A high-airtightness battery box for new energy vehicles and its installation method

Abstract

This invention relates to the field of new energy battery boxes, specifically to a high-airtightness new energy vehicle battery box, comprising an upper box, a lower box, and connecting fasteners for the two. Both the upper and lower boxes include a plate and side frames mounted around the periphery of the plate. Several slots are evenly distributed at the free ends of the side frames. An extension piece adapted to the slots is obliquely extended downwards from the lower end surface of the plate, with its lower end abutting against the core tube. A sealing element is provided between the lower end surface of the plate and the side frame, and a recessed groove for embedding the sealing element is provided on the upper surface of the side frame. This invention solves the problem of insufficient airtightness in existing battery boxes with a split-installation structure.

Description

Technical Field

[0001] This invention relates to the field of new energy battery housings, specifically to a high-airtightness new energy vehicle battery housing and its installation method. Background Technology

[0002] Currently, in the profiles used in new energy battery boxes, as shown in Chinese patent application CN 113206341 A, a battery box includes: an upper box body, a lower box body, a connector, and a fixing member; the upper box body has a first side wall and a first eave protruding circumferentially from the first side wall, and the lower box body has a second side wall and a second eave protruding circumferentially from the second side wall; the first eave and the second eave are arranged opposite each other in the vertical direction, and the first eave is provided with a first connecting hole, the second eave is provided with a second connecting hole and a mounting hole spaced apart from the second connecting hole; the connector passes through the first connecting hole and the second connecting hole to fix the upper box body and the lower box body; the fixing member passes through the mounting hole to install the lower box body to an external device; the material density of the lower box body is greater than that of the upper box body; the height of the first side wall in the vertical direction is greater than that of the second side wall in the vertical direction. Structurally, for the load-bearing lower box body, a material density greater than that of the upper box body is used to reduce the weight of the battery box and ensure structural strength.

[0003] In the above structure, the eaves and side walls are an integral structure. The strength of the battery box under this structure basically depends on the structural strength of the material, which means that the structural strength cannot be further improved. Summary of the Invention

[0004] Therefore, the present invention provides a high airtightness battery box for new energy vehicles and its installation method, which solves the problem that the existing battery boxes cannot guarantee airtightness when using a split installation structure.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0006] A high airtightness battery box for new energy vehicles includes an upper box, a lower box, and connecting fasteners for the two. Both the upper box and the lower box include a plate and a side frame mounted around the periphery of the plate. The side frame includes a horizontal plate for fixing to the plate, an eave for connecting the upper box and the lower box, and an inclined side wall connecting the horizontal plate and the eave. The two ends of the inclined side wall are provided with outwardly extending support arms, and steel core tubes are mounted on the two support arms. The core tubes are attached to the surface of the inclined side wall.

[0007] The free end of the horizontal plate has several slots evenly distributed. The lower end surface of the plate body extends obliquely downward and is provided with an extension piece adapted to the slots. The lower end of the extension piece abuts against the core tube. A sealing element is provided between the lower end surface of the plate body and the horizontal plate. The upper end surface of the horizontal plate is provided with a recessed groove for embedding the sealing element.

[0008] Preferably, the peripheral edge of the upper box body is inclined downward and mounted on the peripheral side frame, extending beyond the side frame.

[0009] Preferably, the center of the lower housing plate is convex, and its peripheral edges are mounted on the side frame and extend beyond the side frame.

[0010] Preferably, the eaves of the upper housing has a downwardly and inwardly extending flange, the eaves of the lower housing are mounted on the flange, and the connecting fastener is located at the flange and the eaves of the lower housing.

[0011] Preferably, the eaves and the flange on the lower housing are inclined.

[0012] A method for installing a high-airtightness battery box for new energy vehicles, wherein the upper box includes an upper plate and an upper side frame, the upper side frame including an upper horizontal plate, an upper eave, an upper inclined side wall, and an upper core tube; the lower box includes a lower plate and a lower side frame, the lower side frame including a lower horizontal plate, a lower eave, a lower inclined side wall, and a lower core tube; the installation process includes the following steps:

[0013] a. Based on the lower plate, with the extension piece on the lower plate facing upward, the lower side frame is installed sequentially along its perimeter. The lower horizontal plate on the lower side frame is placed on the lower plate, so that the slot on the lower horizontal plate is inserted into the extension piece. The extension piece abuts against and squeezes the lower core tube, thereby making the lower side frame as a whole snap on the lower plate. The lower horizontal plate has a sealing element pre-attached to the recessed groove.

[0014] b. Install the corresponding upper side frame on the lower side frame of each side. There are locking holes between the upper side frame and the lower side frame. Secure them with connecting fasteners and pre-attach sealing elements to the recessed groove of the upper horizontal plate.

[0015] c. Based on step b, the extension piece of the upper plate is placed downwards and inserted into the upper side frame of each side, so that the slot on the upper horizontal plate is inserted into the extension piece. After the extension piece abuts against and presses against the upper core tube, the snap-fit ​​installation is completed.

[0016] d. Install L-shaped structural pieces at the corners where the upper and lower side frames connect to complete the installation of the battery box.

[0017] Preferably, in step a above, a sealing compound is injected into the hollow portion between the lower horizontal plate and the lower plate body, which is located outside the sealing element.

[0018] Preferably, in step c above, a sealing compound is injected into the hollow portion between the upper horizontal plate and the upper plate body, which is located outside the sealing element.

[0019] Preferably, in step c above, after a pair of upper side frames are installed on the lower side frame, the upper plate is installed, and then another pair of upper side frames are installed.

[0020] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0021] Unlike the traditional one-piece enclosure structure, where the main sealing structure is at the eaves of the upper and lower enclosures, this technical solution adopts a separate design of sloping side walls and large-area panels for later installation. During installation, the extension pieces on the panels are interlocked with the side frames, and corresponding sealing elements are arranged to meet the sealing requirements.

[0022] Meanwhile, the structural strength of the side frame is designed. Based on traditional aluminum profiles, and especially in cases where the structural strength of a single material cannot be further improved due to its material properties, the internal core tube increases the overall toughness of the profile. Unlike the brittle nature of aluminum, when subjected to inward force at the eaves, the addition of the core tube makes the profile less prone to breakage, thereby structurally increasing the upper limit of the profile's strength. Under stress, it can better ensure the integrity of the entire new energy battery box, reduce the direct impact of external forces on the internal cells, and provide greater protection for the battery.

[0023] The steel core tube is located inside the entire profile, while the outside is made of traditional aluminum alloy material, which ensures external corrosion resistance and reduces the overall weight of the battery box. The entire profile structure has the hardness of aluminum profile and can provide internal support through the core tube to increase toughness under impact. It has a high upper limit of structural strength and wide applicability.

[0024] The separate design of the main body and side frame allows for the recycling of undeformed parts during battery pack recovery, thereby reducing the implementation cost of this project. Similarly, it facilitates the replacement of deformed parts such as the main body below or a single side frame, thus eliminating the prerequisite for subsequent repairs and battery box replacements, which has broad prospects. Furthermore, the separate structural design also greatly reduces the cost of producing scrap, especially when the yield rate of the production process is not high, it can significantly reduce production costs.

[0025] During installation, the use of a split-installation design significantly reduces the power requirements of installation equipment compared to traditional integrated enclosures. Furthermore, the large-area panels and side frames are primarily installed using an extension plate insertion mechanism combined with sealing elements. This allows for easier rework in cases where quality issues arise due to modifications in the processing of the panels and sloping side walls, such as drilling, or differences in installation precision. This reduces the cost increase caused by defective products, lowers production costs, and results in higher efficiency. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the connection structure between the plate and the side frame in an embodiment of the present invention (taking the above box as an example);

[0027] Figure 2 This is a schematic diagram of the connection structure between the upper and lower housings in an embodiment of the present invention.

[0028] Reference numerals: 100, Upper housing; 200, Lower housing; 300, Connecting fastener; 400, Plate; 401, Extension piece; 500, Side frame; 1, Horizontal plate; 11, Slot; 12, Sunken groove; 2, Eaves; 21, Flanged edge; 3, Sloping side wall; 31, Support arm; 32, Reinforcing rib; 4, Core tube; 41, Longitudinal edge; 42, Horizontal edge; 43, Joint edge; 5, Sealing element; 51, Sealing colloid; 400a, Upper plate; 400b, Lower plate; 500a, Upper side frame; 500b, Lower side frame; 1a, Upper horizontal plate; 1b, Lower horizontal plate; 2a, Upper eaves; 2b, Lower eaves; 3a, Upper sloping side wall; 3b, Lower sloping side wall; 4a, Upper core tube; 4b, Lower core tube. Detailed Implementation

[0029] The following will describe in detail the implementation of the present invention with reference to specific embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. Example

[0030] refer to Figure 1A high-airtightness battery box for new energy vehicles includes an upper box 100, a lower box 200, and a connecting fastener 300 for the two. Both the upper box 100 and the lower box 200 include a plate 400 and a side frame 500 mounted around the plate 400. The side frame 500 includes a horizontal plate 1 for fixing to the plate 400, an eave 2 for connecting the upper box 100 and the lower box 200, and an inclined side wall 3 connecting the horizontal plate 1 and the eave 2. The two ends of the inclined side wall 3 are provided with outwardly extending support arms 31. Steel core tubes 4 are mounted on the two support arms 31. The core tubes 4 are attached to the surface of the inclined side wall 3. The core tube 4 has a longitudinal side 41, a horizontal side 42, and a joint side 43 connecting the two. The longitudinal side 41 and the horizontal side 42 are arranged perpendicular to each other. The cross-section of the core tube 4 is triangular. The joint side 43 is attached to the surface of the inclined side wall 3. The longitudinal side 41 extends in a direction perpendicular to the horizontal plate 1, while the horizontal side 42 is set parallel to the horizontal plate 1 and the eaves 2. In this way, when applied to the new energy battery box, the stable triangular structure of the core tube 4 can provide sufficient structural support for the eaves 2, which is the outer edge. Furthermore, the core tubes 4 on the upper box 100 and the lower box 200 of the battery box can form mutual structural support after being subjected to force, which further improves the structural strength of the profile when applied to the battery box.

[0031] Meanwhile, the inclined sidewall 3 has a double-layer structure with several reinforcing ribs 32 evenly distributed inside. This makes the inclined sidewall 3 structurally different from a thin single-layer structure, giving it superior strength. As the side of the battery box, it can withstand greater impact and reduce deformation, providing ample protection for the internal batteries. Structurally, unlike traditional one-piece box structures made from large-area sheet metal, this split aluminum profile is necessary to form the double-layered inclined sidewall 3 structure.

[0032] The horizontal plate 1 has several slots 11 evenly distributed at its free end. The lower end face of the plate 400 extends obliquely downwards and is provided with an extension piece 401 adapted to the slots 11. The lower end of the extension piece 401 abuts against the core tube 4. A sealing element 5 is provided between the lower end face of the plate 400 and the horizontal plate 1. The upper end surface of the horizontal plate 1 has a recessed groove 12 for embedding the sealing element 5. During installation, the lower end of the extension piece 401 extends to the connection position between the longitudinal edge 41 and the transverse edge 42 and is then secured to the transverse edge 42.

[0033] Unlike the traditional integrated box structure, its main sealing structure is the eaves 2 of the upper box 100 and the lower box 200. This technical solution adopts a separate design and installation form of the sloping side wall 3 and the large-area plate 400. During installation, the extension piece 401 on the plate 400 is inserted into the side frame 500, and corresponding sealing elements 5 are arranged to meet the sealing requirements.

[0034] Meanwhile, the structural strength of the 500mm side frame is designed. Based on traditional aluminum profiles, and especially in cases where the structural strength of a single material cannot be further improved due to its material properties, the internal core tube 4 can increase the overall toughness of the profile. Unlike the brittle nature of aluminum, when the eaves 2 are subjected to inward force, the addition of the core tube 4 can make the profile less prone to breakage, thereby structurally increasing the upper limit of the profile's strength. Under stress, it can better ensure the integrity of the entire new energy battery box, reduce the direct impact of external forces on the internal cells, and provide greater protection for the battery.

[0035] The steel core tube 4 is located inside the entire profile, while the outside is made of traditional aluminum alloy material, which ensures external corrosion resistance and reduces the overall weight of the battery box. The entire profile structure has the hardness of aluminum profile and can provide support from the inside through the core tube 4 to increase toughness under impact. It has a high upper limit of structural strength and wide applicability.

[0036] The separate design of the plate 400 and the side frame 500 allows for the recycling of the corresponding undeformed parts during battery pack recycling, thereby reducing the implementation cost of this project. Similarly, it also facilitates the replacement of deformed parts such as the plate 400 below or a single side frame 500, thus eliminating the prerequisite for subsequent repairs and replacement of battery boxes, which has broad prospects. Furthermore, the separate structural design also greatly reduces the cost of producing scrap, especially when the yield rate of the production process is not high, it can greatly reduce production costs.

[0037] Structurally, the peripheral edges of the plate 400 of the upper housing 100 are inclined downwards and mounted on the peripheral side frame 500, extending beyond the side frame 500. This design allows the plate 400 to completely cover the surrounding side frame 500 and cover the sealing position, while a certain gap is formed between the remaining side frame 500s. In subsequent processes, sealing adhesive 51 can be injected into this gap to increase the sealing performance and ensure the connection.

[0038] The lower housing 200 has a plate 400 with a convex center, and its peripheral edges are mounted on the side frame 500 and extend beyond the side frame 500. It not only has the advantages of the downward sloping peripheral edges of the upper housing 100, but also, considering that the lower housing 200 is located at the bottom, the plate 400 of the lower housing 200 has a certain effect of draining water to the periphery after wading, thereby preventing liquid from accumulating on the battery box and reducing the damage of liquid to the sealing element 5 and the sealing colloid 51.

[0039] Structurally, the upper housing 100 has a downwardly and inwardly extending flange 21 on its eaves 2. The lower housing 200's eaves 2 are mounted on this flange 21, and the connecting fastener 300 is located at the flange 21 and the lower housing 200's eaves 2. The flange 21 design facilitates the installation of the upper housing 100 and the upper side frame 500 of the lower housing 200. Furthermore, the inclined arrangement of the lower housing 200's eaves 2 and flange 21 further enhances the drainage effect at the lower housing 200, and is more conducive to drainage compared to traditional horizontally arranged connection structures.

[0040] The installation process of the battery box is as follows: A method for installing a high-airtightness new energy vehicle battery box, as shown below. Figure 2 As shown, the upper housing 100 includes an upper plate 400a and an upper side frame 500a. The upper side frame 500a includes an upper horizontal plate 1a, an upper eave 2a, an upper inclined side wall 3a, and an upper core tube 4a. The lower housing 200 includes a lower plate 400b and a lower side frame 500b. The lower side frame 500b includes a lower horizontal plate 1b, a lower eave 2b, a lower inclined side wall 3b, and a lower core tube 4b. The installation process includes the following steps:

[0041] a. Based on the lower plate 400b, with the extension piece 401 on the lower plate 400b facing upward, the lower side frame 500b is installed sequentially along its periphery. The lower horizontal plate 1b on the lower side frame 500b is placed on the lower plate 400b, so that the slot 11 on the lower horizontal plate 1b is inserted into the extension piece 401. The extension piece 401 abuts against and squeezes the lower core tube 4b, thereby making the lower side frame 500b as a whole snapped onto the lower plate 400b. The sealing element 5 is pre-attached at the recessed groove 12 on the lower horizontal plate 1b.

[0042] b. Install the upper side frame 500a on the lower side frame 500b of each side. There is a locking hole between the upper side frame 500a and the lower side frame 500b. Secure it with the connecting fastener 300 and pre-attach the sealing element 5 at the recessed groove 12 of the upper horizontal plate 1a.

[0043] c. Based on step b, the extension piece 401 of the upper plate 400a is placed downwards and inserted into the upper side frame 500a on each side, so that the slot 11 on the upper horizontal plate 1a is inserted into the extension piece 401. The extension piece 401 abuts against and presses against the upper core tube 4a to complete the snap-fit ​​installation. In step c, a pair of upper side frames 500a are pre-installed on the lower side frame 500b before the upper plate 40a is installed, and then another pair of upper side frames 500a are installed. This design ensures that the snap-fit ​​structure between the extension piece 401 and the core tube is installed in place, and there is no need to press the extension piece 401, which achieves standardized installation and ensures the consistency of the battery box after installation.

[0044] d. Install L-shaped structural pieces (not shown in the figure) at the corners where the upper side frame 500a and the lower side frame 500b connect on each side to complete the installation of the battery box. The L-shaped structural pieces serve to increase the fixing structure, and sealing elements are also provided on the connecting surfaces of the L-shaped structural pieces with the upper side frame 500a and the lower side frame 500b to further ensure the sealing effect. It should be noted that in order to ensure a tight connection at the corners where the upper side frame 500a and the lower side frame 500b connect, the installation positions must be cut at a 45-degree angle before installation to ensure a proper fit at the corners.

[0045] Structurally, in step a above, sealing adhesive 51 is injected into the hollow portion between the lower horizontal plate 1b and the lower plate body 400b, outside the sealing element 5; in step c above, sealing adhesive 51 is injected into the hollow portion between the upper horizontal plate 1a and the upper plate body 400a, outside the sealing element 5. The sealing adhesive 51 between the upper box body 100 and the lower box body 200 is an additional measure after the overall installation is completed and after a sealing test is performed to ensure that the sealing element 5 can accurately and effectively achieve the sealing effect. Firstly, it can increase the tightness of the connection between the lower horizontal plate 1b and the lower plate body 400b, and between the upper horizontal plate 1a and the upper plate body 400a. Secondly, it can also provide a certain degree of protection for the sealing element 5, completely encasing the sealing element 5 after filling.

[0046] During installation, the use of a split-installation design significantly reduces the power requirements of the installation equipment compared to traditional integrated enclosures. Furthermore, the large-area panels and side frames are mainly installed using an extension plate 401 plug-in connection with a sealing element 5. This facilitates rework when quality is compromised due to modifications in the processing of the panel and sloping side walls, such as drilling, or differences in installation precision. This reduces the cost increase caused by defective products, lowers production costs, and results in higher efficiency.

[0047] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A high-airtightness battery box for new energy vehicles, comprising an upper box (100), a lower box (200), and a connecting fastener (300) for the two, characterized in that: The upper box (100) and the lower box (200) both include a plate (400) and a side frame (500) installed around the plate (400). The side frame (500) includes a horizontal plate (1) for fixing to the plate (400), an eave (2) for connecting the upper box (100) and the lower box (200), and an inclined side wall (3) connecting the horizontal plate (1) and the eave (2). The two ends of the inclined side wall (3) are provided with outwardly extending support arms (31). The two support arms (31) are supported and installed with steel core tubes (4). The core tubes (4) are attached to the surface of the inclined side wall (3). The free end of the horizontal plate (1) is provided with a number of slots (11). The lower end face of the plate body (400) is provided with an extension piece (401) that is adapted to the slots (11). The lower end of the extension piece (401) abuts against the core tube (4). A sealing element (5) is provided between the lower end face of the plate body (400) and the horizontal plate (1). The upper end surface of the horizontal plate (1) is provided with a recessed groove (12) for embedding the sealing element (5).

2. The high airtightness battery box for new energy vehicles according to claim 1, characterized in that: The upper box (100) has a plate (400) called an upper plate (400a). The peripheral edge of the upper plate (400a) is inclined downward and is mounted on the peripheral side frame (500), extending beyond the side frame (500).

3. The high airtightness battery box for new energy vehicles according to claim 1, characterized in that: The lower box (200) has a plate (400) called a lower plate (400b). The center of the lower plate (400b) is convex, and its peripheral edges are mounted on the side frame (500) and extend out of the side frame (500).

4. The high airtightness battery box for new energy vehicles according to claim 1, characterized in that: The upper box (100) has an eave (2) with a downward and inwardly extending flange (21), the lower box (200) has an eave (2) mounted on the flange (21), and the connecting fastener (300) is located at the flange (21) and the eave (2) of the lower box (200).

5. A high airtightness battery box for new energy vehicles according to claim 4, characterized in that: The eaves (2) and the flange (21) on the lower box (200) are inclined.

6. A method for installing a high-airtightness battery box for a new energy vehicle according to claim 1, characterized in that: The upper housing (100) includes an upper plate (400a) and an upper side frame (500a). The upper side frame (500a) includes an upper horizontal plate (1a), an upper eave (2a), an upper sloping side wall (3a), and an upper core tube (4a). The lower housing (200) includes a lower plate (400b) and a lower side frame (500b). The lower side frame (500b) includes a lower horizontal plate (1b), a lower eave (2b), a lower sloping side wall (3b), and a lower core tube (4b). The installation process includes the following steps: a. Based on the lower plate (400b), with the extension piece (401) on the lower plate (400b) facing upward, the lower side frame (500b) is installed sequentially along its periphery. The lower horizontal plate (1b) on the lower side frame (500b) is placed on the lower plate (400b), so that the slot (11) on the lower horizontal plate (1b) is inserted into the extension piece (401). The extension piece (401) abuts against and squeezes the lower core tube (4b), thereby making the lower side frame (500b) be snapped onto the lower plate (400b) as a whole. The sealing element (5) is pre-attached to the recessed groove (12) on the lower horizontal plate (1b). b. Install the upper side frame (500a) on each side of the lower side frame (500b) respectively. There is a locking hole between the upper side frame (500a) and the lower side frame (500b). Secure it by connecting fastener (300) and pre-attach sealing element (5) at the recess (12) of the upper horizontal plate (1a). c. Based on step b, the extension piece (401) of the upper plate (400a) is facing down and inserted into the upper side frame (500a) on each side, so that the slot (11) on the upper horizontal plate (1a) is inserted into the extension piece (401), and the extension piece (401) abuts against and squeezes the upper core tube (4a) to complete the snap-fit ​​installation. d. Install L-shaped structural pieces at the corners where the upper side frame (500a) and the lower side frame (500b) meet on each side to complete the installation of the battery box.

7. The method for installing a high-airtightness new energy vehicle battery box according to claim 6, characterized in that: In step a above, sealing glue (51) is injected into the hollow part between the lower horizontal plate (1b) and the lower plate body (400b) and outside the sealing element (5).

8. The method for installing a high-airtightness battery box for a new energy vehicle according to claim 6, characterized in that: In step c above, sealing glue (51) is injected into the hollow part between the upper horizontal plate (1a) and the upper plate body (400a) and outside the sealing element (5).

9. The method for installing a high-airtightness battery box for a new energy vehicle according to claim 6, characterized in that: In step c above, after installing a pair of upper side frames (500a) on the lower side frame (500b), the upper plate (400a) is installed, and then another pair of upper side frames (500a) is installed.

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