Ultrahigh-strength rolling steel battery lower box body and production process thereof

Abstract

The invention relates to the technical field of battery box bodies, and discloses an ultrahigh-strength rolling steel battery lower box body and a production process thereof.The battery lower box body comprises a frame, a liquid cooling plate and a bottom protection plate which are sequentially arranged from top to bottom, sealant is arranged between the lower end of the frame and the liquid cooling plate, and the lower end of the frame and the liquid cooling plate are connected through a step-free double-layer rivet nut; sealing cotton is arranged between the liquid cooling plate and the bottom protection plate and connected through bolts. The frame is mounted on a vehicle body, and the battery is mounted in the frame. An outer edge beam, an inner beam and a vehicle body connecting mounting beam are produced by using an ultra-high-strength sheet 1.0 mm material with the elongation percentage being 5% or above through rolling, pipe coiling and other processes, the strength is guaranteed by designing a reinforced shape, meanwhile, the effects of light weight and low cost are achieved, and the cost of a moped enterprise is reduced, and the product competitiveness is improved; the bottom of the lower box body adopts a step-free double-layer riveting sealing structure, so that a double-layer sealing effect is achieved, a gap between a bottom protection plate and a liquid cooling plate is eliminated, sundries are prevented from being accumulated in a cavity, and the service life of the lower box body is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of battery boxes, and more specifically, the present invention relates to an ultra-high-strength roll-formed steel battery lower box and its production process. Background Art

[0002] As the carrier for power batteries, the battery lower box is widely used in new energy vehicles. The battery lower box provides an installation space for the battery cells and also has certain structural strength, airtightness and other safety performances. Before 2018, the country required that the energy density of power batteries should be greater than 300 Wh / kg. Aluminum extrusion lower boxes were generally used in the market as the carriers for battery cells. However, problems such as low utilization rate of aluminum extrusion materials and high aluminum price costs have kept the price of battery packs high, which is also one of the reasons why new energy vehicles of the same level are more expensive than traditional fuel vehicles. With the cancellation of the battery energy density requirement and the reduction of subsidies for new energy vehicles by the state, in order to solve the vehicle manufacturing cost problem and enhance market competitiveness, the battery lower box has begun to transform from aluminum extrusion to stamped steel and roll-formed steel, thus solving the problems of high cost and excessive carbon emissions. In the current solutions, the technical problems are as follows: Although the stamped steel or roll-formed steel battery lower box reduces the cost to a certain extent compared with the aluminum box, the density of steel is one-third of the density of aluminum, resulting in an increase in the overall weight of the battery pack and a decrease in the endurance ability.

[0003] Therefore, it is necessary to propose an ultra-high-strength roll-formed steel battery lower box and its production process to at least partially solve the problems existing in the prior art, so that while reducing the cost of the battery lower box, the weight is comparable to that of the same aluminum box. Summary of the Invention

[0004] A series of simplified concepts are introduced in the Summary of the Invention section, which will be further described in detail in the Detailed Description section. The Summary of the Invention section of the present invention does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the protection scope of the claimed technical solution.

[0005] To at least partially solve the above problems, the present invention provides an ultra-high-strength roll-formed steel battery lower box, including:

[0006] A frame, a liquid cooling plate and a bottom guard plate arranged in sequence from top to bottom. A sealant is provided between the lower end of the frame and the liquid cooling plate and connected by a stepped double-layer rivet nut. A sealing cotton is provided between the liquid cooling plate and the bottom guard plate and connected by bolts; the frame is installed on the vehicle body, and the battery is installed inside the frame; a phase change heat dissipation frame is detachably connected to the outer side of the frame, and a plurality of heat conduction cylinders are connected to the phase change heat dissipation frame and extend into the interior of the frame.

[0007] Preferably, the frame includes an external side beam, an internal beam, and a body connection mounting beam connected to the vehicle body. The external side beam includes a front side beam, a rear side beam, a left side beam, a right side beam, a left front side beam, and a right front side beam. The left side beam and the right side beam are connected to both ends of the rear side beam. Both ends of the left front side beam are respectively connected to the front side beam and the left side beam. Both ends of the right front side beam are respectively connected to the front side beam and the right side beam.

[0008] Preferably, the external side beam is made of ultra-high strength dual-phase steel. The cross-section of the front side beam is set as a "mouth" shaped cross-section. The cross-sections of the rear side beam, the left side beam, the right side beam, the left front side beam, and the right front side beam are set as "day" shaped cross-sections. The ends of each beam of the external side beam are obliquely cut to form a cut surface. The adjacent cut surfaces are welded and the upper and lower surfaces are flush.

[0009] Preferably, the internal beam includes a front cross beam, a rear cross beam, an intermediate longitudinal beam, and several electrical installation beams. Both ends of the front cross beam are respectively connected to the front sides of the left side beam and the right side beam; both ends of the rear cross beam are respectively connected to the rear sides of the left side beam and the right side beam. The rear side of the rear cross beam is connected to the rear side beam in upper and lower segments; both ends of the intermediate longitudinal beam are respectively connected to the front cross beam and the rear cross beam; both ends of several electrical installation beams are respectively connected to the front side beam and the front cross beam.

[0010] Preferably, the internal beam is made of ultra-high strength dual-phase steel. Each beam of the internal beam is connected by welding and the lower surfaces are flush. The cross-section of each beam of the internal beam is set as a square or a rectangle.

[0011] Preferably, the body connection mounting beam includes a mounting body beam, a sleeve, and a support plate. Several mounting body beams are symmetrically connected to the outer sides of the left side beam and the right side beam; the mounting body beam is provided with holes both above and below. The sleeve is connected to the holes of the mounting body beam. Bolts pass through the sleeve and are connected to the vehicle body. Support plates are connected to both the upper and lower parts of the mounting body beam.

[0012] Preferably, the body connection mounting beam is made of ultra-high strength dual-phase steel. Each component of the body connection mounting beam is connected by welding. The cross-section of the mounting body beam is set as an "L" shape.

[0013] Preferably, the liquid cooling plate includes an upper plate and a lower plate. The top end of the upper plate contacts the frame. The bottom end of the lower plate contacts the bottom guard plate; the frame and the liquid cooling plate are connected by a step-less double-layer rivet nut; the sealing cotton is bonded to the lower part of the liquid cooling plate by tape.

[0014] Preferably, the bottom guard plate is provided with several concave and convex shapes. The bottom guard plate includes a bottom guard plate body and a PVC protective layer arranged below it. The bottom guard plate is connected to the step-less double-layer rivet nut by bolts.

[0015] Preferably, a production process of an ultra-high strength roll-formed steel battery lower box body is applied to the ultra-high strength roll-formed steel battery lower box body described above, and includes:

[0016] Using a roll-forming process to produce several beams of the frame and welding and assembling to form the frame;

[0017] Apply sealant to the bottom surface of the frame;

[0018] Cover the liquid cooling plate under the sealant and connect the liquid cooling plate to the frame through a stepped double-layer rivet nut;

[0019] Bond the sealing cotton under the liquid cooling plate with tape;

[0020] Connect the bottom guard plate to the stepped double-layer rivet nut through bolts;

[0021] Fasten the phase change heat dissipation frame on the outer side surface of the frame.

[0022] Preferably, the sealant is evenly applied to the lower end of the frame using an automatic sealant application device, which includes: a lower box clamping tooling and a sealant application robot. The lower box clamping tooling is used to fix the frame and make the bottom surface of the frame face upward. The sealant application robot is arranged on one side of the lower box clamping tooling and is used to evenly coat the sealant on the bottom surface of the frame.

[0023] Preferably, the lower box clamping tooling includes:

[0024] A moving base, with walking wheels arranged at the bottom of the moving base. The moving base can be moved to a preset sealant application position and locked;

[0025] A tooling bottom plate, connected above the moving base; first clamping units and second clamping units are arranged at the edge of the tooling bottom plate. The first clamping unit is positioned and connected to the body connection mounting beam, and the second clamping unit is positioned and connected to the perimeter of the external side beam.

[0026] Preferably, the first clamping unit includes:

[0027] A first support, connected to the tooling bottom plate;

[0028] A first arm, connected to the first support, and a positioning part is connected to the top of the first arm. The positioning part includes a tapered head, and the tapered head extends into the sleeve and abuts against its inner wall;

[0029] A second arm, rotatably connected to the first support, and a first positioning pressing block is connected to the bottom end of the second arm. The first positioning pressing block presses against the mounting body beam.

[0030] Preferably, the second clamping unit includes:

[0031] A second support, connected to the tooling bottom plate;

[0032] A lower bracket, connected to the outer side surface of the second support, with threaded holes arranged on the lower bracket;

[0033] The upper bracket is slidably connected above the lower bracket, and a second positioning press block is connected to the inner side surface of the upper bracket, and the second positioning press block abuts against the outer side of the external side beam; a waist-shaped groove is provided on the upper bracket, and a bolt passes through the waist-shaped groove and is connected to a threaded hole;

[0034] The support block is connected to the top end of the second support, and the support block abuts against the upper surface of the external side beam.

[0035] Compared with the prior art, the present invention has at least the following beneficial effects:

[0036] The present invention provides an ultra-high-strength roll-formed steel battery lower box body and its production process. By using an ultra-high-strength thin plate material with a thickness of 1.0 mm and an elongation rate of more than 5%, the outer side beam, the internal beam, and the vehicle body connection and mounting beam are produced through processes such as roll forming and pipe rolling. The design of the strengthening shape ensures strength while achieving the effects of lightweight and low cost, helping vehicle manufacturers reduce costs and improve product competitiveness; the bottom of the lower box body uses a stepped double-layer riveting sealing structure to achieve a double-layer sealing effect while eliminating the gap between the bottom guard plate and the liquid cooling plate, avoiding the accumulation of sundries in the cavity, and improving the service life of the lower box body.

[0037] For an ultra-high-strength roll-formed steel battery lower box body and its production process according to the present invention, other advantages, objectives, and features of the present invention will be partially reflected by the following description, and partially will be understood by those skilled in the art through the research and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the present invention, and do not constitute a limitation to the present invention. In the drawings:

[0039] Figure 1 is an exploded view of the structure of an ultra-high-strength roll-formed steel battery lower box body of the present invention;

[0040] Figure 2 is a schematic structural diagram of the frame in the present invention;

[0041] Figure 3 is a schematic cross-sectional view of the front side beam in the present invention;

[0042] Figure 4 is a schematic cross-sectional view of the rear side beam, the left side beam, the right side beam, the left front side beam, and the right front side beam in the present invention;

[0043] Figure 5 is a schematic cross-sectional structure diagram of the ultra-high-strength roll-formed steel battery lower box body in the present invention;

[0044] Figure 6 is a schematic structural diagram of the vehicle body connection and mounting beam in the present invention;

[0045] Figure 7 It is a schematic structural diagram of the automatic glue - applying equipment in the present invention;

[0046] Figure 8 It is a schematic structural diagram of the first clamping unit in the present invention;

[0047] Figure 9 It is a schematic structural diagram of the second clamping unit in the present invention;

[0048] Figure 10 It is a schematic installation structure diagram of the phase - change heat - dissipation frame in the present invention;

[0049] Figure 11 It is a schematic cross - sectional structure diagram of the phase - change heat - dissipation frame in the present invention;

[0050] Figure 12 It is a schematic partial structure diagram of the phase - change heat - dissipation frame in the present invention;

[0051] Figure 13 In the present invention Figure 11 The partial enlarged structure diagram at position A;

[0052] Figure 14 In the present invention Figure 11 The partial enlarged structure diagram at position B.

[0053] In the figure: 1. Frame; 2. Liquid - cooling plate; 3. Bottom guard plate; 4. Sealant; 5. Sealing surface; 7. Step - less double - layer rivet nut; 8. Bolt; 1 - 1. Front beam; 1 - 2. Rear beam; 1 - 3. Left beam; 1 - 4. Right beam; 1 - 5. Left front - side beam; 1 - 6. Right front - side beam; 1 - 7. Front cross - beam; 1 - 8. Rear cross - beam; 1 - 10. Intermediate longitudinal beam; 1 - 11. Body connection and mounting beam; 1 - 12. Electrical installation beam; 1 - 11 - 1. Mounting body beam; 1 - 11 - 2. Sleeve; 1 - 11 - 3. Support plate; 2 - 1. Upper plate; 2 - 2. Lower plate; 3 - 1. Bottom guard - plate body; 3 - 2. PVC protective layer; 21. Mobile base; 22. Tooling base plate; 23. First support; 24. First arm; 25. Tapered head; 26. Second arm; 27. First positioning press - block; 28. Second support; 29. Lower support; 31. Upper support; 32. Second positioning press - block; 33. Threaded hole; 34. Waist - shaped slot; 35. Support block; 41. Phase - change heat - dissipation frame; 42. Heat - conducting cylinder; 43. Support frame; 44. Card slot; 45. Card strip; 46. Heat - dissipation frame sealant; 47. Phase - change heat - dissipation plate; 48. Plug strip; 51. Cylinder body; 52. First thermal expansion airbag; 53. First heat - storage element; 54. Second heat - storage element; 55. Capillary heat - conducting tube; 56. Second thermal expansion airbag; 57. Heat - dissipation tip. Detailed implementation manners

[0054] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments, so that those skilled in the art can implement it according to the description in the specification.

[0055] It should be understood that the terms such as "having", "comprising", and "including" used herein do not exclude the presence or addition of one or more other elements or their combinations.

[0056] Embodiment 1:

[0057] As Figures 1-6 shown, the present invention provides an ultra-high-strength roll-formed steel battery lower box body, including:

[0058] A frame 1, a liquid cooling plate 2, and a bottom protection plate 3 arranged in sequence from top to bottom. A sealant 4 is provided between the lower end of the frame 1 and the liquid cooling plate 2 and is connected by a non-step double-layer rivet nut 7. A sealing cotton 5 is provided between the liquid cooling plate 2 and the bottom protection plate 3 and is connected by bolts 8; the frame 1 is installed on the vehicle body, and the battery is installed in the frame 1; a phase change heat dissipation frame 41 is detachably connected to the outer side surface of the frame 1, and a plurality of heat conduction cylinders 42 are connected to the phase change heat dissipation frame 41, and the heat conduction cylinders 42 extend into the interior of the frame 1.

[0059] It also provides a production process for the ultra-high-strength roll-formed steel battery lower box body, which is applied to the above-mentioned ultra-high-strength roll-formed steel battery lower box body, including:

[0060] Using a roll-forming process to produce several beams of the frame 1 and welding and assembling to form the frame 1;

[0061] Coating the sealant 4 on the bottom surface of the frame 1;

[0062] Covering the liquid cooling plate 2 below the sealant 4 and connecting the liquid cooling plate 2 and the frame 1 by a non-step double-layer rivet nut 7;

[0063] Bonding the sealing cotton 5 to the lower part of the liquid cooling plate 2 by tape;

[0064] Connecting the bottom protection plate 3 and the non-step double-layer rivet nut 7 by bolts 8;

[0065] Fastening the phase change heat dissipation frame 41 on the outer side surface of the frame 1.

[0066] The working principle and beneficial effects of the above technical solutions are as follows:

[0067] An ultra-high-strength roll-formed steel battery lower box body provided by the present invention is produced by the above process. An ultra-high-strength thin plate material with a thickness of 1.0 mm and an elongation rate of more than 5% is used to produce outer side beams, internal beams, and body connection and mounting beams through processes such as roll forming and tube rolling. The designed strengthening shape ensures strength while achieving lightweight and low-cost effects, helping automobile manufacturers reduce costs and improve product competitiveness; the bottom of the lower box body uses a stepped-free double-layer riveting sealing structure to achieve a double-layer sealing effect while eliminating the gap between the bottom guard plate and the liquid cooling plate 2, avoiding the accumulation of debris in the cavity, and extending the service life of the lower box body. The phase change heat dissipation frame 41 is arranged on the outer side of the frame 1, improving the heat dissipation performance of the side of the frame 1, and cooperating with the liquid cooling plate 2 to achieve all-round heat dissipation of the battery.

[0068] Embodiment 2:

[0069] Based on the above Embodiment 1, the frame 1 includes an outer side beam, an internal beam, and a body connection and mounting beam 1-11 connected to the body. The outer side beam includes a front side beam 1-1, a rear side beam 1-2, a left side beam 1-3, a right side beam 1-4, a left front side beam 1-5, and a right front side beam 1-6. The left side beam 1-3 and the right side beam 1-4 are connected to both ends of the rear side beam 1-2, and both ends of the left front side beam 1-5 are respectively connected to the front side beam 1-1 and the left side beam 1-3, and both ends of the right front side beam 1-6 are respectively connected to the front side beam 1-1 and the right side beam 1-4.

[0070] The outer side beam is made of ultra-high-strength dual-phase steel. The cross-section of the front side beam 1-1 is set as a "square" cross-section, and the cross-sections of the rear side beam 1-2, the left side beam 1-3, the right side beam 1-4, the left front side beam 1-5, and the right front side beam 1-6 are set as "day" cross-sections. The ends of each beam of the outer side beam are obliquely cut to form cut surfaces, and the adjacent cut surfaces are welded and the upper and lower surfaces are flush.

[0071] The working principle and beneficial effects of the above technical solution are as follows:

[0072] The outer side beam of the frame 1 is made of ultra-high-strength dual-phase steel such as 550 / 980DP or 820 / 1180DP and above, with a plate thickness of 1.0 mm. The roll forming process is used to produce side beams with a specific cross-sectional shape, and a strengthening shape is set to enhance the torsional stiffness of the side beams. The front side beam 1-1 is set as a full-cavity "square" cross-section to meet the installation cross-section of relevant accessories, and the other side beams are set as "day" cross-sections with crossbeam reinforcement. All side beams are obliquely cut to form certain cut surfaces, and are welded together through the cut surfaces to form an integral body, with the upper and lower surfaces flush. A number of holes are provided inside all side beams.

[0073] Embodiment 3:

[0074] Based on the above-mentioned Embodiment 2, the internal beam includes a front crossbeam 1-7, a rear crossbeam 1-8, an intermediate longitudinal beam 1-10 and several electrical installation beams 1-12. The two ends of the front crossbeam 1-7 are respectively connected to the front sides of the left beam 1-3 and the right beam 1-4; the two ends of the rear crossbeam 1-8 are respectively connected to the rear sides of the left beam 1-3 and the right beam 1-4, and the rear side of the rear crossbeam 1-8 is connected to the rear beam 1-2 in upper and lower sections; the two ends of the intermediate longitudinal beam 1-10 are respectively connected to the front crossbeam 1-7 and the rear crossbeam 1-8; the two ends of several electrical installation beams 1-12 are respectively connected to the front beam 1-1 and the front crossbeam 1-7.

[0075] The internal beam is made of ultra-high strength dual-phase steel. The beams of the internal beam are connected by welding and their lower surfaces are flush. The cross-sections of the beams of the internal beam are set as square or rectangular.

[0076] The working principle and beneficial effects of the above technical solution are as follows:

[0077] The electrical installation beam 1-12 is used to install battery systems such as BMS and BDU. The front crossbeam 1-7, the rear crossbeam 1-8 and the intermediate longitudinal beam 1-10 are made of ultra-high strength dual-phase steel of 550 / 980DP or 820 / 1180DP and above, with a plate thickness of 1.0 mm. The electrical installation beam 1-12 is made of dual-phase steel of 340 / 590DP or 420 / 780DP, with a plate thickness of 1.0 mm. The internal beam in the shape of a square or rectangle is produced by the tube rolling process. The two ends of the front crossbeam 1-7 are connected to the left beam 1-3 and the right beam 1-4 by welding. The two ends of the rear crossbeam 1-8 are connected to the left beam 1-3 and the right beam 1-4 by welding, and are connected to the rear beam 1-2 in upper and lower sections by fillet welding. The weld interval is 150 mm - 200 mm, and the weld length is 30 mm - 50 mm. The two ends of the intermediate longitudinal beam 1-10 are welded to the front crossbeam 1-7 and the rear crossbeam 1-8. The two ends of several electrical installation beams 1-12 are welded to the front beam 1-1 and the front crossbeam 1-7. After all the internal beams are welded to the external side beams, they form a whole, and the lower end surfaces are flush. Several holes are provided on all the internal beams.

[0078] Embodiment 4:

[0079] Based on the above-mentioned Embodiment 2, the vehicle body connection and mounting beam 1-11 includes a mounting body beam 1-11-1, a sleeve 1-11-2 and a support plate 1-11-3. Several mounting body beams 1-11-1 are symmetrically connected to the outer sides of the left beam 1-3 and the right beam 1-4; the mounting body beam 1-11-1 is provided with holes both above and below. The sleeve 1-11-2 is connected to the holes in the mounting body beam 1-11-1, and bolts pass through the sleeve 1-11-2 to connect to the vehicle body. Support plates 1-11-3 are connected to both the upper and lower parts of the mounting body beam 1-11-1.

[0080] The vehicle body connection and mounting beam 1-11 is made of ultra-high strength dual-phase steel, and each component of the vehicle body connection and mounting beam 1-11 is connected by welding. The cross-section of the mounting body beam 1-11-1 is set in an "L" shape.

[0081] The working principle and beneficial effects of the above technical solution are as follows:

[0082] The mounting body beam 1-11-1 is made of ultra-high strength dual-phase steel such as 550 / 980DP or 820 / 1180DP and above, with a plate thickness of 1.5 mm. The roller pressing process is used to produce a specific "L" cross-section shape of the mounting body beam. The sleeve 1-11-2 is made of carbon steel and is realized by the cold heading process. The support plate 1-11-3 is made of dual-phase steel such as 420 / 780DP or 550 / 980DP, with a plate thickness of 1.2 mm, and is formed by the sheet metal cold stamping process. The upper and lower openings of the mounting body beam 1-11-1 are welded to install the sleeve 1-11-2, and bolts pass through the sleeve 1-11-2 to connect with the vehicle body, thereby fixing the lower box on the vehicle. The support plates 1-11-3 are arranged above and below the mounting body beam 1-11-1 and are fixed by welding, playing a role in blocking, supporting and strengthening. The vehicle body connection and mounting beam 1-11 is fixed to the outer beam by welding, and a single-component sealing adhesive is applied to the welding avoidance area after electrophoresis to meet the anti-corrosion requirements.

[0083] Example 5:

[0084] On the basis of the above Example 2, the liquid cooling plate 2 includes an upper plate 2-1 and a lower plate 2-2. The top end of the upper plate 2-1 contacts the frame 1, and the bottom end of the lower plate 2-2 contacts the bottom guard plate 3; the frame 1 and the liquid cooling plate 2 are connected by a non-step double-layer rivet nut 7.

[0085] The working principle and beneficial effects of the above technical solution are as follows:

[0086] Both the upper plate 2-1 and the lower plate 2-2 of the liquid cooling plate 2 are made of aluminum alloy. One side of the lower plate 2-2 in contact with the upper plate 2-1 is coated with a composite layer and sintered together by the brazing process, with a coolant flow channel in the middle.

[0087] Before assembling the liquid cooling plate 2, the frame 1 is coated with a sealant 4. The sealant 4 is a two-component hybrid adhesive and is evenly coated on the lower end of the frame 1 using a special glue gun or automatic glue application equipment. Then, the liquid cooling plate 2 is covered. The frame 1 and the liquid cooling plate 2 are connected by a non-step double-layer rivet nut 7. When the non-step double-layer rivet nut 7 is tightened using a special riveting gun, the non-step double-layer rivet nut 7 collapses in the set area, locking the frame 1 and the liquid cooling plate 2. At the same time, the sealant 4 will be compressed and filled between the frame 1 and the liquid cooling plate 2, playing a sealing role and meeting the IP67 protection level requirements.

[0088] Example 6:

[0089] On the basis of the above-mentioned Embodiment 5, the sealing cotton 5 is adhered to the lower side of the liquid cooling plate 2 by means of a tape.

[0090] The working principle and beneficial effects of the above technical solution are as follows:

[0091] The sealing cotton 5 is made of a polymer elastomer material, with a double-sided tape on one side. After the frame 1 and the liquid cooling plate 2 are locked by the sealant 4 and the step-less double-layer riveting nut 7, the sealing cotton 5 with the tape side is attached to the liquid cooling plate. At the same time, the sealing cotton 5 needs to be perforated to avoid the step-less double-layer riveting nut 7.

[0092] Embodiment 7:

[0093] On the basis of the above-mentioned Embodiment 6, the bottom guard plate 3 is provided with a number of concave and convex shapes. The bottom guard plate 3 includes a bottom guard plate body 3-1 and a PVC protective layer 3-2 provided below it. The bottom guard plate 3 and the step-less double-layer riveting nut 7 are connected by bolts 8.

[0094] The working principle and beneficial effects of the above technical solution are as follows:

[0095] After the sealing cotton 5 is adhered, the bottom guard plate 3 is covered. The bottom guard plate 3 and the step-less double-layer riveting nut 7 are connected by bolts 8. The step-less double-layer riveting nut 7 has been connected to the frame 1 and the liquid cooling plate 2 through collapse. When the bolts 8 are tightened, the sealing cotton 5 will be compressed. The bottom guard plate 3 and the step-less double-layer riveting nut 7 come into contact and are locked to form an effective torque. The compression amount of the sealing cotton 5 is set at 50%-60%, which plays a sealing role and meets the requirements of the IP67 protection level.

[0096] The bottom guard plate 3 is provided with a number of concave and convex shapes, which are formed by sheet metal cold stamping process. The material is 340 / 590DP dual-phase steel, with a thickness of 0.8mm-1.0mm. A PVC protective layer 3-2 is provided below the bottom guard plate body 3-1, with a thickness of 0.5mm-1.0mm.

[0097] Embodiment 8:

[0098] As Figures 7-9 shown, on the basis of the above-mentioned Embodiment 5, the sealant 4 is evenly coated on the lower end of the frame 1 by an automatic gluing device. The automatic gluing device includes: a lower box clamping tooling and a gluing robot. The lower box clamping tooling is used to fix the frame 1 and make the bottom surface of the frame 1 face upward. The gluing robot is arranged on one side of the lower box clamping tooling and is used to evenly coat the sealant on the bottom surface of the frame 1.

[0099] The lower box clamping tooling includes:

[0100] A moving base 21, the bottom of the moving base 21 is provided with walking wheels, and the moving base 21 can be moved to a preset gluing position and locked;

[0101] The tooling base plate 22 is connected above the moving base 21; a first clamping unit and a second clamping unit are arranged on the edge of the tooling base plate 22. The first clamping unit is fixedly connected to the body connection and hanging beam 1-11 for positioning, and the second clamping unit is fixedly connected to the periphery of the external side beam for positioning.

[0102] The working principle and beneficial effects of the above technical solution are as follows:

[0103] When the automatic glue coating equipment is in use, the lower box clamping tooling is moved to the preset glue coating station through the walking wheels at the bottom of the moving base 21 and locked. The bottom surface of the frame 1 is turned upwards, and the two clamping units are used to fix it above the tooling base plate 22, completely exposing the bottom surface of the frame 1; then the glue coating robot is started to coat the bottom surface of the frame 1. A distance sensor is integrally arranged near the glue coating head of the glue coating robot. By measuring the relative distances at each position, the height differences at each position on the bottom surface of the frame 1 are determined; through the glue amount control valve on the glue coating robot, the glue coating amount at each position is adjusted, so as to ensure the flatness of the frame 1 after glue coating, provide a flat installation surface for the subsequent installation of the liquid cooling plate 2, and avoid problems such as excessive local glue overflow or insufficient glue amount at local positions that cannot be effectively bonded during the installation of the liquid cooling plate 2.

[0104] Embodiment 9:

[0105] As Figure 8 shown, on the basis of the above Embodiment 8, the first clamping unit includes:

[0106] A first support 23, and the first support 23 is connected to the tooling base plate 22;

[0107] A first support arm 24, and the first support arm 24 is connected to the first support 23. A positioning member is connected to the top end of the first support arm 24. The positioning member includes a conical head 25, and the conical head 25 extends into the sleeve 1-11-2 and abuts against its inner wall;

[0108] A second support arm 26, and the second support arm 26 is rotatably connected to the first support 23. A first positioning pressing block 27 is connected to the bottom end of the second support arm 26, and the first positioning pressing block 27 presses against the hanging body beam 1-11-1.

[0109] The working principle and beneficial effects of the above technical solution are as follows:

[0110] The first clamping unit includes a second arm 26 located above and a first arm 24 located below. The first arm 24 is used to support the positioning member. Through the setting of the tapered head 25, during clamping, the tapered head 25 penetrates into the sleeve 1-11-2, and the tapered surface of the tapered head 25 contacts the sleeve 1-11-2 and can slide along the tapered surface. Then, rotate the second arm 26 so that the first positioning pressing block 27 presses against the upper part of the mounting beam body 1-11-1. The mounting beam body 1-11-1 drives the sleeve 1-11-2 to move and along the direction of the tapered surface of the tapered head 25 until the sleeve 1-11-2 is guided to the preset installation state. At this time, the sleeve 1-11-2 is coaxial with the tapered head 25 and closely adheres to the surface of the tapered head 25. Through the above structural design, by using the combination of the tapered head 25 and the first positioning pressing block 27, multiple mounting beams 1-11 of the battery lower box body are positioned and clamped. The mounting beam 1-11 can be quickly hooked on the tapered head 25 and slide along the tapered surface, and is stably installed through the first pressing block 27. By clamping the mounting beam 1-11, the space at the bottom surface of the release frame 1 is released, there is no glue application blind area, and the glue application effect is ensured.

[0111] Embodiment 10:

[0112] As Figure 9 shown, on the basis of the above Embodiment 9, the second clamping unit includes:

[0113] A second support 28, which is connected to the tooling base plate 22;

[0114] A lower bracket 29, which is connected to the outer side surface of the second support 28, and a threaded hole 33 is provided on the lower bracket 29;

[0115] An upper bracket 31, which is slidably connected above the lower bracket 29, and a second positioning pressing block 32 is connected to the inner side surface of the upper bracket 31, and the second positioning pressing block 32 abuts against the outside of the external side beam; a waist-shaped groove 34 is provided on the upper bracket 31, and a bolt passes through the waist-shaped groove 34 and is connected to the threaded hole 33;

[0116] A support block 35, which is connected to the top end of the second support 28, and the support block 35 abuts against the upper surface of the external side beam.

[0117] The working principle and beneficial effects of the above technical solution are:

[0118] When the second clamping unit is not performing clamping, the upper support 31 is located at a relatively outer position of the lower support 29, and the support block 35 provides support for the bottom of the frame 1; the space between the upper supports 31 of multiple second clamping units is larger than the size of the frame 1, facilitating the loading of the frame 1; after the first clamping unit finishes clamping, the second clamping unit is used. Rotate the bolt to separate the bolt head from the upper support 31, push the upper support 31, and the bolt slides along the waist-shaped groove 34 to guide the upper support 31; until the second positioning block 32 on the inner side of the upper support 31 contacts the frame, which indicates that the second positioning block 32 reaches the preset clamping state. Reverse-rotate the bolt to make its head press against the upper support 31 to fix the upper support 31 and ensure the stability of the frame 1 during the gluing process. Through the above structural design, after the first clamping unit positions and clamps the hanging beam 1-11, the second clamping unit is used to limit each beam of the outer side beam, reducing the torsion of the frame 1 and further improving the positioning accuracy of the frame 1.

[0119] Embodiment 11:

[0120] As Figures 10-14 shown, on the basis of the above Embodiment 1, a phase change heat dissipation frame 41 is detachably connected to the front and rear of the frame 1, and a plurality of heat conduction cylinders 42 are connected to the phase change heat dissipation frame 41, and the heat conduction cylinders 42 extend into the frame 1.

[0121] The phase change heat dissipation frame 41 includes:

[0122] A support frame 43, the support frame 43 is buckled on the outside of the frame 1, the top end of the support frame 43 is bent inward to form a clamping groove 44, and the clamping groove 44 is clamped on the clamping strip 45 at the top edge of the frame 1; the bottom end of the support frame 43 is bent inward and buckled under the bottom guard plate 3, a plug strip 48 is arranged between the bottom guard plate 3 and the support frame 43, and a heat dissipation frame sealant 46 is applied between the support frame 43 and the bottom guard plate 3;

[0123] A phase change heat dissipation plate 47, the phase change heat dissipation plate 47 is connected inside the support frame 43 and closely attached to the outer wall of the frame 1, the phase change heat dissipation plate 47 is set as a plate made of a phase change material such as a graphite plate or a graphite paraffin composite plate, and the heat conduction cylinder 42 is connected to the phase change heat dissipation plate 47.

[0124] The working principle and beneficial effects of the above technical solution are:

[0125] When the lower battery box is in use, heat dissipation is carried out on the lower part of the battery through the liquid cooling plate 2, and heat dissipation is carried out on the side of the battery through the phase change heat dissipation frame 41. The phase change heat dissipation frame 41 is set in a detachable form and can be selectively installed on the battery box with higher heat dissipation requirements. During installation, the card slot 44 at the top end of the support frame 43 is snapped onto the card strip 45 at the top edge of the frame 1. The card strip 45 is integrally formed with the frame 1, and the support frame 43 is buckled outside the frame 1; the phase change heat dissipation plate 47 on the support frame 43 is in contact with the outer wall of the frame 1, so that the heat on the frame 1 can be better transferred to the phase change heat dissipation plate 47; the bottom end of the support frame 43 is bent and buckled under the bottom protection plate 3, and then a plug strip 48 is inserted between the bottom protection plate 3 and the support frame 43. The plug strip 48 can block the gap between the bottom protection plate 3 and the support frame 43, and then heat dissipation frame sealant 46 is applied outside the plug strip 48 to further seal the gap between the bottom protection plate 3 and the support frame 43; the heat conduction cylinder 42 on the phase change heat dissipation frame 41 passes through the outer wall of the frame 1 and extends into its interior and is in contact with the inner wall of the frame 1. The phase change heat dissipation plate 47 is made of a plate made of a phase change material such as a graphite plate or a graphite paraffin composite plate, and has good heat absorption performance.

[0126] Through the above structural design, the above phase change heat dissipation frame 41 can be added to the battery box with higher heat dissipation requirements. A phase change heat dissipation plate 47 is attached to the outer wall of the frame 1. The phase change material absorbs the instantaneous heat during battery thermal runaway, delays the temperature rise, provides effective temperature control for the battery, and prolongs the service life of the battery; the connection between the phase change heat dissipation frame 41 and the frame 1 is double-sealed with a plug strip 48 and heat dissipation frame sealant 46, which can reinforce the box body structure again, ensure stable installation, and reduce dust accumulation at the connection; the heat conduction cylinder 42 is used to quickly export the heat on the inner wall of the frame 1 to the phase change heat dissipation plate 47, improving the heat dissipation effect.

[0127] Example 12:

[0128] As Figures 10-14 shown, on the basis of the above Example 11, the heat conduction cylinder 42 includes:

[0129] A cylinder body 51, a plurality of cylinder bodies 51 are connected to the inner side of the phase change heat dissipation plate 47, the cylinder body 51 extends into the frame 1, and through holes for the cylinder body 51 to pass through are provided on the outer wall of the frame 1;

[0130] A first thermal expansion airbag 52, the first thermal expansion airbag 52 is connected to the end of the cylinder body 51 and is in contact with the inner wall of the frame 1, and a thermal expansion gas is contained in the first thermal expansion airbag 52;

[0131] A first heat storage member 53, the first heat storage member 53 is connected inside the first thermal expansion airbag 52, and the first heat storage member 53 has elasticity;

[0132] A second heat storage member 54, the second heat storage member 54 is arranged in the phase change heat dissipation plate 47;

[0133] The capillary heat conduction tube 55, two capillary heat conduction tubes 55 are connected to the inner wall of the cylinder body 51, both ends of the capillary heat conduction tube 55 are respectively communicated with the first heat storage member 53 and the second heat storage member 54, and a coolant is contained in the first heat storage member 53, the second heat storage member 54 and the capillary heat conduction tube 55;

[0134] The second thermal expansion airbag 56, the second thermal expansion airbag 56 is disposed around the outside of the second heat storage member 54, a cavity for accommodating the second thermal expansion airbag 56 is provided in the phase change heat dissipation plate 47, a thermal expansion gas is contained in the second thermal expansion airbag 56, and a plurality of heat dissipation tips 57 are provided on the outer surface of the second thermal expansion airbag 56, and the heat dissipation tips 57 are inserted into the phase change heat dissipation plate 47.

[0135] The working principle and beneficial effects of the above technical solution are as follows:

[0136] After the heat conduction cylinder 42 is inserted into the frame 1, the first thermal expansion airbag 52 inside the heat conduction cylinder 42 contacts the inner wall of the frame 1, and the heat of the inner wall of the frame 1 is transferred to the inside of the first thermal expansion airbag 52 to cause it to expand. The inner side of the first thermal expansion airbag 52 is the expansion side. The first thermal expansion airbag 52 presses the first heat storage member 53, so that the coolant inside it flows from the outlet of the first heat storage member 53 into one of the capillary heat conduction tubes 55. The coolant flows into the second heat storage member 54, causing the second heat storage member 54 to heat up. The heat is transferred to the inside of the second thermal expansion airbag 56 to cause it to expand. The second thermal expansion airbag 56 is in full contact with the cavity of the phase change heat dissipation plate 47, and transfers the heat to the phase change heat dissipation plate 47; the heat dissipation tips 57 improve the heat transfer effect; the original coolant in the second heat storage member 54 flows back into the first heat storage member 53 through the capillary heat conduction tube 55 on the other side, causing the first heat storage member 53 to cool down. After the first thermal expansion airbag 52 cools down, it contracts, causing the inner wall of the frame 1 to cool down.

[0137] Through the above structural design, by providing the heat conduction cylinder 42 on the phase change heat dissipation plate 47, the heat of the inner wall of the frame 1 can be quickly transferred to the phase change heat dissipation plate 47 directly through the heat conduction cylinder 42, improving the heat transfer efficiency; the expansion of the first thermal expansion airbag 52 provides power for the flow of the coolant, responds to the high-temperature environment in a timely manner, and automatically realizes the heat dissipation cycle of the coolant; the expansion of the second thermal expansion airbag 56 eliminates the gap between it and the phase change heat dissipation plate 47, so that the heated second thermal expansion airbag 56 is in full contact with the phase change heat dissipation plate 47, and combines with the heat dissipation tips 57 for heat conduction, effectively improving the heat dissipation effect.

[0138] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation on the present invention.

[0139] In the present invention, unless otherwise clearly defined and limited, the terms "installed", "connected", "connected", "fixed", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection, an electrical connection or communicate with each other; it can be directly connected, or indirectly connected through an intermediate medium, and can be the communication inside two elements or the interaction relationship between two elements, unless otherwise clearly limited. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0140] Although the embodiments of the present invention have been disclosed as above, it is not limited to the applications listed in the specification and embodiments. It can be fully applied to various fields suitable for the present invention. For those familiar with the field, additional modifications can be easily made. Therefore, without departing from the general concept defined by the claims and the equivalent scope, the present invention is not limited to the specific details and the examples shown and described herein.

Claims

1. An ultra-high strength roll-formed steel battery lower box body, characterized in that, Comprising: A frame (1), a liquid cooling plate (2), and a bottom guard plate (3) are arranged in sequence from top to bottom. A sealant (4) is provided between the lower end of the frame (1) and the liquid cooling plate (2) and they are connected by a non-step double-layer rivet nut (7). A sealing cotton (5) is provided between the liquid cooling plate (2) and the bottom guard plate (3) and they are connected by bolts (8); the frame (1) is installed on the vehicle body, and the battery is installed inside the frame (1); a phase change heat dissipation frame (41) is detachably connected to the outer side of the frame (1), and a plurality of heat conduction cylinders (42) are connected to the phase change heat dissipation frame (41), and the heat conduction cylinders (42) extend into the interior of the frame (1).

2. The ultra-high-strength roll-formed steel battery lower box body according to claim 1, wherein The frame (1) includes an outer side beam, an inner beam, and a vehicle body connection and mounting beam (1-11) connected to the vehicle body. The outer side beam includes a front side beam (1-1), a rear side beam (1-2), a left side beam (1-3), a right side beam (1-4), a left front side beam (1-5), and a right front side beam (1-6). The left side beam (1-3) and the right side beam (1-4) are connected to both ends of the rear side beam (1-2). Both ends of the left front side beam (1-5) are respectively connected to the front side beam (1-1) and the left side beam (1-3). Both ends of the right front side beam (1-6) are respectively connected to the front side beam (1-1) and the right side beam (1-4).

3. The ultra-high strength roll-formed steel battery lower box according to claim 2, characterized in that, The outer side beam is made of ultra-high strength dual-phase steel. The cross-section of the front side beam (1-1) is set as a "mouth" - shaped cross-section, and the cross-sections of the rear side beam (1-2), the left side beam (1-3), the right side beam (1-4), the left front side beam (1-5), and the right front side beam (1-6) are set as "day" - shaped cross-sections. The ends of each beam of the outer side beam are obliquely cut to form cut surfaces, and the adjacent cut surfaces are welded and the upper and lower surfaces are flush.

4. An ultra-high-strength roll-formed steel battery lower box according to claim 2, characterized in that, The inner beam includes a front cross beam (1-7), a rear cross beam (1-8), an intermediate longitudinal beam (1-10), and several electrical installation beams (1-12). Both ends of the front cross beam (1-7) are respectively connected to the front sides of the left side beam (1-3) and the right side beam (1-4); both ends of the rear cross beam (1-8) are respectively connected to the rear sides of the left side beam (1-3) and the right side beam (1-4), and the rear side of the rear cross beam (1-8) is connected to the rear side beam (1-2) in upper and lower segments; both ends of the intermediate longitudinal beam (1-10) are respectively connected to the front cross beam (1-7) and the rear cross beam (1-8); both ends of several electrical installation beams (1-12) are respectively connected to the front side beam (1-1) and the front cross beam (1-7); the inner beam is made of ultra-high strength dual-phase steel, and each beam of the inner beam is connected by welding and the lower surfaces are flush. The cross-sections of each beam of the inner beam are set as square or rectangular.

5. The ultra-high strength roll-formed steel battery lower box body according to claim 2, characterized in that, The vehicle body connection and mounting beam (1-11) includes a mounting body beam (1-11-1), a sleeve (1-11-2), and a support plate (1-11-3). Several mounting body beams (1-11-1) are symmetrically connected to the outer sides of the left side beam (1-3) and the right side beam (1-4); the mounting body beam (1-11-1) has openings both above and below, the sleeve (1-11-2) is connected to the opening of the mounting body beam (1-11-1), bolts pass through the sleeve (1-11-2) to connect to the vehicle body, and support plates (1-11-3) are connected to both the upper and lower parts of the mounting body beam (1-11-1).

6. The ultra-high strength roll-formed steel battery lower box according to claim 5, characterized in that, The body connection and mounting beam (1-11) is made of ultra-high strength dual-phase steel, and each component of the body connection and mounting beam (1-11) is connected by welding. The cross-section of the mounting body beam (1-11-1) is set in an "L" shape.

7. An ultra-high strength roll-formed steel battery lower box according to claim 1, characterized in that, The liquid cooling plate (2) includes an upper plate (2-1) and a lower plate (2-2). The top end of the upper plate (2-1) contacts the frame (1), and the bottom end of the lower plate (2-2) contacts the bottom guard plate (3); the frame (1) and the liquid cooling plate (2) are connected by a non-step double-layer rivet nut (7); the sealing cotton (5) is adhesively bonded to the lower part of the liquid cooling plate (2) by tape.

8. An ultra-high-strength roll-formed steel battery lower box according to claim 1, characterized in that, The bottom guard plate (3) is provided with a number of concave and convex shapes. The bottom guard plate (3) includes a bottom guard plate body (3-1) and a PVC protective layer (3-2) provided below it. The bottom guard plate (3) and the non-step double-layer rivet nut (7) are connected by bolts (8).

9. The ultra-high-strength roll-formed steel battery lower box body according to claim 1, wherein The phase change heat dissipation frame (41) includes: A support frame (43), the support frame (43) is buckled on the outside of the frame (1). The top end of the support frame (43) is bent inward to form a card slot (44), and the card slot (44) is clamped on the card strip (45) at the top edge of the frame (1); the bottom end of the support frame (43) is bent inward and buckled under the bottom guard plate (3). A plug strip (48) is provided between the bottom guard plate (3) and the support frame (43), and a heat dissipation frame sealant (46) is applied between the support frame (43) and the bottom guard plate (3); A phase change heat dissipation plate (47), the phase change heat dissipation plate (47) is connected inside the support frame (43) and closely adheres to the outer wall of the frame (1). The phase change heat dissipation plate (47) is set as a plate made of a phase change material such as a graphite plate or a graphite paraffin composite plate, and a heat conduction cylinder (42) is connected to the phase change heat dissipation plate (47).

10. A production process for an ultra-high-strength roll-formed steel battery lower box body, which is applied to an ultra-high-strength roll-formed steel battery lower box body according to any one of claims 1-9, and is characterized in that, Including: Using a rolling process to produce several beams of the frame (1) and welding and assembling to form the frame (1); Coating a sealant (4) on the bottom surface of the frame (1); Covering the liquid cooling plate (2) under the sealant (4) and connecting the liquid cooling plate (2) and the frame (1) by a non-step double-layer rivet nut (7); Adhesively bonding the sealing cotton (5) to the lower part of the liquid cooling plate (2) by tape; Connecting the bottom guard plate (3) and the non-step double-layer rivet nut (7) by bolts (8); Buckling the phase change heat dissipation frame (41) on the outer side of the frame (1).

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