Battery frame for vehicle drive battery and manufacturing thereof

Abstract

The invention relates to a method (100) for manufacturing a battery frame (300) for a drive battery (401) of a vehicle (400), the manufacturing method (100) comprising: casting (101) the battery frame (300) as a single body in an aluminum alloy die-casting process, the battery frame (300) being cast in a die-casting manner, and the battery frame (300) being cast in a die-casting manner, the battery frame (300) is configured to completely surround the drive battery (401) from the lateral direction.

Description

[0001] The present invention relates to a method for manufacturing a battery frame for a vehicle drive battery according to the appended claims, a battery frame for a vehicle drive battery, and a vehicle.

[0002] The drive battery for a vehicle is secured by a tray, which is, for example, arranged on the vehicle's frame. Alternatively, a battery casing is known to surround the drive battery and accordingly protect it from environmental influences.

[0003] The battery casing typically consists of a battery frame, a base plate, and an optional cover plate. Here, since its size is usually between 50 cm and 300 cm, the battery frame is assembled modularly from multiple components.

[0004] Furthermore, CN 205376596 U discloses a tray for holding a battery on a vehicle, the tray being arranged below on a support structure to secure the battery between the support structure and the tray. The tray is substantially flat and open to the environment. Cooling elements for guiding coolant are arranged on the tray.

[0005] In addition, aluminum die-casting methods for manufacturing shell components are known from CN 113957302 A, CN 116000246 A and CN 113245521 A, respectively.

[0006] Within the scope of this invention, a method for manufacturing a battery frame, a battery frame, and a vehicle are proposed. Further features and details of the invention are derived from the various dependent claims, the specification, and the drawings. The features and details described herein in conjunction with the manufacturing method according to the invention are also applicable to the battery frame according to the invention or the vehicle according to the invention, and vice versa, such that the disclosures regarding various aspects of the invention are always mutually referenced or may be mutually referenced.

[0007] In this context, the technical problem to be solved by the present invention is to provide a possibility for rapidly and material-savingly manufacturing a robust battery frame for vehicle drive batteries.

[0008] Therefore, according to a first aspect of the present invention, a method for manufacturing a battery frame for a vehicle drive battery is provided.

[0009] The manufacturing method includes casting the battery frame as a single casting in an aluminum die-casting process, wherein the battery frame is cast in a drop-out manner, and wherein the battery frame is configured to completely surround the drive battery from the side.

[0010] In the context of this invention, the battery frame should be understood as a structure configured to completely enclose a drive battery, i.e., a battery for providing electrical energy to a vehicle drive system, particularly a high-voltage energy storage device, from the sides. Accordingly, the battery frame completely or continuously encloses the drive battery on four sides and at a predetermined height. In particular, the battery frame is adapted to form a groove together with a base plate into which the drive battery can be introduced. In conjunction with the base plate and a cover plate, the battery frame is adapted to form a housing for the drive battery that protects the drive battery from environmental influences or completely encloses it from all sides.

[0011] In the context of this invention, drop-out casting process should be understood as a process in which a component, namely the battery frame according to the invention, is cast in such a manner that, after the casting process, the component can be easily removed from the mold or detached from the mold without moving a slider or the like. In particular, to achieve the drop-out construction, the component does not include side recesses (or undercuts), but only includes side-by-side extending structures.

[0012] The proposed manufacturing method is based on so-called "monocasting," a die-casting process in which aluminum or aluminum alloy is introduced into a mold to form a single monolithic component, thereby eliminating the need for subsequent complex steps for assembling the battery frame.

[0013] Because the battery frame to be provided by the proposed manufacturing method must be suitable for housing or surrounding the driving battery, the battery frame must be manufactured to be very large, which in turn requires very large equipment for casting the battery frame, for example, several meters in length. The equipment for casting the battery frame also requires very high pressure.

[0014] Casting such a battery frame is technically challenging due to the size required to fit the battery frame surrounding the drive battery.

[0015] It can be stipulated that the aluminum die-casting process is carried out at a pressure of at least 3,000 tons, particularly at least 4,000 tons, preferably at least 8,000 tons, to cast the battery frame.

[0016] For the purpose of single-cell casting suitable for enclosing large battery frames, pressing aluminum or aluminum alloy into the appropriate mold using a pressure of at least 3,000 tons (30,000 kN) has proven advantageous. Depending on the size of the battery frame, pressures greater than 4,000 tons (40,000 kN) or even greater than 8,000 tons (80,000 kN) may be advantageous.

[0017] A press can be used to provide the pressure for introducing aluminum or aluminum alloy into the corresponding mold.

[0018] Furthermore, it can be specified that the battery frame is cast in a die-casting mold comprising a first plate, a second plate, and a third plate, wherein a casting system for distributing casting material in the die-casting mold is constructed between the first plate and the second plate, and a mold for forming the battery frame is constructed between the second plate and the third plate.

[0019] A die-casting mold with three plates allows aluminum or aluminum alloy to be introduced centrally into the mold, so that the aluminum or aluminum alloy is evenly distributed in multiple directions in the mold at the same time, rather than flowing from one side to the other in the form of a leading edge.

[0020] By using a die-casting mold with three plates, multiple casting points spaced apart from each other can be achieved, thus enabling the manufacture of particularly large components on a single piece.

[0021] Furthermore, it can be specified that, during the casting of the battery frame, the basic skeleton of the battery frame is cast in the first sub-step, and in the second sub-step, additional material is selectively applied to the basic skeleton at predetermined points.

[0022] A two-stage casting process can achieve exceptionally high or strong component geometries, for example, by reinforcing the basic structure with additional materials.

[0023] In addition, it can be specified that the battery frame is manufactured together with the base plate.

[0024] By manufacturing the battery frame together with the base plate, a slot can be formed to accommodate the drive battery.

[0025] Furthermore, the manufacturing method may also include connecting the battery frame to at least one additional profile.

[0026] By connecting the battery frame to the additional profile, the individual battery frame can be adapted to the corresponding drive battery by means of the additional profile, for example by forming multiple compartments in the battery frame for multiple battery cells and / or drive battery control electronics.

[0027] Therefore, it can be stipulated that the additional profiles are welded or bonded to the battery frame.

[0028] In addition, it can be specified that the length of the cast battery frame is between 50 cm and 250 cm and / or the width is between 30 cm and 200 cm.

[0029] To completely or circumferentially enclose the drive battery, the battery frame must be cast to be longer and wider than the drive battery. To cast such a battery frame individually, exceptionally large and powerful die-casting equipment is required, with molds correspondingly larger than the battery frame itself.

[0030] According to a second aspect, the present invention relates to a battery frame for a vehicle drive battery, wherein the battery frame is a single-unit component.

[0031] The proposed battery frame is configured to completely and uninterruptedly surround the drive battery.

[0032] The proposed battery frame is a single component, and accordingly it consists of only one piece of metal.

[0033] It can be specified that the proposed battery frame is manufactured through one possible implementation of the proposed manufacturing method.

[0034] The proposed manufacturing method enables the production of the proposed battery frame in a particularly fast and material-saving manner.

[0035] According to a third aspect, the present invention relates to a vehicle. The proposed vehicle includes one possible embodiment of the proposed battery frame.

[0036] Due to the proposed battery frame, the proposed vehicle is particularly able to withstand mechanical loads.

[0037] Other advantages, features, and details of the invention will become apparent from the following description, in which embodiments of the invention are described in detail with reference to the accompanying drawings. Herein, the features mentioned in the claims and specification may each constitute a substantial feature of the invention individually or in any combination. Wherein:

[0038] Figure 1 One possible implementation of the proposed manufacturing method is shown.

[0039] Figure 2 It shows that according to Figure 1 Detailed view of the manufacturing method

[0040] Figure 3 One possible implementation of the proposed battery frame is shown.

[0041] Figure 4 One possible implementation of the proposed vehicle is shown.

[0042] exist Figure 1 The image shows a method 100 for manufacturing a battery frame for a vehicle drive battery.

[0043] The manufacturing method 100 includes a casting step 101, in which the battery frame is cast as a single unit in an aluminum die-casting process. Here, the battery frame is cast using a drop-out casting method.

[0044] The battery frame is configured to completely surround the drive battery from the side. Accordingly, the battery frame is cast in the form of a closed or continuous frame.

[0045] exist Figure 2 The text shows the data based on... Figure 1 One possible implementation of the manufacturing method 100. Here, the first plate 201, the second plate 203, and the third plate 205 are pressed together.

[0046] Liquid aluminum alloy is pressed between the first plate 201 and the second plate 203, such that the aluminum alloy is distributed on the second plate 203 according to the distribution geometry formed in the first plate 201, and flows into a mold formed between the second plate 203 and the third plate 205.

[0047] Here, the casting point 207 for introducing aluminum alloy into the first plate 201 is located at the center or center of the first plate 201.

[0048] Furthermore, multiple casting points 209, 211, and 213 are located within or above the second plate 203, such that the component formed in the mold is formed from multiple converging local areas. Accordingly, the flow time of the aluminum alloy in the mold is minimized by casting points 209, 211, and 213, which ensures high process stability due to minimal heat loss.

[0049] exist Figure 3 The image shows a battery frame 300. The battery frame 300 is monolithically formed and includes multiple compartments 301 for accommodating multiple battery bars of a vehicle drive battery.

[0050] exist Figure 4 The image shows vehicle 400. Vehicle 400 includes, according to... Figure 3 The battery frame 300 and the drive battery 401 disposed therein.

[0051] List of reference numerals

[0052] 100 Manufacturing Methods

[0053] 101 Casting Steps

[0054] 201 First Board

[0055] 203 Second Board

[0056] 205 Third Board

[0057] 207 casting point

[0058] 209 casting point

[0059] 211 casting point

[0060] 213 casting point

[0061] 300 battery frame

[0062] 301 compartment

[0063] 400 vehicles

[0064] 401 drive battery

Claims

1. A method (100) for manufacturing a battery frame (300) of a drive battery (401) for a vehicle (400), in, The manufacturing method (100) includes: - In the aluminum die-casting process, the battery frame (300) is cast as a single unit (101). The battery frame (300) is cast using a drop-molding method, and The battery frame (300) is configured to completely surround the drive battery (401) from the side.

2. The manufacturing method (100) according to claim 1, Its features are, The aluminum die-casting process is carried out at a pressure of at least 3,000 tons, particularly at least 4,000 tons, preferably at least 8,000 tons, to cast (101) the battery frame (300).

3. The manufacturing method (100) according to claim 1 or 2, Its features are, The battery frame (300) is cast in a die-casting mold, the die-casting mold including a first plate (201), a second plate (203) and a third plate (205), wherein a casting system for distributing casting material in the die-casting mold is constructed between the first plate (201) and the second plate (203), and a mold for forming the battery frame (300) is constructed between the second plate (203) and the third plate (205).

4. The manufacturing method (100) according to any one of the preceding claims, Its features are, When casting (101) the battery frame (300), the basic skeleton of the battery frame (300) is cast in a first sub-step, and additional material is selectively applied to the basic skeleton at predetermined points in a second sub-step.

5. The manufacturing method (100) according to any one of the preceding claims, Its features are, The battery frame (300) is manufactured together with the base plate.

6. The manufacturing method (100) according to any one of the preceding claims, Its features are, The manufacturing method (100) further includes: - Connect the battery frame (300) to at least one additional profile.

7. The manufacturing method (100) according to claim 6, Its features are, The additional profile is welded or bonded to the battery frame (300).

8. The manufacturing method (100) according to any one of the preceding claims, Its features are, The battery frame (300) is cast in a length of 50 cm to 250 cm and / or a width of 30 cm to 200 cm.

9. Battery frame (300) for a drive battery (401) in a vehicle (400), in, The battery frame (300) is a single component.

10. The battery frame (300) according to claim 9, Its features are, The battery frame (300) is manufactured by the manufacturing method (100) according to any one of claims 1 to 8.

11. Vehicles (400), in, The vehicle includes a battery frame (300) according to claim 9 or 10.

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