are provided on the connecting surface of the reinforcing ribs, and the extending direction of the glue-coating grooves 2314 is the same as the length direction of the reinforcing ribs where they are located.
  • the gluing groove 2314 is used to accommodate the glue, prevent the glue from overflowing, ensure that there is a sufficient amount of glue on the bonding surface, and improve the bonding effect.
  • the glue application groove 2314 of the split structure is set across the connecting surface of each sub-reinforcing rib 2313, so that the glue can be kept on the bonding surface as much as possible, and will not overflow the outside of the split structure, thereby improving the bonding effect.
  • a group of three sub-reinforcing ribs 2313 constituting the reinforcing rib structure is equivalent to the sum of the widths of the reinforcing ribs in Embodiment 1.
  • the distance between two adjacent sub-reinforcing ribs 2313 is equivalent to the width of one sub-reinforcing rib 2313, which can be equal, slightly larger or slightly smaller.
  • this embodiment is basically the same as Embodiment 1, the difference is that: the edge of the inner shell 22 is provided with a flanging 221, and the flanging 221 is buckled on the edge of the outer shell 21 , and cooperate with the edge of the outer shell 21 to improve the connection and fixation effect between the inner shell 22 and the outer shell 21, improve the integrity between the outer shell 21 and the inner shell 22, and enhance the strength of the lower box 2.
  • the ways of the flange 221 to cooperate with the edge of the outer casing 21 include adhesive connection, welding connection or clip connection. Through the above-mentioned mating connection manner, the overall connection strength and integrity of the outer shell 21 and the inner shell 22 can be further increased.
  • the upper cover 1 is set on the lower box body 2 and seals the accommodating cavity through the sealing ring 3 .
  • the reinforcing ribs 231 can be evenly spaced between the outer casing 21 and the inner casing 22 .
  • the longitudinal direction of the reinforcing ribs 231 arranged at intervals is along the transverse direction of the battery box.
  • the longitudinal direction of the battery box (the direction with longer length) usually also bears more force when the battery box is connected with the electric vehicle.
  • the longitudinal orientation of the battery box provides more strength.
  • the reinforcing rib 231 and the outer shell 21 are integrally formed on the inner surface of the outer shell 21 , the reinforcing rib 231 and the inner shell 22 may also be connected by welding.
  • the connecting area of the inner casing 22 for connecting with the reinforcing rib 231 can be 10-30% of the surface area of the outer casing 21 and the inner casing 22, for example, it can be 10%, 12%, 15%, 18%, 22%. %, 25%, 28%, 30%, etc., or any value between these values. If the bonding area is too small, the connection strength will be low; if the bonding area is too large (too much glue or the width of the reinforcement rib is too large), it will increase the contact area between the inner and outer shells, which will reduce the heat preservation effect and increase the insulation effect. The weight of the box.
  • the reinforcing rib 231 can be formed on the outer surface of the inner casing 22 (ie, the surface of the inner casing 22 facing the outer casing 21 ), and the reinforcing rib 231 is bonded or welded to the outer casing 21 .
  • the reinforcing rib When the reinforcing rib is a split structure, it can be arranged on the outer surface of the inner casing.
  • the number of sub-ribs can be set to be three or more.
  • the height of the chamber structure between the outer shell 21 and the inner shell 22 can be 1-15mm, or the thickness of the light heat insulating material in the chamber structure can be set to 1-15mm.
  • the height of the cavity structure between the outer casing 21 and the inner casing 22 may be 3-10mm or the thickness of the light heat insulating material in the cavity structure may be 3-10mm.
  • the higher the height of the chamber structure the better the heat preservation effect, but the higher the height will occupy the space of the accommodating chamber when the overall volume of the battery box is limited, thereby reducing the energy density of the battery. Therefore, the value of the height is a comprehensive consideration of many aspects. In the case of using lightweight thermal insulation materials, especially the use of airgel felt, the thickness of about 5mm can meet the strength requirements and thermal insulation requirements of the battery pack, and has little impact on the energy density of the battery.
  • the material of the outer casing 21 and the inner casing 22 can also be other polymer composite materials with light weight, certain strength and high temperature performance, preferably the polymer composite material is a fiber-reinforced resin-based composite material.
  • the fiber reinforced resin matrix composite may be carbon fiber reinforced resin matrix composite, and/or resin fiber reinforced resin matrix composite, and/or ceramic fiber reinforced resin matrix composite, and/or other types of glass fiber reinforced resin matrix composite .
  • the lightweight thermal insulation material can further enhance the thermal insulation effect of the lower box body 2 by utilizing the advantages of good thermal insulation effect and light weight of lightweight thermal insulation materials such as polymer foam materials, and has little impact on the quality of the lower box body 2 .
  • Polymer foaming material is based on polymer (plastic, rubber, elastomer or natural polymer material) and has a microporous material with numerous bubbles inside.
  • Typical foaming materials such as polyurethane (Polyurethane) foam, polystyrene ((Polystyrene) foam, etc.
  • the reinforcement structure 211 of the lower box can also be equipped with quick-change units of other structures, or a battery pack fixing unit.
  • the quick-change units of other structures are used for detachable connection with the electric vehicle, and the battery pack fixing unit is used for Car fixed connection.
  • other quick-change units include, but are not limited to: electrical/liquid cooling connectors, locking mechanisms (battery pack ends), etc.
  • Electric/liquid cooling connectors include electrical connectors and/or liquid cooling connectors. Electrical connectors are used for electrical connection with electric vehicles. Liquid cooling connectors are mainly used as liquid cooling mechanisms when using liquid cooling mechanisms inside the battery pack. The interface between the cold mechanism and the electric vehicle cools the battery pack and improves safety.
  • the locking mechanism (battery pack side) includes a threaded locking mechanism (a locking mechanism that fixes the battery box to the vehicle body through multiple bolts), a lock pin locking mechanism (the battery box is fixed to the vehicle body by locking pins) locking mechanism), rotation locking mechanism (locking mechanism that fixes the battery box and the ), top pressure locking mechanism (the locking mechanism that fixes the battery box and the vehicle body by the top pressure locking method), other types of staggered tooth locking mechanism (the battery box and the vehicle body are fixed by the staggered tooth locking method) locking mechanism), latch locking mechanism (a locking mechanism that fixes the battery box and the vehicle body by a latch locking method), push-pull locking mechanism (a locking mechanism that fixes the battery box and the vehicle body by a push-pull locking method) Wait for the locking mechanism that is arranged on the battery pack end (relative to the car end).
  • the fixing unit includes a bolt-type locking mechanism or other types of fixed connection mechanisms (including but not limited to mechanical, electrical or magnetic connections, etc.) and the like.
  • the polyurea layer can be sprayed on the entire bottom surface (including the part extending from the L-shaped connecting plate to the bottom surface).
  • the battery pack can be used for quick-change electric vehicles (the battery pack is detachably connected to the Body, with charging on the body as the main means of energy supplement), electric vehicles with quick change and charging functions and other types of electric vehicles.
  • a quick-change electric vehicle currently uses sheet metal battery packs (using mica sheets as insulation materials), and its weight is 371.5kg.
  • sheet metal battery packs using mica sheets as insulation materials
  • its weight is 371.5kg.
  • non-metallic composite battery packs with the same dimensions (external dimensions and internal space dimensions of the battery box) were prepared.
  • the non-metallic composite material lower box body obtained in Example 1 is recorded as the non-metallic composite material lower box body A, which is combined by snap-fit connection, and combined with the non-metallic composite material upper cover to form a non-metallic battery box.
  • the non-metallic composite material lower box body obtained in Example 2 is recorded as the non-metallic composite material lower box body B, which is combined by snap-fit connection, and combined with the non-metallic composite material upper cover to form a non-metallic battery box.
  • non-metallic composite material upper cover used to form the non-metallic composite material battery box with the non-metallic composite material lower box body A and the non-metallic composite material lower box body B respectively adopts the following structure:
  • the upper cover 1 is used to cover the lower box body 2 to form a battery box 3a, and after placing the battery cells (and electrical components) and connecting the necessary components, a battery pack is formed for use in electric car.
  • Loam cake 1 comprises box cover shell 11a, heat insulating layer 12a and protective layer 13a, and heat insulating layer 12a and protective layer 13a cover and are fixed on box cover shell 11a towards lower box body 2 side (that is heat insulating layer 12a covers and Fixed on the side of the case cover shell 11a facing the lower box body 2, the protective layer covers and is fixed on the side of the heat insulating layer 12a facing the lower case body 2), and the case cover shell 11a is made of non-metallic composite material.
  • the upper cover 1 is made of non-metallic composite material, and an insulating layer is provided between the case cover shell 11a and the protective layer 13a, compared with the shell made of metal, the insulating effect is better, and it is more suitable for use in cold regions. And it weighs less.
  • the upper cover 1 is compositely made of the case cover shell 11a, the heat insulating layer 12a and the protective layer 13a, so that the structure of the lower box body 2 is strengthened, meets the strength requirement of the battery box, and is also convenient for processing the upper cover 1 .
  • the material of the cover shell is SMC (Sheet molding compound), also known as sheet molding compound (a glass fiber reinforced resin-based composite material).
  • SMC Sheet molding compound
  • sheet molding compound a glass fiber reinforced resin-based composite material.
  • the heat insulation layer is made of airgel felt, and the protective layer is made of fireproof cloth.
  • the shell of the box cover, the heat insulation layer and the protective layer are bonded and connected by structural adhesive.
  • SMC Sheet molding compound
  • sheet molding compound is a glass fiber reinforced resin-based composite material.
  • the main raw materials are composed of SMC special yarn, unsaturated resin, low shrinkage additives, fillers and various additives. It is molded at high temperature at one time, with high mechanical strength, light material weight, corrosion resistance, long service life, high insulation strength, arc resistance, flame retardancy, good sealing performance, flexible product design, easy large-scale production, and safe and beautiful It has the advantages of all-weather protection, and overcomes the defects of easy corrosion, short life and poor heat insulation performance of the metal box.
  • Airgel felt uses silica airgel as the main material and is compounded in reinforcing fibers. It has the characteristics of softness, easy cutting, low density, inorganic fire prevention, overall hydrophobicity, and environmental protection. Further, the thickness of the airgel blanket used as the heat insulation layer in this test example is 5mm.
  • Fireproof cloth is light in weight, has a certain tensile strength, is flexible, and is easy to bond. Commercially available fireproof cloth can be used.
  • the upper cover 1 can be provided with a certain degree of flame retardant and heat insulation performance, so as to avoid the The material of the box body is burned due to the fire of the battery inside the battery box, so as to avoid open flames.
  • the box cover shell 11a has a top plate 111a and a side wall 112a disposed around the edge of the top plate 111a and facing the lower box body 2 Both the inner surface and the outer surface of the cover shell 11a are provided with a concave-convex structure 1111a, specifically a concave structure 1111 protruding toward the outer surface of the top plate 111a of the cover shell 11a to form a depression on the inner surface.
  • the strength of the cover shell 11a is increased by the concave-convex structure 1111a, and the concave-convex structure 1111a is also convenient for the battery box 3a to be attached and fixed to the bottom of the electric vehicle.
  • the concave-convex structure 1111a includes longitudinal ribs and transverse ribs, and the longitudinal ribs and transverse ribs are intersected. On the side, there is also a connecting rib in the middle of the two longitudinal ribs to enhance the strength of the cover shell 11a in the longitudinal and transverse directions, as shown in Figures 11-13 and 15.
  • the case cover shell 11a has a first extension 1121a arranged around its edge and extending outward.
  • the first extension 1121a is arranged on the side wall 112a and faces the edge of the lower case 2, more specifically
  • the first extension part 1121a is an extension plate extending outward from the edge of the cover shell 11a, the extension plate is arranged around the edge of the cover shell 11a, and the transition between the extension plate and the cover shell 11a is gentle.
  • the first extension part 1121a forms the edge structure of the case cover shell 11a, which is convenient for connecting with the lower case body 2, and also facilitates setting a connection structure thereon without affecting the strength of the case body.
  • the first extension 1121a is provided with a sealing portion 1122a facing the direction of the lower box body 2, and the heat insulating layer 12a and the protective layer 13a extend from the box cover shell 11a to the inside of the sealing portion 1122a (that is, the heat insulating layer 12a and the outer edges of the protective layer 13a are attached to the inner side of the sealing portion 1122a).
  • the above-mentioned structural arrangement avoids the adverse effect on the sealing caused by the extrusion of the heat insulation layer by the sealing part, and also avoids the decrease of the sealing performance caused by the extrusion of the heat insulation layer by the sealing part.
  • the thermal insulation layer and the protective layer can also play a role of heat preservation at the junction of the upper cover and the lower box body, thereby improving the heat preservation effect of the battery box.
  • the sealing portion is a sealing vertical plate 1127a arranged on the surface of the first extension portion 1121a facing the lower box body 2, the sealing vertical plate 1127a is extended around the edge of the box cover shell 11a, and the sealing vertical plate 1127a is used to realize the sealing between the upper cover 1 and the lower box body 2 by cooperating with the sealing strip 3 and embedded in the sealing groove provided in the lower box body 2 .
  • the sealing vertical plate 1127a and the sealing groove form a U-shaped seal, without increasing the width of the box body occupied by the sealing structure, the sealing area and the interaction force between the sealing part and the sealing strip are greatly increased, and the sealing effect is improved.
  • one end of the sealing vertical plate 1127a is formed at the position close to the middle of the surface of the first extension 1121a facing the lower box body, and is arranged around the edge of the box cover shell 11a, and the other end faces the seal groove.
  • the width of the sealing vertical plate 1127a on the section perpendicular to its extension direction gradually decreases along the direction away from the first extension portion 1121a, and the cross section of the sealing vertical plate 1127a forms a structure similar to an inverted trapezoid (also can be other similar shapes), which is convenient
  • the sealing vertical plate 1127a and the sealing strip 3 are embedded in the sealing groove, the sealing strip 3 is compressed and sealed to improve the sealing effect.
  • the first extension part 1121a is also provided with an assembly connection structure, which is used for the connection between the upper cover 1 and the lower box body 2, so that the installation of the connection structure is firm and reliable without affecting the upper cover 1 strength.
  • the assembly connection structure includes a buckle-type connection structure
  • the snap-type connection structure includes a second extension 1123a and a plurality of recesses 1124a provided on the second extension 1123a, and the second extension 1123a extends from the edge of the first extension 1121a It is extended toward the lower box body 2 to form a plate-like structure that surrounds the outer edge of the first extension part 1121 a and surrounds the lower box body 2 .
  • the side of the second extension part 1123 a facing the lower box body 2 is its inner side.
  • a plurality of recessed parts 1124a are arranged at intervals around the edge of the case cover shell 11a, and the recessed parts 1124a are used to engage and connect with the corresponding raised parts 21a provided on the lower case body 2, so as to realize the fastening of the upper cover 1 and the lower case body 2 connection.
  • the above-mentioned structural arrangement is adopted, and the installation is reliable in the way of snap-fit connection. During installation, it is molded once and shaped, and it is easy to disassemble.
  • the buckle-type connection structure is arranged on the side of the box without occupying the lateral width.
  • metal parts bolts and nuts
  • the box body is made of non-metallic composite materials, metal parts (bolts and nuts) may not be used at the connection between the upper cover of the battery box and the lower box body, thereby avoiding the thermal insulation performance caused by the use of metal parts decline.
  • the connection between the upper cover 1 and the lower box body 2 is not connected with bolts and nuts, the quality of the battery box can also be reduced.
  • the edge of the recessed part 1124a is provided with a slide guide groove, which is used to guide the protrusion 21a to slide into the recessed part 1124a, so as to improve the convenience of operation.
  • the recessed portion 1124a is a through hole.
  • the recessed portion 1124a may also be a blind hole, and when the recessed portion is a blind hole, the recessed portion is formed on the inner side surface of the second extension portion 1123a.
  • the strength of the case cover shell 11a can be enhanced to prevent the case cover case 1 from breaking at the recessed part 1124a.
  • the recessed portion 1124a is provided on the second extension portion 1123a, and the outer surface of the second extension portion 1123a is provided with an outwardly protruding reinforcing portion 1125a around the recessed portion 1124a, increasing the box around the recessed portion 1124a.
  • the thickness of the cover shell 11a is increased, thereby enhancing the strength of the box cover shell 11a at the recessed portion 1124a.
  • the protruding portion 21a is provided with a sliding guide surface 22a, which is used to guide the protruding portion 21a to slide into the concave portion 1124a, so as to improve the convenience of snap-fit connection operation.
  • the slide guide groove and the slide guide surface 22a are provided at the same time, so that the fastening between the upper cover 1 and the lower box body 2 is smoother.
  • an explosion-proof valve 1126a is fixed on the cover shell 11a, and the explosion-proof valve 1126a has an exposed portion exposed to the inside of the cover shell 11a (can be seen from the inside of the cover shell 11a, and the exposed portion is at least
  • the inner side of the upper cover can be used to act on the explosion-proof valve 1126a to release the pressure
  • the inner side of the cover shell 11a is provided with a heat preservation cover 11261a that at least surrounds the exposed part
  • the heat preservation cover 11261a is provided with a ventilation hole 11262a .
  • the explosion-proof valve 1126a works to discharge the liquid or gas in the battery box 3a through the vent hole 11262a, improving the safety of the battery box 3a.
  • the setting of the heat preservation cover 11261a can prevent the heat exchange of the battery box 3a from the installation position of the explosion-proof valve 1126a, and improve the heat preservation effect.
  • the ventilation hole adopts a single-hole ventilation hole, which has a simple structure and good ventilation effect.
  • the mass of the non-metallic composite material lower box B obtained in Example 2 is 45kg, while the sheet metal lower box of the same size and specification (using mica sheet as the insulation material) has a mass of 60.4kg.
  • the lower box B made of non-metallic composite material has a weight reduction of 25.5%.
  • the weight of the battery box B made of non-metallic composite material is 57.8kg, and the weight of the battery box made of sheet metal is 70.772kg.
  • the weight advantage of the battery box made of non-metallic composite material is obvious.
  • the non-metallic composite material lower box A prepared in Example 1 lacks the airgel felt placed in the chamber structure, because the density of the airgel felt is small , and the amount of use is not large, therefore, the quality of the lower box A of the non-metallic composite material is equivalent to that of the lower box B of the non-metallic composite material, slightly reduced (almost negligible).
  • the overall weight of the battery pack the overall weight of the non-metallic composite battery pack A and the non-metallic composite battery pack B is 2-3% less than that of the sheet metal battery pack, and the weight advantage is obvious.
  • the initial temperature in the package is 20-30°C, and it is placed in an environment of 7-9°C for 600 minutes
  • the accumulative temperature change rate of the cells in the pack of non-metallic composite battery pack A (The accumulative cooling rate) is lower than 50% of the battery pack made of sheet metal (the temperature of the single cell is measured by optical fiber)
  • the accumulative temperature change rate of the single cell in the non-metallic composite battery pack B is only the sheet metal battery pack.
  • About 40% of the battery pack is made of gold material. This advantage is more obvious at lower temperatures, and it can ensure that the temperature of the battery core is at a better operating temperature when used in cold northern regions.
  • the non-metallic composite material battery pack A and the non-metallic composite material battery pack B can withstand a high temperature of 1000°C.
  • the non-metallic composite material box is basically in the whole test process. In good condition with only smoke and no open flames.
  • non-metallic composite battery pack A and non-metallic composite battery pack B are filled with thermally conductive glue (the filling height of thermally conductive glue is about 1/3 of the height of the battery), so as to increase the temperature uniformity between the cells , to avoid thermal runaway caused by abnormal temperature of individual cells.
  • thermally conductive glue the filling height of thermally conductive glue is about 1/3 of the height of the battery
  • the battery cells (or battery modules formed by the battery cells) inside the battery box are formed as a whole, which increases the overall strength of the battery pack. Comparing the non-metallic composite battery pack B in the above case with the above-mentioned sheet metal battery pack, in the same environment, when charging with a charging current of 40A (SOC from 0-100%), the sheet metal battery pack is faster than the non-metallic battery pack.
  • the accumulative temperature rise of metal composite battery pack B is more than 5°C, the charging capacity of non-metallic composite battery pack B is more than 5% higher than that of sheet metal battery packs, and the maximum temperature difference inside the box of composite non-metallic battery packs ( Obtained by recording all positive and negative lug temperatures) Uniformity maintained at 1.5-2°C.
  • This is not only related to the use of thermally conductive adhesive, but also related to the specific heat capacity and thermal insulation performance of SMC higher than that of sheet metal materials. The above factors make the non-metallic composite battery pack of this application more advantageous than sheet metal battery packs in terms of avoiding thermal runaway .
  • SMC meets the following performance requirements: material grade (disordered glass fiber state) tensile strength ⁇ 70Mpa (GB/T 1447-2005), bending strength ⁇ 160MPa (GB/T 1449-2005), impact toughness ⁇ 55KJ/m2 (GB /T 1451-2005), elongation at break ⁇ 1.3% (GB/T 1447-2005).
  • Airgel felt has a density of about 0.16 mg/cm3.
  • Structural adhesive shear strength (anodized aluminum - anodized aluminum) ⁇ 6MPa, tensile strength ⁇ 5MPa, flame retardant grade V0.
  • the above-mentioned SMC, airgel felt and structural glue can be commercially available products or self-made products that meet the above performance requirements, and the rest of the materials are commercially available products.

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Abstract

本发明公开了一种电池箱的下箱体、电池箱、电池包及电动汽车，下箱体具有上端开口的容置腔，下箱体包括外壳体、内壳体和支撑结构，支撑结构设置于外壳体与内壳体之间，外壳体与内壳体之间形成有腔室结构，外壳体和内壳体均由非金属复合材料制成。该下箱体由外壳体和内壳体组成，并且在外壳体和内壳体之间设置有支撑结构，使得下箱体的结构得到了强化，以满足电池箱的强度要求；并且，在外壳体与内壳体之间还形成有腔室结构，以提高下箱体的隔热保温效果；相对于金属材料下箱体，该非金属复合材料下箱体在满足电池箱强度要求的情况下，保温性能更好，重量比金属材质箱体轻，生产工艺更加简单，提高了经济效益。

Description

电池箱的下箱体、电池箱、电池包及电动汽车
本申请要求申请日为2021年12月20日的中国专利申请CN202111567173.8的优先权以及申请日为2021年12月31日的中国专利申请202111673422.1的优先权。本申请引用上述中国专利申请的全文。
技术领域
本发明涉及电动汽车领域，特别涉及一种电池箱的下箱体、电池箱、电池包及电动汽车。
背景技术
电动汽车具有零排放、低噪音、运营和维护都十分经济等优点，越来越受到用户的青睐。电动汽车使用的能源为自身搭载的电池包提供的电能，电动汽车在电能使用完后需要充电。电动汽车的电池包设置方式一般分为固定式和可换式，其中，固定式电池包一般是固定在车辆上，在充电时直接以车辆作为充电对象。而可换式的电池包一般通过活动安装的方式被固定在车辆的托架上，电池包可以被取下，以单独进行更换或充电操作，在更换下的电池包充电完毕后，再安装在车辆上。
现有电池箱的壳体，尤其是下箱体，基于强度方面的考虑，通常用金属材质制成，例如钢、铝等材质。但是，金属材质壳体的导热系数一般比较大，导致电池包保温效果差，电池包的温度易随环境温度变化而变化。虽然现有技术中，有金属材质壳体电池箱通过增加云母片来提升保温性能，但是提升效果有限。特别是当电池包在寒区使用时，当环境温度较低时，电池包的温度下降也就越快，电池包效能降低就越发明显。
发明内容
本发明要解决的技术问题是为了克服现有技术中的电池箱保温效果差的缺陷，提供一种电池箱的下箱体、电池箱、电池包及电动汽车。
本发明是通过下述技术方案来解决上述技术问题：
一种电池箱的下箱体，所述下箱体具有上端开口的容置腔，所述下箱体包括外壳体、内壳体和支撑结构，所述支撑结构设置于所述外壳体与所述内壳体之间，所述外壳体与所述内壳体之间形成有腔室结构，所述外壳体和所述内壳体均由非金属复合材料制成。
在本方案中，该下箱体由外壳体、内壳体组成，并且在外壳体和内壳体之间设置有支撑结构，使得非金属复合材质下箱体的结构得到了强化，以满足电池箱的强度要求。并且，在外壳体与内壳体之间还形成有腔室结构，以提高下箱体的隔热保温效果，同时，下箱体由非金属复合材料制成，与金属材料的壳体相比，进一步增强了保温性能，而且非金属复合材料的密度比金属材料更小。相对于金属材料下箱体，本申请的非金属复合材料下箱体在满足电池箱强度要求的情况下，保温性能更好，重量比金属材质箱体轻，生产工艺更加简单，提高了经济效益。
较佳地，所述支撑结构为加强筋，所述加强筋在所述内壳体与所述外壳体之间沿二者相对的表面延伸并间隔或交错设置，所述加强筋将所述外壳体与所述内壳体之间隔成若干腔室，以形成所述腔室结构。
在本方案中，采用上述结构形式，尤其是在采用交错设置的加强筋的情况下，使得加强筋形成网格化结构，增强并均衡下箱体底部的强度。
较佳地，所述加强筋形成于所述外壳体的内侧表面，且所述加强筋与所述内壳体连接；
或者，所述加强筋形成于所述内壳体的外侧表面，且所述加强筋与所述外壳体连接。
在本方案中，采用上述加强筋与外壳体或内壳体一体成型的方案，有利于增强整体结构强度，简化制作工艺，同时也便于在加强筋上涂胶。
较佳地，所述加强筋与所述内壳体或所述外壳体的连接方式包括粘接连接或焊接连接。
较佳地，所述外壳体用于与所述加强筋连接的连接面积或所述内壳体用于与所述加强筋连接的连接面积为所述外壳体与所述内壳体相对的表面面积的10％-30％。
在本方案中，若粘接面积过小，连接强度低；若粘接面积过大，会增加内壳体与外壳体之间的接触面积，从而会降低保温效果，粘接面积过大，会使用到较宽的加强筋和/或较多的结构胶，这会增加下箱体的重量。优选为，内壳体与外壳体的粘接面积占外壳体或内壳体用于粘接所在的平面面积的百分比为20％。
较佳地，所述加强筋垂直于其延伸方向所在的截面为连续结构；
或者，所述加强筋垂直于其延伸方向所在的截面为分体式结构，所述分体式结构由间隔形成于所述外壳体的内侧表面或外壳体的内侧表面上的至少两个子加强筋构成。
在本方案中，可以采用较粗的加强筋或几个并列的较窄的子加强筋形成的加强筋来增强下箱体的强度，其中子加强筋结构能够减少内壳体和外壳体之间的接触面积，子加强筋之间形成的间隙用于隔热，能够提高保温效果，也有利于减轻下箱体的重量。
较佳地，所述加强筋的连接面上设有涂胶凹槽，所述涂胶凹槽的延伸方向与其所在所述加强筋的长度方向相同。
在本方案中，涂胶凹槽用于容纳粘胶，防止胶水外溢，保证粘接面上有足够量的胶水，提高粘接效果。
较佳地，所述加强筋垂直于其延伸方向所在的截面为分体式结构，所述分体式结构具有并列布置且隔有间隙的至少两个子加强筋，所述涂胶凹槽横跨各子加强筋的连接面设置。
在本方案中，采用上述结构形式，使得胶水尽量多地保持在粘接面上，且不会溢出分体式结构的外部，提高粘接效果。
较佳地，交错设置的所述加强筋的连接面上的涂胶凹槽在所述加强筋的相交处相连通。
在本方案中，采用上述结构形式，使得胶水多地方能够沿涂胶凹槽流动至胶水少的地方，并均匀分布在涂胶凹槽内，提高胶水分布的均匀性。另外也能提高粘接面的连贯性，增强粘接连接的强度。
较佳地，所述内壳体和所述外壳体叠放设置，且所述外壳体和所述内壳体均具有底板以及包围于 所述底板的边缘的侧板，所述外壳体的底板和所述内壳体的底板共同构成所述下箱体的底壁，所述外壳体的侧板和所述内壳体的侧板构成所述下箱体的侧壁，所述容置腔形成于所述内壳体中，所述加强筋包括设置于所述内壳体的底板与所述外壳体的底板之间的底部加强筋以及设置于所述内壳体的侧板与所述外壳体的侧板之间的侧部加强筋。
在本方案中，加强筋设置于内壳体的底板与外壳体的底板之间，以及内壳体的侧板与外壳体的侧板之间，在整个下箱体的内、外壳体相对的表面上都能起到结构加强和保温作用。而且采用上述结构形式，便于制成非金属复合材料的下箱体，提高下箱体的整体的强度。由于内壳体、外壳体均由非金属复合材料制成，便于底壁与侧壁一体成型(模压、注塑等方式)，简化制作工艺。
较佳地，所述侧部加强筋形成于所述外壳体的侧板内表面，且所述侧部加强筋与所述内壳体连接；
所述侧部加强筋包括间隔设置且沿竖向方向延伸的竖向加强筋，且所述竖向加强筋与所述底部加强筋相连接。
在本方案中，竖向加强筋与底部的加强筋相连，能够提升加强筋的整体强度。
较佳地，所述竖向加强筋的底部沿所述外壳体的侧板的内表面延伸至所述外壳体的底板，所述底部加强筋伸入至所述竖向加强筋的涂胶凹槽中，并与所述竖向加强筋的底部相连；
和/或，所述竖向加强筋的下部厚度大于上部厚度；
和/或，所述竖向加强筋的顶部沿所述外壳体的侧板内表面高度方向逐渐向所述外壳体的侧板内表面收缩。
在本方案中，电池箱的侧壁是电池包与电动汽车之间连接的主要受力部件。竖向加强筋的涂胶凹槽比底部加强筋更宽，能够容纳更多的结构胶，提升竖向加强筋与内壳体的侧板之间的粘接强度，增强内、外壳体侧板的一体性，提升整体强度。
竖向加强筋下部厚度较大，不仅有利于模具成型过程中，产品与模具的分离；而且由于竖向加强筋的底部位于外壳体的侧板与底板的连接处，属于应力集中处，将竖向加强筋下部加厚，有利于增强应力集中处的强度。
竖向加强筋顶部收缩，优选采用R角的方式收缩，这样的结构有利于外壳体的边缘与内壳体的边缘平缓过度，避免在二者边缘处出现应力集中。
较佳地，所述腔室结构内设有轻质保温材料，所述轻质保温材料包括聚合物发泡材料或气凝胶毡。
在本方案中，利用聚合物发泡材料、气凝胶毡等轻质保温材料隔热效果佳、质轻的优点，置于腔室结构内，进一步增强下箱体的保温效果，并且对下箱体质量影响较小。聚合物发泡材料是以聚合物(塑料、橡胶、弹性体或天然高分子材料)为基础而其内部具有无数气泡的微孔材料，典型的发泡材料如聚氨酯(Polyurethane)泡沫、聚苯乙烯(Polystyrene)泡沫等。气凝胶毡是以二氧化硅气凝胶为主体材料，并复合于增强性纤维中，具有柔软﹑易裁剪﹑密度小、无机防火﹑整体疏水、绿色环保等特性。
较佳地，所述外壳体与所述内壳体之间的腔室结构的高度为1～15mm或轻质保温材料的厚度为1～15mm；优选所述外壳体与所述内壳体之间的腔室结构的高度为3～10mm或轻质保温材料的厚度为 3～10mm；进一步优选所述外壳体与所述内壳体之间的腔室结构的高度为5mm或轻质保温材料的厚度为5mm。
在本方案中，腔室结构高度越高，保温效果越好，但是高度越高，会使得电池箱总体体积受限的情况下，侵占容置腔的空间，从而降低电池能量密度。因此，高度的取值是一个综合多方面考虑的问题。在采用了轻质保温材料的情况下，尤其是采用气凝胶毡的情况下，5mm左右的厚度的能够满足保温要求，且对电池能量密度影响较小。本申请中优选所述轻质保温材料为气凝胶毡。气凝胶毡可以采用结构胶粘接于腔室结构内，或者填充于腔室结构内。气凝胶毡尽量以不被压缩的方式置于腔室结构中，以避免影响气凝胶毡的保温性能。
较佳地，所述内壳体的边缘处设有翻边，所述翻边扣设于所述外壳体的边缘上，并与所述外壳体的边缘配合连接。
在本方案中，在内壳体边缘设置翻边并扣设在外壳体上，提高内壳体与外壳体边缘处的连接固定效果，进一步提升外壳体和内壳体之间的整体性，增强下箱体的强度。
较佳地，所述翻边与所述外壳体的边缘配合连接的方式包括粘接连接、焊接连接或卡接连接。
在本方案中，通过上述配合连接方式，能够进一步增加外壳体与内壳体的整体连接强度和一体性。
较佳地，所述非金属复合材料包括纤维增强树脂基复合材料；优选所述纤维增强树脂基复合材料包括玻璃纤维增强树脂基复合材料、和/或碳纤维增强树脂基复合材料、和/或树脂纤维增强树脂基复合材料、和/或陶瓷纤维增强树脂基复合材料。
在本方案中，非金属复合材料可以是纤维增强树脂基复合材料，也可以是其他重量轻、具有一定强度和高温性能的高分子复合材料，优选非金属复合材料为纤维增强树脂基复合材料，其具有较好的强度和保温性能，而且加工成型方便。进一步优选非金属复合材料为玻璃纤维增强树脂基复合材料，更进一步优选非金属复合材料为SMC(Sheet molding compound)，又称为片状模塑料，是一种高分子复合材料，主要原料由SMC专用纱、不饱和树脂、低收缩添加剂，填料及各种助剂组成。经高温一次模压成型，具有机械强度高、材料重量轻、耐腐蚀、使用寿命长，绝缘强度高、耐电弧、阻燃、密封性能好，且产品设计灵活，易规模化生产，并有安全美观的优点，具有全天候防护功能，克服了金属材质箱体的易锈蚀、寿命短和隔热保温性能差等缺陷。
较佳地，所述外壳体的侧面外周环绕设置有加强结构，所述外壳体侧面向外延展形成所述加强结构。
在本方案中，通过设置加强结构，能够增强外壳体侧面强度。加强结构能够作为受力部位，实现在该加强结构上固定快换单元实现与电动汽车的可拆卸连接，或者通过固定单元将采用该下箱体的电池包固定于电动汽车上。锁止机构锁止机构
较佳地，所述外壳体的至少外侧底部的外露面上覆有聚脲层。
在本方案中，聚脲层能提高非金属复合材料自身强度，并且具有耐磨、隔热保温的作用，能够提高箱底强度，并且有一定柔软度，在冲击下能保证稳定性。
一种电池箱，所述电池箱包括上盖和如上所述的下箱体，所述上盖盖设于所述下箱体上并将所述 容置腔封闭。
在本方案中，该电池箱通过上盖盖在下箱体上，形成具有内部容置腔的电池箱的壳体，该壳体能够保护安装在容纳腔内的电池模组，也能够对其进行保温。
较佳地，所述内壳体的边缘处设有翻边，所述外壳体的边缘处设有开口朝向上盖的密封槽，所述翻边扣设于所述密封槽内，所述上盖在与所述密封槽相对应的位置设有密封立板，所述上盖与所述下箱体之间至少通过所述密封槽、密封立板以及设置于所述密封槽与所述密封立板之间的密封条实现密封，所述密封条至少与所述翻边相抵接。
在本方案中，采用上述结构形式，利用密封槽与翻边连接，不仅能够提高内壳体与外壳体的连接固定效果，增强下箱体的整体强度，而且能够提高密封效果。
一种电池包，所述电池包包括如上所述的电池箱以及设置于所述容置腔内的电池单元，所述电池单元包括电芯或由电芯形成的电池模组，所述下箱体的外侧面安装有快换单元或固定单元，所述快换单元用于实现所述电池包相对电动汽车的可拆卸连接；所述固定单元用于实现所述电池包与电动汽车的固定连接。
在本方案中，该电池包将电池单元封闭在上盖与下箱体围成的容纳腔内，对电池模组形成保护屏障且具有保温效果。并且，该电池包的下箱体采用非金属复合材质制成，与金属材质的壳体相比可减轻重量，进一步提高保温效果和经济效益。
其中，快换单元包括但不限于：电/液冷连接器、锁止机构等，锁止机构包括螺纹锁止机构(通过多个螺栓把电池箱与车身进行固定的锁止机构)、锁销锁止机构(通过锁销锁止方式把电池箱与车身进行固定的锁止机构)、旋转锁止机构(通过旋转锁止方式把电池箱与车身进行固定的锁止机构)、翻转锁止机构(通过翻转锁止方式把电池箱与车身进行固定的锁止机构)、顶压锁止机构(通过顶压锁止方式把电池箱与车身进行固定的锁止机构)、错齿锁止机构(通过错齿锁止方式把电池箱与车身进行固定的锁止机构)、插销锁止机构(通过插销锁止方式把电池箱与车身进行固定的锁止机构)、推拉锁止机构(通过推拉锁止方式把电池箱与车身进行固定的锁止机构)。
固定单元包括螺栓式锁紧机构或其他类型的固定连接式机构(包括但不限于机械式、电连接式或磁连接式等)等。
较佳地，所述快换单元或所述固定单元于所述下箱体的连接处与所述下箱体的加强筋对应设置。
本方案中，快换单元或固定单元作为电池包与电动汽车连接时的主要受力部件，容易成为强度薄弱环节，将其与下箱体的加强筋对应设置，能够增强强度，提升电池包与电动汽车连接的可靠性。
一种电动汽车，包括上述的电池包。
在符合本领域常识的基础上，上述各优选条件，可任意组合，即得本发明各较佳实例。
本发明的积极进步效果在于：该下箱体由外壳体、内壳体组成，并且在内壳体、外壳体之间设置有支撑结构，使得下箱体的结构得到了强化，以满足电池箱的强度要求。并且，在外壳体与内壳体之间还形成有腔室结构，以提高下箱体的隔热保温效果，同时，下箱体由非金属复合材料制成，与金属材料的壳体相比，进一步增强了保温性能，而且非金属复合材料的密度比金属材料更小。相对于金属 材料下箱体，本申请的非金属复合材料下箱体在满足电池箱强度要求的情况下，保温性能更好，重量比金属材质箱体轻，生产工艺更加简单，提高了经济效益。
附图说明
图1为实施例1电池箱的下箱体的结构示意图。
图2为实施例1的外壳体的结构示意图。
图3为实施例1的外壳体的局部结构示意图。
图4为实施例1的电池箱第一视角的立体结构示意图。
图5为实施例1的电池箱第二视角的立体结构示意图。
图6为图5中沿A-A线的剖面图。
图7为图6中B部分的放大图。
图8为实施例3的外壳体的局部结构示意图。
图9为实施例4电池箱的下箱体的分解结构示意图。
图10为实施例4电池箱的局部剖面结构示意图。
图11为试验例1的电池箱的上箱盖的分解结构示意图。
图12为试验例1的电池箱的结构示意图。
图13为试验例1的电池箱的上箱盖的俯视图。
图14为图13中沿C-C线的剖面图。
图15为试验例2的电池箱的结构示意图。
图16为试验例2的电池箱的局部剖面结构示意图。
图17为试验例2的下箱体的局部结构示意图。
图18为试验例2的上箱盖上的防爆阀剖面结构示意图。
附图标记说明：
上盖1
密封立板11
下箱体2
外壳体21
第一加强部201
第二加强部202
外部加强筋203
加强结构211
内壳体22
翻边221
支撑结构23
加强筋231
底部加强筋2311
侧部加强筋2312
子加强筋2313
涂胶凹槽2314
密封条3
锁轴10
导向块20
电池箱3a
箱盖外壳11a
隔热层12a
保护层13a
顶板111a
侧壁112a
凹凸结构1111a
第一延伸部1121a
密封部1122a
密封立板1127a
第二延伸部1123a
凹陷部1124a
加强部1125a
凸起部21a
导滑面22a
防爆阀1126a
保温罩11261a
通气孔11262a
具体实施方式
下面通过实施例的方式进一步说明本发明，但并不因此将本发明限制在所述的实施例范围之中。
实施例1
如图1-图7所示，本实施例公开了一种电池箱的下箱体，该下箱体可与上盖组合形成电池箱，放置电芯(以及电气部件)并连接必要部件后，形成电池包，用于电动汽车。
该下箱体2具有上端开口的容置腔，下箱体2包括外壳体21、内壳体22和支撑结构23，支撑结构23设置在外壳体21与内壳体22之间，使得下箱体2的结构得到了强化，以满足电池箱的强度要 求。并且，在外壳体21与内壳体22之间还形成有腔室结构，以提高下箱体2的隔热保温效果。在本实施例中，外壳体21和内壳体22均由非金属复合材料制成，与金属材料的壳体相比，保温性能更好，重量与金属材质箱体相比更轻，生产工艺更加简单，提高了经济效益。
如图2所示，在本实施例中，支撑结构23为加强筋231，加强筋231在内壳体22与外壳体21之间沿二者相对的表面延伸并交错设置，加强筋231将外壳体21与内壳体22之间隔成若干腔室，以形成腔室结构，使得加强筋231形成网格化的腔室结构，增强并均衡下箱体2底部的强度和保温效果。更具体地，本实施例中，加强筋231采用纵横相交的交错形式。
在本实施例中，加强筋231与外壳体21一体形成于外壳体21的内侧表面(即外壳体21上相对于内壳体22一侧的表面)，且外壳体21通过加强筋231与内壳体22粘接连接。加强筋231与外壳体21一体成型的方案相对于加强筋231与外壳体21粘接或焊接的方案，连接强度更高，有利于增强整体结构强度，而且加强筋231与外壳体21可以一体模压(或注塑等其他非金属复合材料成型工艺)成型，简化制作工艺，同时这种加强筋231与外壳体21的连接方式，使得加强筋231与内壳体22的连接面位于加强筋231的顶部，也便于在加强筋231上涂胶。
本实施例中，内壳体22用于与加强筋231连接的连接面积为外壳体21与内壳体22相对的表面面积的20％。能更好地平衡保温效果和下箱体的重量。
如图1和图2所示，本实施例中，加强筋231垂直于其延伸方向所在的截面为连续结构，以形成宽度较大的加强筋231，增强下箱体的强度。
如图3所示，本实施例中，加强筋231的连接面上设有涂胶凹槽2314，涂胶凹槽2314的延伸方向与其所在加强筋231的长度方向相同。涂胶凹槽2314形成于加强筋231的顶部，为位于涂胶凹槽2314顶部的凹陷，涂胶凹槽2314的截面形状为矩形，具有一定的深度，足够容纳满足粘接强度所需的粘胶，涂胶凹槽2314用于容纳粘胶，防止胶水外溢，内壳体22外侧表面同时与涂胶凹槽2314内的粘胶以及涂胶凹槽2314的槽壁顶部接触，保证粘接面上有足够量的胶水，提高粘接效果，并保证连接强度。
如图3所示，本实施例中，交错设置的加强筋231的连接面上的涂胶凹槽2314在加强筋231的相交处相连通，使得粘胶多地方能够沿涂胶凹槽2314流动至胶水少的地方，并均匀分布在涂胶凹槽2314内，提高粘胶分布的均匀性以及与内壳体22粘接的均匀性，也在一定程度上避免了粘胶的外溢。另外也能提高粘接面的连贯性，增强粘接连接的强度。本是实施例中，粘接用的胶水采用结构胶。
如图1和图3所示，本实施例中，内壳体22和外壳体21叠放设置，且外壳体21和内壳体22均具有底板以及包围于底板的边缘的侧板，外壳体21的底板和内壳体22的底板共同构成下箱体2的底壁，外壳体21的侧板和内壳体22的侧板构成下箱体2的侧壁，容置腔形成于内壳体22中，加强筋231包括设置于内壳体22的底板与外壳体21的底板之间的底部加强筋2311以及设置于内壳体22的侧板与外壳体21的侧板之间的侧部加强筋2312。加强筋231在整个下箱体2的侧壁和底壁上都能起到结构加强和保温作用，从而提高下箱体2的整体的强度。而且该结构形式，对于非金属复合材料的下箱体2而言，其制作成型是很容易实现的，由于内壳体22、外壳体21均由非金属复合材料制成， 便于底壁与侧壁一体成型(模压、注塑等方式)，简化制作工艺。本实施例中采用模压成型的方式制备外壳体21和内壳体22。
如图3所示，本实施例中，侧部加强筋2312形成于外壳体21的侧板内表面，且侧部加强筋2312与内壳体22连接。侧部加强筋2312包括间隔设置且沿竖向方向延伸的竖向加强筋，且竖向加强筋与底部加强筋2311相连接，能够提升加强筋231的整体强度。
在本实施例中，电池箱的侧壁是电池包与电动汽车之间连接的主要受力部件。竖向加强筋的涂胶凹槽2314比底部加强筋2311更宽，能够容纳更多的结构胶，提升竖向加强筋与内壳体22的侧板之间的粘接强度，增强内壳体22和外壳体21侧板的一体性，提升整体强度。
进一步地，本实施例中，竖向加强筋的底部沿外壳体21的侧板的内表面(及外壳体21的朝向内壳体22的表面)延伸至外壳体21的底板，底部加强筋2311伸入至竖向加强筋的涂胶凹槽2314中，并与竖向加强筋相连形成一体，竖向加强筋的下部厚度大于上部厚度，不仅有利于模具成型过程中，产品与模具的分离；而且由于竖向加强筋的底部位于外壳体21的侧板与底板的连接处，属于应力集中处，将竖向加强筋下部加厚，有利于增强应力集中处的强度。
更进一步地，本实施例中，竖向加强筋的顶部沿外壳体21的侧板内表面高度方向逐渐向外壳体21的侧板内表面收缩。竖向加强筋顶部收缩，优选采用R角的方式收缩，这样的结构有利于外壳体21的边缘与内壳体22的边缘平缓过度，避免在二者边缘处出现应力集中。
更进一步地，本实施例中，外壳体21与内壳体22之间的腔室结构的高度为5mm。利用外壳体21与内壳体22之间的空腔中的空气作为热的不良导体，起到隔热保温的作用。结构更加简单，重量更轻。在电池箱外部尺寸确定以及内部电池单元容量确定的情况下，腔室结构的高度(也就是外壳体21与内壳体22之间相对的表面之间的距离)会影响内外壳体的厚度，或者在内外壳体厚度确定的情况下，腔室结构的高度会影响到该下箱体2所形成的电池箱承载电池单元的空间的容积。而5mm的腔室结构高度，是各方面一个较为均衡的选择。在满足电池包使用强度的情况下，同时满足保温要求，且基本上不会对电池能量密度带来影响。
本实施例中，制作外壳体21和内壳体22的非金属复合材料为SMC(Sheet molding compound)，又称为片状模塑料，这是一种高分子复合材料，主要原料由SMC专用纱、不饱和树脂、低收缩添加剂，填料及各种助剂组成。经高温一次模压成型，具有机械强度高、材料重量轻、耐腐蚀、使用寿命长，绝缘强度高、耐电弧、阻燃、密封性能好，比热容也高于钣金材料，且产品设计灵活，易规模化生产，并有安全美观的优点，具有全天候防护功能，能够满足室外工程项目中各种恶劣环境和场所的需要，克服了金属材料箱体的易锈蚀、寿命短和隔热保温性能差等缺陷。
使用SMC作为内外壳体材料，不仅质量轻，保温性能好，而且能够为电池箱带来一定程度上的阻燃隔热性能，避免由于电池箱内部的电芯失火造成的箱体材料的燃烧，能够避免产生明火。
如图7所示，进一步地，在本实施例中，内壳体22的边缘处设有翻边221，外壳体21的边缘处设有开口朝向上盖1的密封槽，翻边221扣设于密封槽内，上盖1在与密封槽相对应的位置设有密封立板11，上盖1与下箱体2之间通过密封槽、密封立板11以及设置于密封槽与密封立板11之间的密 封条3实现密封，密封条3与翻边221相抵接。利用密封槽与翻边221连接，不仅能够提高内壳体22与外壳体21的连接固定效果，增强下箱体2的整体强度，而且能够提高密封效果。
进一步地，在本实施例中，如图1所示，外壳体21的侧面外周环绕设置有加强结构211，外壳体21侧面向外延展形成加强结构211。进一步地，加强结构211加强结构包括第一加强部201、第二加强部202和若干外部加强筋203，第一加强部201和第二加强部202一上一下环绕侧壁间隔设置，若干外部加强筋203沿侧壁的周向方向间隔设置于第一加强部201和第二加强部202之间。第一加强部201和第二加强部202均为板状结构，能够在周向方向强化下箱体的侧壁的强度。外部加强筋203设在第一加强部201和第二加强部202之间，以强化侧壁在竖向方向的强度。第一加强部201、第二加强部202和若干外部加强筋203的结构形式，增强下箱体的侧壁在环向和竖向方向上的强度，而且有利于下箱体结构的轻量化。通过设置加强结构211，增强外壳体21侧面强度。加强结构211作为受力部位，能够实现在该加强结构211上固定快换单元实现与电动汽车的可拆卸连接。
进一步地，在本实施例中，如图2和图4所示，在加强结构上安装有L型连接板，L形连接板上安装有锁轴10和导向块20构成的错齿锁止机构(电池包端)以及电连接器，用于快速挂接到快换电动汽车上。
进一步地，快换单元于下箱体2的连接处与下箱体2的加强筋231对应设置，使得快换单元与下箱体2的连接部位的强度足够大，提高下箱体2的可靠性。更进一步地，快换单元于下箱体2的连接处与下箱体2的加强筋231对应设置的偏差在±5cm之内。
进一步地，在本实施例中，在外壳体21的外侧底部的外露面上覆有聚脲层。优选地，聚脲层的厚度为0.8-1.2mm。聚脲层能提高非金属复合材料自身强度，并且具有耐磨、隔热保温的作用，能够提高箱底强度，并且有一定柔软度，在冲击下能保证稳定性。
如图4-图7所示，本实施例还公开了一种电池箱，该电池箱包括上盖1和如上的下箱体2，上盖1盖设于下箱体2上并将容置腔封闭。该电池箱通过上盖1盖在下箱体2上，形成具有内部容置腔的电池箱的壳体，该壳体能够保护安装在容纳腔内的电池模组，也能够对其进行保温。
本实施例还公开了一种电池包，该电池包包括如上的电池箱以及设置于容置腔内的电池单元，电池单元包括由电芯形成的电池模组，下箱体的外侧面安装有快换单元。快换单元用于实现电池包相对电动汽车的可拆卸连接。该电池包将电池单元封闭在上盖1与下箱体2围成的容纳腔内，对电池模组形成保护屏障且具有保温效果。并且，该电池包的下箱体采用非金属材质制成，与金属材质的壳体相比可减轻重量，进一步提高保温效果和经济效益。
本实施例还公开了一种电动汽车，包括上述的电池包。电动汽车为快换电动汽车(电池包可拆卸地连接于车身，可以进行快速的车电分离)。
实施例2
本实施例与实施例1基本相同，其不同之处在于，在本实施例中，腔室结构内设有轻质保温材料。轻质保温材料采用气凝胶毡。气凝胶毡是以二氧化硅气凝胶为主体材料，并复合于增强性纤维中，具 有柔软﹑易裁剪﹑密度小、无机防火﹑整体疏水、绿色环保等特性。在使用SMC作为内外壳体材料的情况下，同时使用，不仅质量轻，保温性能好，而且能够为电池箱带来一定程度上的阻燃隔热性能，避免由于电池箱内部的电芯失火造成的箱体材料的燃烧，能够避免产生明火。
进一步地，在本实施例中，本实施例中，气凝胶毡采用结构胶粘接的方式，以尽量充满并不被压缩(以避免影响气凝胶毡的保温性能)的形式粘接于腔室结构中。
实施例3
如图8所示，本实施例与实施例1基本相同，其不同之处在于：加强筋垂直于其延伸方向所在的截面为分体式结构，分体式结构由间隔形成于外壳体21的内侧表面上的三个子加强筋2313构成，子加强筋2313结构能够减少内壳体(图中未示出)和外壳体21之间的接触面积，子加强筋2313之间形成的间隙内填充的空气用于隔热，能够提高保温效果，也有利于减轻下箱体2的重量。
进一步地，在本实施例中，仅底部加强筋2311采用分体式结构，分体式结构的子加强筋2313的长度方向与电池箱的横向方向一致，以尽可能增加电池箱纵向方向上的强度。在受力较小的电池箱横向方向上设置宽度较子加强筋窄的窄加强筋。通过上述设置，可以在保证箱体强度的同时，少用加强筋，有利于减轻箱体质量。
加强筋的连接面上设有涂胶凹槽2314，涂胶凹槽2314的延伸方向与其所在加强筋的长度方向相同。涂胶凹槽2314用于容纳粘胶，防止胶水外溢，保证粘接面上有足够量的胶水，提高粘接效果。分体式结构的涂胶凹槽2314横跨各子加强筋2313的连接面设置，使得胶水尽量多地保持在粘接面上，且不会溢出分体式结构的外部，提高粘接效果。
更进一步地，本实施例中，构成加强筋结构的一组共三个子加强筋2313，其宽度之和与实施例1中的加强筋相当。相邻两个子加强筋2313之间间隔的距离与一个子加强筋2313的宽度相当，可以相等、略大或略小。
实施例4
如图9和图10所示，本实施例与实施例1基本相同，其不同之处在于：内壳体22的边缘处设有翻边221，翻边221扣设于外壳体21的边缘上，并与外壳体21的边缘配合连接，提高内壳体22与外壳体21的连接固定效果，提升外壳体21和内壳体22之间的整体性，增强下箱体2的强度。
其中，翻边221与外壳体21的边缘配合连接的方式包括粘接连接、焊接连接或卡接连接。通过上述配合连接方式，能够进一步增加外壳体21与内壳体22的整体连接强度和一体性。上盖1盖设于下箱体2上并通过密封圈3将容置腔封闭。
除了上述实施例，在其他的实施例中还可以：
加强筋231可均匀间隔设置在外壳体21和内壳体22之间。优选间隔设置的加强筋231的长度方向沿电池箱横向方向。电池箱的纵向方向(长度较长的方向)在电池箱与电动汽车连接时，通常也会承受更多的力，将间隔设置的加强筋231的长度方向设置在电池箱横向方向上，能够为电池箱的纵向 方向提供更多的强度。
当加强筋231与外壳体21一体形成于外壳体21的内侧表面时，加强筋231与内壳体22之间也可采用焊接连接的方式。
内壳体22用于与加强筋231连接的连接面积可以为外壳体21与内壳体22相对的表面面积的10-30％，例如可以为10％、12％、15％、18％、22％、25％、28％、30％等，或这些数值间的任意值。若粘接面积过小，连接强度低；若粘接面积过大(涂胶过多或加强筋宽度过大)，会增加内外壳体之间的接触面积，从而会降低保温效果，并增加下箱体的重量。
加强筋231可形成于内壳体22的外侧表面(即内壳体22的朝向外壳体21的表面)，且加强筋231与外壳体21粘接或焊接连接。
当加强筋为分体式结构时，可以设置在内壳体的外侧表面。子加强筋的数量可以设置为三个以上。
外壳体21与内壳体22之间的腔室结构的高度可以为1-15mm，或者将腔室结构内的轻质保温材料的厚度设置为1-15mm。优选地，外壳体21与内壳体22之间的腔室结构的高度可以为3-10mm或者腔室结构中的轻质保温材料的厚度可以为3-10mm。腔室结构高度越高，保温效果越好，但是高度越高，会使得电池箱总体体积受限的情况下，侵占容置腔的空间，从而降低电池能量密度。因此，高度的取值是一个综合多方面考虑的问题。在采用了轻质保温材料的情况下，尤其是采用气凝胶毡的情况下，5mm左右的厚度能够满足电池包的强度要求和保温要求，且对电池能量密度影响较小。
外壳体21和内壳体22的材质也可以是其他重量轻、具有一定强度和高温性能的高分子复合材料，优选高分子复合材料为纤维增强树脂基复合材料。纤维增强树脂基复合材料可以是碳纤维增强树脂基复合材料、和/或树脂纤维增强树脂基复合材料、和/或陶瓷纤维增强树脂基复合材料、和/或其他类型的玻璃纤维增强树脂基复合材料。
轻质保温材料可以利用聚合物发泡材料等轻质保温材料隔热效果佳、质轻的优点，进一步增强下箱体2的保温效果，并且对下箱体2质量影响较小。聚合物发泡材料是以聚合物(塑料、橡胶、弹性体或天然高分子材料)为基础而其内部具有无数气泡的微孔材料，典型的发泡材料如聚氨酯(Polyurethane)泡沫、聚苯乙烯((Polystyrene)泡沫等。
下箱体的加强结构211上还可以安装有其他结构的快换单元，或者安装有电池包固定单元，其他结构的快换单元用于与电动汽车可拆卸连接，电池包固定单元用于与电动汽车固定连接。其中，其他快换单元包括但不限于：电/液冷连接器、锁止机构(电池包端)等。电/液冷连接器包括电连接器和/或液冷连接器，电连接器用于与电动汽车的电连接，液冷连接器主要是用于在电池包内部使用液冷机构的情况下作为液冷机构与电动汽车连接的接口，对电池包进行冷却，提高安全性。锁止机构(电池包端)包括螺纹锁止机构(通过多个螺栓把电池箱与车身进行固定的锁止机构)、锁销锁止机构(通过锁销锁止方式把电池箱与车身进行固定的锁止机构)、旋转锁止机构(通过旋转锁止方式把电池箱与车身进行固定的锁止机构)、翻转锁止机构(通过翻转锁止方式把电池箱与车身进行固定的锁止机构)、顶压锁止机构(通过顶压锁止方式把电池箱与车身进行固定的锁止机构)、其他类型的错齿锁止机构(通过错齿锁止方式把电池箱与车身进行固定的锁止机构)、插销锁止机构(通过插销锁止方式 把电池箱与车身进行固定的锁止机构)、推拉锁止机构(通过推拉锁止方式把电池箱与车身进行固定的锁止机构)等等设置于电池包端(相对于车端而言)的锁止机构。固定单元包括螺栓式锁紧机构或其他类型的固定连接式机构(包括但不限于机械式、电连接式或磁连接式等)等。
在电池箱下箱体设有L型连接板的情况下，可以在整个底面(包含L型连接板向底面延伸的部分)喷涂聚脲层。
通过安装合适的快换单元或电池包固定单元，使得电池包可用于快换电动汽车(电池包可拆卸地连接于车身，可以进行快速的车电分离)、充电型电动汽车(电池包固定于车身，以装载在车身上充电作为主要的补能手段)、兼具快换和充电功能的电动汽车等类型的电动汽车。
试验例
某快换电动汽车目前使用钣金材质电池包(使用云母片作为保温材料)，其重量为371.5kg。根据实施例1和实施例2来制备得到相同的尺寸规格(外部尺寸以及电池箱内部空间尺寸)的非金属复合材质电池包。
将实施例1制得的非金属复合材质下箱体记作非金属复合材质下箱体A，采用卡扣扣合连接的方式组合，与非金属复合材料上盖组合形成非金属电池箱，记作非金属复合材质电池箱A，装入电池模组及必要的电气元件后形成非金属复合材质电池包A。
将实施例2制得的非金属复合材质下箱体记作非金属复合材质下箱体B，采用卡扣扣合连接的方式组合，与非金属复合材料上盖组合形成非金属电池箱，记作非金属复合材质电池箱B，装入电池模组及必要的电气元件后形成非金属复合材质电池包B。
上述用于与非金属复合材质下箱体A以及与非金属复合材质下箱体B分别形成非金属复合材质电池箱的非金属复合材质上盖采用以下结构：
如图11-图14所示，该上盖1用于盖设于下箱体2上，以形成电池箱3a，放置电芯(以及电气部件)并连接必要部件后，形成电池包，用于电动汽车。上盖1包括箱盖外壳11a、隔热层12a和保护层13a，隔热层12a和保护层13a依次覆盖并固定于箱盖外壳11a朝向下箱体2一侧(即隔热层12a覆盖并固定于箱盖外壳11a朝向下箱体2的一侧，保护层覆盖并固定在隔热层12a朝向下箱体2的一侧)，箱盖外壳11a由非金属复合材料制成。由于上盖1由非金属复合材料制成，并且在箱盖外壳11a与保护层13a之间设置有保温层，与金属材质的壳体相比，保温效果更好，更适用于寒区使用，并且重量更轻。该上盖1由箱盖外壳11a、隔热层12a和保护层13a复合制成，使得下箱体2的结构得到了强化，满足电池箱的强度要求，也便于加工制作上盖1。
在本试验例中，箱盖外壳的材质为SMC(Sheet molding compound)，又称为片状模塑料(一种玻璃纤维增强树脂基复合材料)。隔热层的材质为气凝胶毡，保护层的材质为防火布。箱盖外壳、隔热层与保护层之间通过结构胶粘接连接。
SMC(Sheet molding compound)，又称为片状模塑料，是一种玻璃纤维增强树脂基复合材料，主要原料由SMC专用纱、不饱和树脂、低收缩添加剂，填料及各种助剂组成。经高温一次模压成型， 具有机械强度高、材料重量轻、耐腐蚀、使用寿命长，绝缘强度高、耐电弧、阻燃、密封性能好，且产品设计灵活，易规模化生产，并有安全美观的优点，具有全天候防护功能，克服了金属材质箱体的易锈蚀、寿命短和隔热保温性能差等缺陷。
气凝胶毡以二氧化硅气凝胶为主体材料，并复合于增强性纤维中，具有柔软﹑易裁剪﹑密度小、无机防火﹑整体疏水、绿色环保等特性。进一步地，本试验例中用作隔热层的气凝胶毡的厚度为5mm。
防火布重量轻，具有一定的拉伸强度，柔性，容易粘接。可以选用市售的防火布。
粘接固定的方式，便于分开制作不同部件，然后将多个部件复合制成上盖。
在使用SMC作为箱盖外壳11a，气凝胶毡层作为隔热蹭的情况下，不仅质量轻，保温性能好，而且能够为上盖1带来一定程度上的阻燃隔热性能，避免由于电池箱内部的电芯失火造成的箱体材料燃烧，避免产生明火。
增强树脂基复合材料增强树脂基复合材料增强树脂基复合材料增强树脂基复合材料在本试验例中，箱盖外壳11a具有顶板111a以及环绕顶板111a的边缘设置并朝向下箱体2的侧壁112a，箱盖外壳11a的内表面和外表面均设有凹凸结构1111a，具体地为向箱盖外壳11a的顶板111a的外表面凸出从而在内表面形成凹陷的凹陷结构1111。通过凹凸结构1111a以增加箱盖外壳11a的强度，同时凹凸结构1111a也便于电池箱3a与电动汽车的底部贴合固定。具体地，凹凸结构1111a包括纵向凸筋和横向凸筋，纵向凸筋和横向凸筋交叉设置，多个间隔布置的横向凸筋连接于相对顶板长度方向中线对称布置的两个纵向凸筋的两侧，两个纵向凸筋的中间还连接有一连接凸筋，以增强箱盖外壳11a在纵向和横向的强度，如图11-图13和图15所示。
如图14所示，箱盖外壳11a具有环绕其边缘设置并向外延展的第一延伸部1121a，第一延伸部1121a设置于侧壁112a上且朝向下箱体2的边缘处，更具体地，第一延伸部1121a为从箱盖外壳11a的边缘向外侧延展的延伸板，该延伸板环绕箱盖外壳11a边缘一周设置，且延伸板与箱盖外壳11a的连接处过渡平缓。第一延伸部1121a形成箱盖外壳11a的边缘结构，便于与下箱体2连接，也便于在其上设置连接结构，而不会影响箱体的强度。
如图14所示，第一延伸部1121a上设有朝向下箱体2方向的密封部1122a，隔热层12a和保护层13a从箱盖外壳11a延伸至密封部1122a内(即：隔热层12a和保护层13a的外侧边缘贴合于密封部1122a的内侧)。上述结构设置，一来避免了隔热层被密封部挤压对密封的不利影响，二来也避免了隔热层被密封部挤压造成的密封性能下降。使得隔热层和保护层在上盖与下箱体的结合部位也能够起到保温作用，提高电池箱的保温效果。
如图15-图18所示，密封部为设置于第一延伸部1121a朝向下箱体2的表面上的密封立板1127a，密封立板1127a环绕箱盖外壳11a的边缘延伸设置，密封立板1127a用于通过与密封条3配合并嵌入设置于下箱体2的密封槽内，以实现上盖1与下箱体2的密封。密封立板1127a与密封槽形成U形密封的方式，在不增加密封结构占用箱体宽度的情况下，大幅提升密封面积以及密封部与密封条之间的相互作用力，提高密封效果。
如图16所示，本试验例中，密封立板1127a的一端形成于第一延伸部1121a朝向下箱体的表面 的靠近中部的位置处，并环绕箱盖外壳11a边缘一周设置，另一端朝向密封槽。密封立板1127a在垂直于其延伸方向的截面上的宽度沿远离第一延伸部1121a的方向逐渐减小，密封立板1127a横截面形成类似倒梯形的结构(也可以是其他类似形状)，便于密封立板1127a和密封条3嵌入密封槽时，将密封条3压紧密封，提高密封效果。
如图16和图17所示，第一延伸部1121a上还设有装配连接结构，装配连接结构用于上盖1与下箱体2的连接，使得连接结构安装牢固可靠，不会影响上盖1的强度。装配连接结构包括卡扣式连接结构，卡扣式连接结构包括第二延伸部1123a以及设于第二延伸部1123a上的多个凹陷部1124a，第二延伸部1123a从第一延伸部1121a的边缘向下箱体2方向延伸设置，形成环绕第一延伸部1121a外侧边缘一周且将下箱体2包围的板状结构，第二延伸部1123a朝向下箱体2的一侧为其内侧。多个凹陷部1124a环绕箱盖外壳11a的边缘间隔布置，凹陷部1124a用于与对应设置于下箱体2上的凸起部21a卡合连接，以实现上盖1与下箱体2的扣接连接。
在本方案中，采用上述结构设置，卡合连接的方式安装可靠，安装时一次模压定型，拆装方便。另外，卡扣式连接结构设置于箱体的侧面，不占用横向宽度。而且在箱体采用非金属复合材料的情况下，使得电池箱的上盖与下箱体之间的连接处可以不采用金属件(螺栓和螺母)，避免了采用金属件所带来的保温性能下降。而且由于在上盖1与下箱体2的连接处不使用螺栓和螺母连接，也能够降低电池箱的质量。
凹陷部1124a的边缘设置有导滑槽，导滑槽用于引导凸起部21a滑入凹陷部1124a，提高操作的便捷性。
如图15和图16所示，凹陷部1124a为通孔。通孔时，便于观察凸起部21a是否卡合到位，也便于通过通孔对凸起部21a进行辅助校正操作。当然，本试验例中，凹陷部1124a还可为盲孔，当凹陷部为盲孔时，凹陷部形成在第二延伸部1123a朝向内侧的一侧表面。凹陷部1124a为盲孔时，可增强箱盖外壳11a的强度，避免箱盖外壳1在凹陷部1124a处断开。
如图16所示，凹陷部1124a设于第二延伸部1123a上，第二延伸部1123a的外表面在凹陷部1124a周围设有向外凸起的加强部1125a，增加了凹陷部1124a周围的箱盖外壳11a的厚度，从而增强箱盖外壳11a在凹陷部1124a处的强度。
如图17所示，凸起部21a上设有导滑面22a，导滑面22a用于引导凸起部21a滑入凹陷部1124a，提高卡扣式连接操作的便捷性。本试验例中同时设置导滑槽与导滑面22a，上盖1与下箱体2之间的扣合更加顺畅。
如图15和图18所示，箱盖外壳11a上固定有防爆阀1126a，防爆阀1126a具有暴露于箱盖外壳11a的内侧的暴露部(可从箱盖外壳11a内侧被看到，暴露部至少可以起到上盖内侧气体能够作用到防爆阀1126a上起到泄压作用的部件上)，箱盖外壳11a的内侧设置有至少包围暴露部的保温罩11261a，保温罩11261a上设有通气孔11262a。当电池箱3a内的电池热失控时，防爆阀1126a工作，将电池箱3a内的液体或气体通过通气孔11262a排出，提高电池箱3a的安全性。保温罩11261a的设置，可防止电池箱3a从防爆阀1126a安装位置处进行热交换，提高保温效果。通气孔采用单孔的通气孔，结 构简单，通气效果好。
对相同尺寸规格的非金属复合材质电池包A、非金属复合材质电池包B以及钣金材质电池包进行测试。
重量测试方面，实施例2制得的非金属复合材料下箱体B，其质量为45kg，而相同尺寸规格的钣金材质下箱体(使用云母片作为保温材料)其质量为60.4kg。相较于钣金材质下箱体，非金属复合材质下箱体B减重达到25.5％。非金属复合材料电池箱B的重量为57.8kg，钣金材质电池箱的重量为70.772kg，非金属复合材质电池箱重量优势明显。实施例1制得的非金属复合材料下箱体A，相较于非金属复合材料下箱体B，缺少了在腔室结构中放置的气凝胶毡，由于气凝胶毡的密度较小，而使用量不大，因此，非金属复合材料下箱体A的质量与非金属复合材料下箱体B相当，略有降低(几乎可以忽略)。在电池包总体重量方面，非金属复合材料电池包A和非金属复合材料电池包B的总体重量相较于钣金材质电池包，总体重量减少2-3％，重量优势明显。
强度测试方面，非金属复合材质下箱体A和非金属复合材质下箱体B，以及用于与二者组合形成复合材料非金属电池箱的非金属复合材料上盖均满足GB/T 31467.3-2015《电动汽车用锂离子动力蓄电池包和系统第3部分：安全性要求与测试方法》所规定的强度等方面的要求(实际测试中可达到标准的1.5倍)。能够用于电动汽车。
保温性能和隔热性能方面：初始包内温度在20-30℃，并放置在7-9℃的环境中经历600min，非金属复合材质电池包A的包内电芯单体的累计温度变化率(累计降温速率)低于钣金材质电池包的50％(电芯单体温度通过光纤测量)，非金属复合材质电池包B的包内电芯单体的累计温度变化率更是仅有钣金材质电池包的约40％。在更低温度下，这个优势更加明显，在北方寒冷地区使用，能够保证电芯的温度处于较佳的运行温度下。而且经过测试，非金属复合材料电池包A和非金属复合材料电池包B可耐1000℃高温，在模拟电池起火的试验中，即使电池完全燃烧，非金属复合材料箱体在整个试验过程中基本保持完好，仅出现过冒烟而没有明火。
非金属复合材质电池包A和非金属复合材质电池包B的电芯放置腔内灌注导热胶(导热胶灌注高度为电池高度的1/3左右)，一来增加电芯之间的温度均一性，避免由于个别电芯温度异常导致的热失控。二来也使得电池箱内部的各电芯(或者由电芯形成的电池模组)形成一个整体，增加了电池包的整体强度。上述情况下的非金属复合材料电池包B与上述钣金材料电池包相比，在相同的环境中，以40A的充电电流充电(SOC从0-100％)时，钣金材质电池包比非金属复合材质电池包B累计温升高5℃以上，非金属复合材质电池包B相较于钣金材质电池包充电容量高5％以上，且复合材料非金属电池包的箱体内部最大温差(通过记录所有正负极耳温度获得)均匀性维持在1.5-2℃。这不仅与使用了导热胶有关，还与SMC的比热容及保温性能高于钣金材料有关，上述因素使得本申请的非金属复合材料电池包在避免热失控方面较钣金材质电池包更具优势。
上述试验例所使用到的部分原料性能如下：
SMC满足以下性能要求：材料级(无序玻纤状态)拉伸强度≥70Mpa(GB/T 1447-2005)，弯曲强度≥160MPa(GB/T 1449-2005)，冲击韧性≥55KJ/m2(GB/T 1451-2005)，断裂延伸率≥1.3％(GB/T 1447-2005)。
气凝胶毡的密度为约0.16mg/cm3。
结构胶剪切强度(阳极氧化铝-阳极氧化铝)≥6MPa，拉伸强度≥5MPa，阻燃等级V0。
上述SMC、气凝胶毡和结构胶可以是复合以上性能要求的市售产品或自制产品，其余材料为市售产品。
虽然以上描述了本发明的具体实施方式，但是本领域的技术人员应当理解，这仅是举例说明，本发明的保护范围是由所附权利要求书限定的。本领域的技术人员在不背离本发明的原理和实质的前提下，可以对这些实施方式做出多种变更或修改，但这些变更和修改均落入本发明的保护范围。

Claims (20)

  1. 一种电池箱的下箱体，所述下箱体具有上端开口的容置腔，其特征在于，所述下箱体包括外壳体、内壳体和支撑结构，所述支撑结构设置于所述外壳体与所述内壳体之间，所述外壳体与所述内壳体之间形成有腔室结构，所述外壳体和所述内壳体均由非金属复合材料制成。
  2. 如权利要求1所述的电池箱的下箱体，其特征在于，所述支撑结构为加强筋，所述加强筋在所述内壳体与所述外壳体之间沿二者相对的表面延伸并间隔或交错设置，所述加强筋将所述外壳体与所述内壳体之间隔成若干腔室，以形成所述腔室结构。
  3. 如权利要求2所述的电池箱的下箱体，其特征在于，所述加强筋形成于所述外壳体的内侧表面，且所述加强筋与所述内壳体连接；
    或者，所述加强筋形成于所述内壳体的外侧表面，且所述加强筋与所述外壳体连接。
  4. 如权利要求2或3所述的电池箱的下箱体，其特征在于，所述加强筋与所述内壳体或所述外壳体的连接方式包括粘接连接或焊接连接。
  5. 如权利要求2-4中至少一项所述的电池箱的下箱体，其特征在于，所述外壳体用于与所述加强筋连接的连接面积或所述内壳体用于与所述加强筋连接的连接面积为所述外壳体与所述内壳体相对的表面面积的10％-30％。
  6. 如权利要求2-5中至少一项所述的电池箱的下箱体，其特征在于，所述加强筋垂直于其延伸方向所在的截面为连续结构；
    或者，所述加强筋垂直于其延伸方向所在的截面为分体式结构，所述分体式结构由间隔形成于所述外壳体的内侧表面或外壳体的内侧表面上的至少两个子加强筋构成。
  7. 如权利要求2-6中至少一项所述的电池箱的下箱体，其特征在于，所述加强筋的连接面上设有涂胶凹槽，所述涂胶凹槽的延伸方向与其所在所述加强筋的长度方向相同。
  8. 如权利要求7所述的电池箱的下箱体，其特征在于，所述加强筋垂直于其延伸方向所在的截面为分体式结构，所述分体式结构具有并列布置且隔有间隙的至少两个子加强筋，所述涂胶凹槽横跨各子加强筋的连接面设置。
  9. 如权利要求7或8所述的电池箱的下箱体，其特征在于，交错设置的所述加强筋的连接面上的涂胶凹槽在所述加强筋的相交处相连通。
  10. 如权利要求2-9中至少一项所述的电池箱的下箱体，其特征在于，所述内壳体和所述外壳体叠放设置，且所述外壳体和所述内壳体均具有底板以及包围于所述底板的边缘的侧板，所述外壳体的底板和所述内壳体的底板共同构成所述下箱体的底壁，所述外壳体的侧板和所述内壳体的侧板构成所述下箱体的侧壁，所述容置腔形成于所述内壳体中，所述加强筋包括设置于所述内壳体的底板与所述外壳体的底板之间的底部加强筋以及设置于所述内壳体的侧板与所述外壳体的侧板之间的侧部加强筋。
  11. 如权利要求10所述的电池箱的下箱体，其特征在于，所述侧部加强筋形成于所述外壳体的侧板内表面，且所述侧部加强筋与所述内壳体连接；
    所述侧部加强筋包括间隔设置且沿竖向方向延伸的竖向加强筋，且所述竖向加强筋与所述底部加强筋相连接。
  12. 如权利要求11所述的电池箱的下箱体，其特征在于，所述竖向加强筋的底部沿所述外壳体的侧板的内表面延伸至所述外壳体的底板，所述底部加强筋伸入至所述竖向加强筋的涂胶凹槽中，并与所述竖向加强筋的底部相连；
    和/或，所述竖向加强筋的下部厚度大于上部厚度；
    和/或，所述竖向加强筋的顶部沿所述外壳体的侧板内表面高度方向逐渐向所述外壳体的侧板内表面收缩。
  13. 如权利要求1-12中至少一项所述的电池箱的下箱体，其特征在于，所述腔室结构内设有轻质保温材料，所述轻质保温材料包括聚合物发泡材料或气凝胶毡；
    优选的，所述外壳体与所述内壳体之间的腔室结构的高度为1～15mm或轻质保温材料的厚度为1～15mm；优选所述外壳体与所述内壳体之间的腔室结构的高度为3～10mm或轻质保温材料的厚度为3～10mm，进一步优选所述外壳体与所述内壳体之间的腔室结构的高度为5mm或轻质保温材料的厚度为5mm。
  14. 如权利要求1-13中至少一项所述的电池箱的下箱体，其特征在于，所述内壳体的边缘处设有翻边，所述翻边扣设于所述外壳体的边缘上，并与所述外壳体的边缘配合连接；
    优选的，所述翻边与所述外壳体的边缘配合连接的方式包括粘接连接、焊接连接或卡接连接。
  15. 如权利要求1-14中至少一项所述的电池箱的下箱体，其特征在于，所述非金属复合材料包括纤维增强树脂基复合材料；优选所述纤维增强树脂基复合材料包括玻璃纤维增强树脂基复合材料、和/或碳纤维增强树脂基复合材料、和/或树脂纤维增强树脂基复合材料、和/或陶瓷纤维增强树脂基复合材料。
  16. 如权利要求1-15中至少一项所述的电池箱的下箱体，其特征在于，所述外壳体的侧面外周环绕设置有加强结构，所述外壳体的侧面向外延展形成所述加强结构；
    和/或，所述外壳体的至少外侧底部的外露面上覆有聚脲层。
  17. 一种电池箱，其特征在于，所述电池箱包括上盖和如权利要求1-16中任一项所述的电池箱的下箱体，所述上盖盖设于所述下箱体上并将所述容置腔封闭。
  18. 如权利要求17所述的电池箱，其特征在于，所述内壳体的边缘处设有翻边，所述外壳体的边缘处设有开口朝向上盖的密封槽，所述翻边扣设于所述密封槽内，所述上盖在与所述密封槽相对应的位置设有密封立板，所述上盖与所述下箱体之间至少通过所述密封槽、密封立板以及设置于所述密封槽与所述密封立板之间的密封条实现密封，所述密封条至少与所述翻边相抵接。
  19. 一种电池包，其特征在于，所述电池包包括如权利要求17或18所述的电池箱以及设置于所述容置腔内的电池单元，所述电池单元包括电芯或由电芯形成的电池模组，所述下箱体的外侧面安装有快换单元或固定单元，所述快换单元用于实现所述电池包相对电动汽车的可拆卸连接；所述固定单元用于实现所述电池包与电动汽车的固定连接；
    优选的，所述快换单元或所述固定单元于所述下箱体的连接处与所述下箱体的加强筋对应设置。
  20. 一种电动汽车，其特征在于，包括如权利要求19所述的电池包。
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