Sealed battery box body and processing method thereof

Abstract

The invention discloses a sealed battery box. The sealed battery box comprises a handle, a handle fixing beam, a box body, a front panel and a rear panel, the box body is formed by bending and welding an integrally-formed section through a metal plate, frames are arranged on the two sides of the box body, threaded holes and connecting structures are arranged on the frames, the connecting structures are arranged at the bending positions of the section, each connecting structure comprises a first bending block and a second bending block, the bending blocks are in an arc shape, and the first bending blocks and the second bending blocks are connected through bolts. The thickness of the bending blocks is one half of that of the frame of the box body, the two bending blocks are distributed in a staggered mode, the positions of the two bending blocks are overlapped after bending, the outer circular arcs coincide with the bending circular arc of the box body, and the structure can assist in bending, reduce the welding workload, reduce the welding cost, improve the assembly precision and reduce the assembly error at the same time.

Description

Technical Field

[0001] This invention relates to the field of battery box technology, and in particular to a sealed battery box body and its processing method. Background Technology

[0002] The battery housing, a crucial component in electric motorcycles and electric vehicles, is responsible for protecting the battery pack and ensuring its stability and safety. Its primary function is to provide physical protection against external shocks, vibrations, and other hazards. Simultaneously, the battery housing must be waterproof and dustproof to ensure the battery pack functions properly in harsh environments. The design of the battery housing not only affects battery safety but also directly impacts the vehicle's weight, range, and overall performance.

[0003] The manufacturing process of battery boxes mainly relies on welding technology. The various components of the battery box are fixed together by welding or bolting. This method is simple, but in actual production, the high amount of welding work can lead to local stress concentration, which in turn can cause structural deformation or cracks, resulting in insufficient overall strength and safety of the battery box. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a sealed battery box and its processing method, which aims to solve the technical problems of the existing technology.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: On one hand, embodiments of this application provide a sealed battery housing, including a handle, a handle fixing beam, a housing, a front panel, and a rear panel; The box body is formed by bending and welding a one-piece profile. The box body has a frame on both sides. The frame has threaded holes and a connecting structure. The connecting structure is located at the bending point of the profile. The connecting structure includes a first bending block and a second bending block. The bending block is arc-shaped and its thickness is half that of the box body frame. The two bending blocks are staggered. After bending, the two bending blocks overlap and their outer arcs coincide with the bending arc of the box body.

[0006] The housing is provided with mounting holes. The handle and the handle fixing beam are respectively located on the outer and inner sides of the housing. The handle is fixedly installed on the handle fixing beam by self-tapping screws. The self-tapping screws pass through the mounting holes to fix the handle and the handle fixing beam to the housing.

[0007] The bottom of the box is provided with a triangular protrusion, which is formed by bending the two ends of the box profile and then splicing them together at an angle.

[0008] The front panel and the rear panel are installed on the two side frames of the box body through pre-tightening screws, and sealing gaskets are clamped between the front panel, the rear panel and the box body.

[0009] The sealing gasket is provided with through holes corresponding to the threaded holes on the side frame, and the pre-tightening screws pass through the through holes on the sealing gasket when fixing the panel, so as to position and fix the sealing gasket.

[0010] A processing method for sealing a battery box body, and the specific steps are as follows: Step S1, box body base profile extrusion, the box body base profile is extruded through a mold by high pressure to form a profile with a frame strip on both sides; Step S2, base profile processing, the extruded base profile is precisely processed, mainly including processing threaded holes and mounting holes on the box frame strip, and milling a bending block of the bending connection structure on the base profile; Step S3, sheet metal processing, the processed base profile is processed through bending, cutting and other sheet metal processes to form the final shape of the battery box body; Step S4, box body welding, laser welding is performed on the triangular joint and the bending connection structure of the bent box body, so that the box body becomes an integral structure; Step S5, handle installation, the handle and the handle fixing beam are fixed on the outer and inner sides of the box body through self-tapping screws; Step S6, panel installation, the front panel and the rear panel of the battery box body are fixed on both sides of the box body through bolts and sealing rings.

[0011] In summary, the beneficial effects of the present application compared with the prior art are: Box body structure design: the box body can be integrally formed by bending the sheet metal part, reducing the welding joint.

[0012] Triangular protrusion positioning design: the unique triangular protrusion structure plays a positioning role in positioning the position of the battery and the position of the battery box body, facilitating installation.

[0013] Bending connection structure: the existence of the structure can assist bending, reduce welding workload, reduce welding cost, improve assembly precision and reduce assembly error.

[0014] Panel design: through air tightness test, the battery box body can be used in complex environment, enhancing impact resistance and improving structural strength.

[0015] Integrated sheet metal processing: the sheet metal part is integrally formed by processing, improving the structural strength and air tightness, reducing the weight of the box body, and developing towards light weight.

[0016] Reduce welding workload: reduce welding distance, avoid stress concentration, improve welding quality and box strength, improve air tightness, simplify production process. BRIEF DESCRIPTION OF DRAWINGS

[0017] The above and other objects, features and advantages of the present application will become more apparent from the following detailed description read in conjunction with the accompanying drawings, in which: Figure 1 It is a sealed battery box structure diagram; Figure 2 It is a box handle installation diagram; Figure 3 It is a box unfolding diagram; Figure 4 It is a box interior diagram; Figure 5 It is a sealed battery box processing method step diagram. DETAILED DESCRIPTION

[0018] The principles and spirits of the present application will be described below with reference to several exemplary embodiments. It should be understood that these embodiments are given only to enable those skilled in the art to better understand and implement the present application, and do not limit the scope of the present application in any way. On the contrary, these embodiments are provided to make the present disclosure more thorough and complete, and to fully convey the scope of the present disclosure to those skilled in the art. "Embodiment" or "embodiment" in the specification can mean one embodiment or one embodiment, or the case of several embodiments or several embodiments.

[0019] According to an embodiment of the present application, a sealed battery box is provided, comprising a handle 1, a handle fixing beam 2, a box 3, a front panel 4 and a rear panel 5.

[0020] The box 3 is made of a profile formed by extrusion, and is formed by bending and welding of sheet metal. Long strip plates are provided with frame strips on both sides, which form a frame covering the edges of the box after bending of the profile. Threaded holes and connecting structures 3-3 are formed on the frame strips by machining. The connecting structures 3-3 are arranged at the bending positions of the profile. The connecting structures 3-3 include first bending blocks 3-3-1 and second bending blocks 3-3-2. The bending blocks are in the shape of a quarter of a circular arc, and the thickness of the bending blocks is half of the thickness of the frame of the box. The two bending blocks are staggered and have gaps at the top. When the base profile is bent, the bending blocks 3-3-1 and the bending blocks 3-3-2 move relative to each other. As the bending angle increases, the arc portions of the two bending blocks gradually insert into the gaps of the other. When the sheet metal is bent to 90°, the two bending blocks completely coincide. From the outside of the box, the two bending blocks form smooth fillets at the bending positions. The presence of the bending structure can reduce the welding workload. In the traditional processing method, the bending positions need to be spliced and welded. The welding seam is long, and the welding stress is concentrated, which may cause structural deformation and cracks. Now only the upper and lower bending structures need to be welded, which reduces the welding distance, improves the welding quality, reduces the welding cost, enhances the strength and air tightness of the box. In addition, the connecting structure is spliced and welded after the profile is bent. The bending degree of the profile can be determined by the splicing degree of the connecting structure.

[0021] The box 3 is provided with mounting holes 3-2. The handle 1 and the handle fixing beam 2 are arranged on the outer and inner sides of the box 3, respectively. The handle 1 is fixedly installed on the handle fixing beam 2 by self-tapping screws. The self-tapping screws pass through the mounting holes 3-2 to fixedly connect the handle 1 and the handle fixing beam 2 with the box 3.

[0022] The box 3 is provided with triangular protrusions 3-1 at the bottom. The triangular protrusions 3-1 are formed by splicing of the two ends of the profile of the box 3 after bending. The top of the triangular protrusion 3-1 is connected by welding to form a triangular joint 3-1-1. The main function of the triangular protrusion 3-1 is to fix the position of the battery and ensure the position fixing and stability of the whole battery box. The triangular protrusion 3-1 forms a positioning point in the battery box, which plays a role of installation guide and positioning, helps to accurately install the battery module, and enables the battery to be quickly and stably positioned in the box. It ensures that the battery module is not easily misaligned during installation, thereby avoiding possible safety hazards.

[0023] The front panel 4 and the rear panel 5 are mounted on the side frames of the box body 3 by pre-tightening screws, and sealing gaskets are clamped between the front panel 4, the rear panel 5 and the box body, the sealing gaskets are provided with through holes corresponding to the threaded holes on the side frames, and the pre-tightening screws are fixed through the through holes on the sealing gaskets when the face plates are fixed, so as to position and fix the sealing gaskets, help to ensure that the face plates and the box body form a complete seal, and prevent the entry of moisture, dust or other contaminants.

[0024] According to an embodiment of the present application, a processing method for sealing a battery box is provided, and the specific steps are as follows: Step S1, box base profile extrusion. The box base profile is formed by extruding aluminum alloy material through a mold under high pressure to form a profile with side frame strips. The extruded base profile is cooled and cut to meet the size requirements of the processing. In addition, this processing method can make the battery box match different specifications of battery modules through specific processing of the base profile and sheet metal, thereby expanding the application range.

[0025] Step S2, base profile processing. The extruded base profile is precisely processed, mainly including processing threaded holes, mounting holes and the like on the box frame strips, and milling bending blocks of the bending connection structure on the base profile to prepare for subsequent bending. The processing of these holes can be performed by a numerical control machine tool or a drilling machine. Numerical control processing can ensure high hole position accuracy and accurate hole diameter. Through precise processing of hole positions and sizes, perfect docking and assembly accuracy between parts are ensured, assembly errors are avoided to cause insufficient strength or insecure installation of the box body, and the overall strength and stability of the battery box are improved.

[0026] Step S3, sheet metal processing. The processed base profile is processed by bending, cutting and other sheet metal processes to form the final shape of the battery box. The existence of the bending connection structure can assist bending and reduce bending errors. Through the bending process, the integrated molding of the box structure can be completed under the premise of maintaining the continuity of the material. Compared with the traditional multi-piece splicing and welding method, the welding workload is significantly reduced, the stress concentration points are reduced, and the overall airtightness of the box body is improved. In addition, the bending structure is welded on the outside of the upper and lower sides of the box, which reduces the welding difficulty, improves the structural strength of the battery box, makes the box have higher overall rigidity and impact resistance, effectively resists vibration and external impact during the operation of the electric motorcycle, and ensures the safety of the battery. In addition, the bending connection structure assists the sheet metal bending forming to reduce the number of processes, shorten the production cycle, improve the production efficiency, reduce the production cost, and improve the production consistency and reliability of the box body.

[0027] Step S4, box welding. The folded box triangular joint and the folded connection structure are laser welded. The purpose of this step is to firmly connect the sheet metal parts and ensure that the box has sufficient strength and stability. By reducing the welding workload, the excess heat input is reduced, effectively reducing the material deformation or stress concentration problems that may occur during welding, ensuring the long-term safety and reliability of the battery box. Laser welding makes the box into an integral structure, and the welding of the folded connection structure at both ends of the box improves the overall strength of the box, thereby enhancing the impact resistance and vibration resistance of the battery box. The presence of the folded connection structure reduces the welding workload. Unlike traditional welding of a long weld seam, only the folded connection structure at both ends of the box needs to be welded, reducing the welding distance of complex parts, reducing the length of the welding seam, reducing welding errors, avoiding stress concentration, eliminating the possibility of misalignment and deformation during welding, and simplifying the process flow. Due to the absence of long-distance welding, the heat-affected zone during welding is small, reducing the probability of welding defects, and the structural strength and air tightness of the entire box are improved.

[0028] Step S5, handle installation. After the frame of the battery box is basically completed, the handle is installed. The handle and the handle fixing beam are fixed to the two sides of the box by self-tapping screws. During installation, it is necessary to ensure that the handle is accurately connected with the designed hole position of the box, and that the handle can bear the corresponding weight and external force during use, without loosening or falling off, thereby ensuring the stability and safety of the whole.

[0029] Step S6, panel installation. The upper and lower panels of the battery box are fixed to the upper and lower sides of the box by bolts and sealing rings. These panels affect the air tightness of the battery box and play an important role in protecting the battery pack and preventing water and dust, effectively blocking the external environment from affecting the battery pack and ensuring the safe operation of the battery in harsh weather or complex environments. In addition, the installation of the panels also improves the overall strength of the box and enhances its impact resistance and deformation resistance. The battery box can cope with various complex environments to improve the overall safety and durability.

[0030] The above description is only an exemplary embodiment of the present application, and is not intended to limit the protection scope of the present application, which is determined by the appended claims.

Claims

1. A sealed battery casing and its processing method, characterized in that, A sealed battery case includes a handle, a handle fixing beam, a case body, a front panel, and a rear panel. The case body is formed by bending and welding a sheet metal profile. The case body has frame sides, threaded holes, and connecting structures on the frame. The connecting structures are located at the bending points of the profile and include a first bending block and a second bending block. The bending blocks are arc-shaped and have a thickness of half that of the case body frame. The first bending block and the second bending block are staggered. After bending, the first bending block and the second bending block overlap, and their outer arcs coincide with the bending arcs of the case body.

2. The sealed battery case according to claim 1, characterized in that, The housing is provided with mounting holes. The handle and the handle fixing beam are respectively located on the outer and inner sides of the housing. The handle is fixedly installed on the handle fixing beam by self-tapping screws. The self-tapping screws pass through the mounting holes to fix the handle and the handle fixing beam to the housing.

3. The sealed battery case and its processing method according to claim 1, characterized in that, The bottom of the box is provided with a triangular protrusion, which is formed by bending the two ends of the box profile and then splicing them together at an angle.

4. The sealed battery case and its processing method according to claim 1, characterized in that, The front panel and the rear panel are mounted on the side frames of the housing by pre-tightening screws, and sealing gaskets are clamped between the front panel and the rear panel and the housing.

5. A sealed battery case and its processing method according to claim 4, characterized in that, The sealing gasket has a through hole corresponding to the threaded hole on the frame. When the pre-tightening screw fixes the panel, it passes through the through hole on the sealing gasket, thereby positioning and fixing the sealing gasket.

6. A method for processing a sealed battery casing, comprising the following steps: Step S1, extrusion of the box body base profile: aluminum alloy material is extruded through a mold under high pressure to form a profile with side frame strips. Step S2, basic profile processing, precision processing of the extruded basic profile, mainly includes processing threaded holes and mounting holes on the box frame strip, and milling bending blocks for bending connection structure on the basic profile; Step S3, sheet metal processing: The processed basic profile is processed through sheet metal processes such as bending and cutting to form the final shape of the battery box. Step S4, box welding: Laser welding is performed on the triangular joints and bending connection structures of the bent box to make the box into a single structure. Step S5: Install the handle. The handle and the handle fixing beam are fixed to the outer and inner sides of the box body respectively with self-tapping screws. Step S6, Panel Installation: Fix the front and rear panels of the battery box to both sides of the box using bolts and sealing rings.

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