New energy vehicle integrated liquid-cooled battery pack box based on ctc architecture and manufacturing method

Abstract

The application discloses a new energy automobile integrated liquid cooling battery pack box based on a CTC architecture and a manufacturing method thereof, which comprises a liquid cooling plate main body and a side frame arranged in a ring shape on the liquid cooling plate main body, and a battery compartment for accommodating a battery pack is formed between the side frame and the liquid cooling plate main body; the liquid cooling plate main body comprises a base plate, a flow channel plate and a reinforcing plate which are sequentially stacked, the base plate is arranged correspondingly to the battery compartment, the flow channel plate comprises a cooling liquid flow channel for circulating flow of cooling liquid, a liquid cooling channel comprising inlet and outlet ports is formed between the flow channel plate and the base plate, and the reinforcing plate supports the flow channel plate, so that the formed liquid cooling channel is flat, the overall thickness of the liquid cooling plate main body can be reduced, the amount of material can be reduced, and the reinforcing plate can reinforce and support the flow channel plate and the base plate, so that the battery box has the advantages of high strength, light weight, integrated liquid cooling, air tightness and reliability and low cost.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of battery box manufacturing, and particularly relates to a new energy automobile integrated liquid-cooled battery pack box based on a CTC architecture and a manufacturing method. BACKGROUND

[0002] With the continuous development of cell technology and pack grouping technology, the electric vehicle pack structure design has experienced the upgrading of small modules, modules, CTP and CTC; and the battery box, as one of the most important structural parts in the pack, is also constantly upgraded and replaced, and the traditional battery box cannot meet the requirements of high strength, lightweight, integrated liquid cooling and low cost of the CTC. SUMMARY

[0003] The application provides a new energy automobile integrated liquid-cooled battery pack box based on a CTC architecture and a manufacturing method, which has the advantages of high strength and lightweight.

[0004] TECHNICAL SOLUTION

[0005] The new energy automobile integrated liquid-cooled battery pack box based on the CTC architecture comprises a liquid cooling plate main body and a side frame arranged in a ring shape on the liquid cooling plate main body, and a battery compartment for accommodating a battery pack is formed between the side frame and the liquid cooling plate main body; the liquid cooling plate main body comprises a substrate, a flow channel plate and a reinforcing plate which are sequentially stacked, the substrate is arranged corresponding to the battery compartment, the flow channel plate comprises a cooling liquid flow channel for circulating flow of cooling liquid, a liquid cooling channel comprising an inlet and an outlet is formed between the flow channel plate and the substrate, and the reinforcing plate supports the flow channel plate.

[0006] Further, one side of the liquid cooling plate main body corresponding to the inlet and outlet of the liquid cooling channel extends to the outside of the enclosed area of the side frame, and the inlet and outlet are provided with liquid cooling connectors directly connected to the liquid cooling pipeline.

[0007] Further, the side frame comprises a front side frame corresponding to the area segment where the inlet and outlet are located and an edge side frame corresponding to the remaining area segment, the front side frame and the edge side frame are connected end to end to form a ring structure, the edge side frame is arranged corresponding to the outer edge of the liquid cooling plate main body, and the front side frame is arranged on the plate surface of the liquid cooling plate main body adjacent to the inlet and outlet.

[0008] Further, the plate body of the substrate corresponding to the edge side frame is bent towards the side where the battery compartment is located and forms a connecting strip plate, and the connecting strip plate is connected and fixed with the inner side wall of the edge side frame.

[0009] Further, the flow channel plate and the reinforcing plate are directly connected to the bottom wall of the side frame of the edge portion, and the flow channel plate and the reinforcing plate are indirectly connected to the bottom wall of the side frame of the front portion through the base plate.

[0010] Further, the side frame of the front portion located at one side outside the battery compartment is provided with a side frame skirt, and the side frame skirt is provided with a perforation corresponding to the inlet and outlet ports.

[0011] Further, the connecting strip plate comprises a plurality of inserts on the outer edge edge parallel to the bending line, and the plurality of inserts are arranged at intervals along the length direction of the outer edge edge, the side wall of the side frame of the edge portion is provided with a linear insertion slot for matching and inserting the inserts, and the inserts are bent towards the flow channel plate after passing through the linear insertion slot and are attached to the side wall of the side frame away from the battery compartment.

[0012] Further, a plurality of pull rivet holes are formed on the connecting strip plate along the length direction, and the inserts are located between two adjacent pull rivet holes.

[0013] Further, an adsorption layer is arranged in the gap between the insert, the connecting strip plate and the side frame of the edge portion.

[0014] A manufacturing method of a new energy vehicle integrated liquid-cooled battery pack box based on a CTC architecture, comprising the following steps:

[0015] S1: According to the strength requirement, the section of the frame profile is designed, the profile is extruded, and the required part shape is machined; according to the heat dissipation requirement, the flow channel section is designed, and the base plate, flow channel plate and reinforcing plate are punched out;

[0016] S2: The reinforcing plate, flow channel plate and base plate are sequentially stacked and respectively formed into a liquid-cooled plate body by brazing;

[0017] S3: The front portion side frame corresponding to the area segment of the inlet and outlet ports and the edge portion side frame corresponding to the remaining area segment are fixedly connected end to end and enclosed into a ring structure, the front portion side frame is arranged on the plate surface of the liquid-cooled plate body adjacent to the inlet and outlet ports, and the inlet and outlet ports are located outside the battery compartment enclosed;

[0018] S4: The plate body edge of the base plate corresponding to the edge portion side frame is vertically bent towards the inside of the battery compartment, and the bent plate body is connected with the edge portion side frame by pull riveting;

[0019] S5: The base plate and the front frame are welded by stirring welding.

[0020] Beneficial effects: the present application is through the mutual stacking of the substrate, the flow channel plate and the reinforcing plate, so that the liquid cooling channel is flat, the thickness of the liquid cooling plate body is reduced, the amount of material is reduced, and the reinforcing plate supports the flow channel plate and the substrate, so that the battery box has the advantages of high strength, light weight, integrated liquid cooling, air tightness, reliability and low cost. BRIEF DESCRIPTION OF DRAWINGS

[0021] BRIEF DESCRIPTION OF DRAWINGS Figure 1 It is a schematic diagram of the overall structure of the present application;

[0022] BRIEF DESCRIPTION OF DRAWINGS Figure 2 It is an exploded schematic diagram of the overall structure of the present application;

[0023] BRIEF DESCRIPTION OF DRAWINGS Figure 3 It is an assembly schematic diagram of the liquid cooling plate body and the front frame of the present application;

[0024] BRIEF DESCRIPTION OF DRAWINGS Figure 4 It is a schematic diagram of the structure of another embodiment of the liquid cooling plate body of the present application;

[0025] BRIEF DESCRIPTION OF DRAWINGS Figure 5 It is an enlarged schematic diagram of the structure of part A of the present application;

[0026] BRIEF DESCRIPTION OF DRAWINGS Figure 6 It is a half-section schematic diagram of the insert and the side frame of the present application. DETAILED DESCRIPTION

[0027] The present application will be further described below in conjunction with the drawings.

[0028] As shown in the drawings, Figure 1 to the drawings, Figure 3 The new energy vehicle integrated liquid cooling battery pack box based on CTC architecture includes a liquid cooling plate body and a side frame arranged in a ring shape on the liquid cooling plate body, and a battery compartment for accommodating a battery pack is formed between the side frame and the liquid cooling plate body; the liquid cooling plate body includes a substrate 1, a flow channel plate 2 and a reinforcing plate 3 arranged in sequence, the substrate 1 is arranged corresponding to the battery compartment, the flow channel plate 2 contains a cooling liquid flow channel 4 for circulating flow of cooling liquid, the flow channel plate 2 is a plate structure, a plurality of protruding structures are punched on the side of the flow channel plate 2 from the reinforcing plate towards the substrate, the grooves between the protruding structures constitute the cooling liquid flow channel 4, and the strength of the flow channel plate is also improved correspondingly, the liquid cooling channel containing inlet and outlet ports is formed between the flow channel plate 2 and the substrate 1, the flow channel plate 2 and the substrate 1 are circumferentially brazed to seal the liquid cooling channel, then the inlet and outlet ports are opened on the substrate to make the cooling liquid circulate, and the reinforcing plate 3 is located at the bottom of the flow channel plate 2 and supports the flow channel plate 2, protects and supports the flow channel plate, improves the strength and safety.

[0029] The traditional integrated liquid cooling tank inlet and outlet nozzle is designed on the inside of the tank, and the nozzle structure is welded on the front beam corresponding to the inlet and outlet nozzle side. The traditional way not only increases the number of parts, but also increases the risk of leakage caused by the failure of the connector to contact the position.

[0030] In this scheme, the side of the liquid cooling plate body corresponding to the inlet and outlet of the liquid cooling channel extends to the outside of the enclosed area of the side frame, and the inlet and outlet are provided with a liquid cooling connector 5 directly connected to the liquid cooling pipeline. In this way, the inlet and outlet are located outside the battery compartment, which can avoid the risk of cooling liquid leakage caused by the failure of the liquid cooling nozzle connector and the connector plugging in the liquid cooling pipeline, and further cause the risk of battery leakage. In this scheme, even if there is liquid leakage at the liquid cooling connector nozzle, the leaked liquid is only outside the battery compartment and does not affect the battery pack inside the compartment, which can greatly improve safety; at the same time, it also simplifies the liquid cooling circuit, reduces the liquid cooling parts, and reduces the cost.

[0031] The side frame includes a front side frame 6 corresponding to the area segment where the inlet and outlet are located, and a side side frame 7 corresponding to the remaining area segment. The front side frame 6 and the side side frame 7 are connected end to end to form a ring structure. In this embodiment, the base plate, the flow channel plate and the reinforcing plate are rectangular profile structures. The front side frame 6 is a side frame in the width direction. The side side frame 7 includes another side frame in the width direction and two side frames in the length direction. The side side frame 7 is arranged corresponding to the outer edge of the liquid cooling plate body. The front side frame 6 is arranged on the plate surface of the liquid cooling plate body adjacent to the inlet and outlet, so that the inlet and outlet are located outside the side frame. The structure is simple, easy to manufacture and easy to assemble.

[0032] The plate body of the base plate 1 corresponding to the side side frame 7 is bent towards the side where the battery compartment is located and forms a connecting strip plate 11. The end portions of adjacent connecting strip plates are sealed by welding or gluing. The connecting strip plate 11 is attached to the inner side wall of the side side frame 7 and is fixed by pull rivet connection. A plurality of pull rivet holes 110 are formed in the connecting strip plate 11 along the length direction. The side side frame 7 also has pull rivet holes corresponding to the connecting strip plate.

[0033] When a gap appears between the connecting surface of the flow channel plate and the base plate and liquid seeps, the connecting strip plate protruding above the bottom surface of the base plate can block and protect the seeping liquid from entering the battery compartment.

[0034] During assembly, the flow channel plate 2 and the reinforcing plate 3 are welded as a whole and then connected to the bottom wall of the side side frame 7 by screws or welding. The liquid cooling plate body is connected to the side frame at multiple positions, improving the overall connection strength.

[0035] The flow channel plate 2 and the reinforcing plate 3 are indirectly connected to the bottom wall of the front side frame 6 through the base plate 1, and the base plate 1 is tightly attached to the front side frame 6, so that the battery compartment is closed on the side, and the part of the liquid cooling plate body containing the inlet and outlet ports extends to the outside of the battery compartment.

[0036] The front side frame 6 is provided with a side frame skirt 8 on one side outside the battery compartment, the side frame skirt 8 is provided with a through hole 9 for the liquid cooling connector 5 to pass through corresponding to the inlet and outlet ports, and the side frame skirt 8 is connected and fixed with the base plate by friction welding.

[0037] The liquid cooling plate and the frame are high-strength connected and meet the IP67 sealing, which has always been a difficult point of the box. The traditional structure design is that the liquid cooling plate body is sealed by arc welding, which has high arc welding heat input and is easy to cause liquid cooling plate welding leakage and deformation. The scheme can make the liquid cooling plate body and the frame all connected by stirring welding process through the design of the side frame skirt 8 on the front side frame 6, which has small welding heat output, more reliable sealing, and further reduces the influence on the liquid cooling channel during welding through the isolation of the base plate 1, and eliminates the deformation.

[0038] As shown in the accompanying Figure 4 to the accompanying Figure 6 It also includes an optimized embodiment: the connecting strip plate 11 includes a plurality of inserts 12 on the outer edge edges parallel to the bending lines, and a plurality of inserts 12 are arranged at intervals along the length direction of the outer edge edges, the side frame 7 is provided with a linear insertion slot 13 on the side wall facing the battery compartment for matching and inserting the insert 12, and the insert 12 is bent towards the flow channel plate after passing through the linear insertion slot 13 and attached to the side wall of the side frame 7 away from the battery compartment. On the one hand, the insert 12 can improve the connection strength between the frame and the liquid cooling plate body, on the other hand, the insert can further increase the attachment degree of the connecting strip plate and the frame, when liquid leakage occurs, the leaked liquid can be prevented from entering the battery compartment through the bent insert, after the insert 12 passes through the linear insertion slot 13, the gap between the linear insertion slot and the insert 12, and the gap between the connecting strip plate and the side frame can be filled and sealed; thirdly, since the side frame 7 is a hollow rectangular tubular structure, the leaked liquid can also be guided into the hollow cavity of the side frame 7 to prevent overflow to the outside of the box.

[0039] The insert 12 is attached to the outer side wall of the side frame after passing through the linear insertion slot 13, and the insert 12, the connecting strip plate 11 and the side frame 7 are respectively provided with an adsorption layer, such as a sponge pad or a fiber material, a fabric material which does not react with the cooling liquid, etc., for adsorbing the liquid when the liquid leaks.

[0040] And the first adsorption layer is clamped between the connecting strip plate 11 and the edge side frame 7, the second adsorption layer is clamped between the insert piece 12 and the edge side frame 7, and the first adsorption layer and the second adsorption layer are in contact. When the liquid cooling plate body leaks, the liquid seeps through the gap between the edge side frame 7 and the connecting strip plate, and is adsorbed by the first adsorption layer, and then is adsorbed and guided by the second adsorption layer. Preferably, the thickness of the second adsorption layer is greater than the thickness of the first adsorption layer, so that the adsorption capacity of the second adsorption layer is greater than the adsorption capacity of the first adsorption layer, and the discharge of the seepage is accelerated.

[0041] The insert piece 12 is located between two adjacent pull rivet holes 110, and the connecting strip plate 11 strengthens the adhesion and connection strength of the plate body between the two pull rivet holes and the edge side frame, thereby also being able to limit the seepage into the battery compartment.

[0042] The front side frame 6 and the edge side frame 7 are both hollow rectangular tube structures, and the edge side frame 7 is attached to one side wall of the connecting strip plate 11 as a mounting wall. A plurality of linear insertion grooves 13 are formed on the mounting wall, and the insert piece 12 is attached to the mounting wall. The edge side frame is a non-sealed hollow structure and can exchange gas with the outside air. When the adsorption layer adsorbs the leaked liquid, the adsorption layer can evaporate the seepage by convection with the air, thereby maintaining its continuous adsorption capacity.

[0043] The bottom of the front side frame 6 and the edge side frame 7 is also provided with a raised boss structure 14, and the bottom of the front side frame 6 is also provided with an air avoidance groove corresponding to the boss structure. The boss structure 14 is higher than the reinforcing plate and is supported by the boss structure.

[0044] A manufacturing method of a new energy vehicle integrated liquid cooling battery pack box based on a CTC architecture, comprising the following steps:

[0045] S1: According to the strength requirement, the section of the frame profile is designed, the profile is extruded, and the required part shape is machined; according to the heat dissipation requirement, the flow channel section is designed, and the base plate, flow channel plate and reinforcing plate are punched out;

[0046] S2: The reinforcing plate, flow channel plate and base plate are stacked in sequence, and the liquid cooling plate body is formed by brazing;

[0047] S3: The front side frame corresponding to the area segment where the inlet and outlet are located and the edge side frame corresponding to the remaining area segment are fixedly connected and enclosed into a ring structure, the front side frame is arranged on the plate surface of the liquid cooling plate body adjacent to the inlet and outlet, and the inlet and outlet are located outside the enclosed battery compartment;

[0048] S4: The plate body edge of the base plate corresponding to the edge side frame is vertically bent towards the inside of the battery compartment, and the bent plate body is connected with the edge side frame by pull riveting;

[0049] S5: The substrate is welded with the front frame by means of stirring welding.

[0050] The above only describes the preferred embodiments of the present application, and it should be pointed out that for ordinary skilled in the art, without departing from the principles of the present application, can make several improvements and refinements, these improvements and refinements should also be considered as the protection scope of the present application.

Claims

1. A new energy vehicle integrated liquid-cooled battery pack box based on a CTC architecture, characterized in that: The application relates to a liquid cooling plate body and a side frame arranged in a ring shape on the liquid cooling plate body, wherein the side frame and the liquid cooling plate body form a battery compartment for accommodating a battery pack; the liquid cooling plate body comprises a substrate (1), a flow channel plate (2) and a reinforcing plate (3) arranged in sequence, the substrate (1) is arranged corresponding to the battery compartment, the flow channel plate (2) comprises a cooling liquid flow channel (4) for circulating flow of cooling liquid, the flow channel plate (2) and the substrate (1) form a liquid cooling channel comprising inlet and outlet ports, and the reinforcing plate (3) supports the flow channel plate (2). The side frame comprises a front side frame (6) corresponding to the area segment of the inlet and outlet ports and an edge side frame (7) corresponding to the remaining area segment, the front side frame (6) and the edge side frame (7) are connected end to end to form a ring structure, the edge side frame (7) is arranged corresponding to the outer side edge of the liquid cooling plate body, and the front side frame (6) is arranged on the plate surface of the liquid cooling plate body adjacent to the inlet and outlet ports. The plate body of the substrate (1) is bent towards the side of the battery compartment and forms a connecting strip plate (11) corresponding to the edge side frame (7), the connecting strip plate (11) is connected and fixed with the inner side wall of the edge side frame (7). The connecting strip plate (11) comprises a plurality of inserts (12) on the outer edge edge parallel to the bending line, and the plurality of inserts (12) are arranged at intervals along the length direction of the outer edge edge, the edge side frame (7) is provided with a linear insertion slot (13) on the side wall facing the battery compartment, the insert (12) is matched and inserted into the linear insertion slot (13) and passes through, and the insert (12) is bent towards the flow channel plate after passing through the linear insertion slot (13) and is attached to the side wall of the edge side frame (7) away from the battery compartment. An adsorption layer is arranged in the gap between the insert (12), the connecting strip plate (11) and the edge side frame (7); a first adsorption layer is arranged between the connecting strip plate (11) and the edge side frame (7), a second adsorption layer is arranged between the insert (12) and the edge side frame (7), the first adsorption layer and the second adsorption layer are arranged in contact, and the thickness of the second adsorption layer is greater than that of the first adsorption layer; when the liquid cooling plate body leaks, the liquid seeps through the gap between the edge side frame (7) and the connecting strip plate and is adsorbed by the first adsorption layer, and then is adsorbed and guided by the second adsorption layer; The front side frame (6) and the edge side frame (7) are both hollow rectangular tube structures, one side wall of the edge side frame (7) attached to the connecting strip plate (11) is a mounting wall, a plurality of linear insertion slots (13) are arranged on the mounting wall, and the insert (12) is attached to the mounting wall; the first adsorption layer and the second adsorption layer can guide the seepage liquid into the hollow cavity in the edge side frame (7) to prevent overflow to the outside of the box; and the edge side frame is a non-sealed hollow structure and can exchange gas with the outside air, when the adsorption layer adsorbs the leaked liquid, the adsorption layer can convect with the air to evaporate the seepage liquid and maintain its continuous adsorption capacity.

2. The new energy vehicle integrated liquid-cooled battery pack box based on the CTC architecture according to claim 1, characterized in that: The liquid cooling plate body is extended to the outside of the enclosed area of the side frame on the side corresponding to the inlet and outlet of the liquid cooling channel, and the inlet and outlet are provided with liquid cooling connectors (5) directly connected to the liquid cooling pipeline.

3. The new energy vehicle integrated liquid-cooled battery pack box based on the CTC architecture according to claim 1, characterized in that: The flow channel plate (2) and the reinforcing plate (3) are directly connected to the bottom wall of the edge side frame (7), and the flow channel plate (2) and the reinforcing plate (3) are indirectly connected to the bottom wall of the front side frame (6) through the base plate (1).

4. The new energy vehicle integrated liquid-cooled battery pack box based on the CTC architecture according to claim 3, characterized in that: The front side frame (6) is provided with a side frame skirt (8) on the side outside the battery compartment, and the side frame skirt (8) is provided with a perforation (9) corresponding to the inlet and outlet.

5. The new energy vehicle integrated liquid-cooled battery pack box based on the CTC architecture according to claim 1, characterized in that: The connecting strip plate (11) is provided with a plurality of rivet holes (110) along the length direction, and the insert piece (12) is located between two adjacent rivet holes (110).

6. A manufacturing method of a new energy vehicle integrated liquid-cooled battery pack box based on a CTC architecture according to any one of claims 1-5, characterized in that: The method comprises the following steps: S1: according to the strength requirement, the section of the frame profile is designed, the profile is extruded, and the required part shape is machined; according to the heat dissipation requirement, the flow channel section is designed, and the base plate, the flow channel plate and the reinforcing plate are punched out; S2: the reinforcing plate, the flow channel plate and the base plate are stacked in sequence, and are respectively formed into a liquid cooling plate body by brazing; S3: the front side frame corresponding to the area segment where the inlet and outlet are located and the edge side frame corresponding to the remaining area segment are fixedly connected and enclosed into a ring structure, the front side frame is arranged on the plate surface of the liquid cooling plate body adjacent to the inlet and outlet, and the inlet and outlet are located outside the battery compartment enclosed; S4: the plate body edge of the base plate corresponding to the edge side frame is vertically bent towards the inside of the battery compartment, and the bent plate body is connected with the edge side frame by riveting; S5: the base plate and the front frame are welded by stirring welding.

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