Lightweight high-strength battery tray

Abstract

The application relates to the technical field of battery tray, in particular to a light-weight battery tray with high strength, which comprises a bottom plate, first welding plates arranged on the two sides of the bottom plate, the first welding plates and the side walls of the bottom plate forming a stepped shape, side beams connected with the two sides of the bottom plate, the side beams being provided with second welding plates matched with the first welding plates, front beams and rear beams connected with the side beams and forming a frame shape, and a cross beam detachably connected with the side beams and capable of sliding on the side beams; the first welding plates and the second welding plates are welded in a stepped shape, so that the light weight of the battery box is ensured and the strength of the battery box is improved; the installation space of the battery pack is adjusted through the sliding cross beam, the battery tray is applicable to battery packs of different sizes, and the compatibility is high.

Description

Technical Field

[0001] This invention relates to the field of battery tray technology, and more particularly to a lightweight and high-strength battery tray. Background Technology

[0002] The battery tray is a core structural component of the battery system of new energy vehicles. It is mainly used to support and protect the battery module and is the skeleton of the battery system. It has properties such as high precision, corrosion resistance, high temperature resistance and impact resistance. Currently, the mainstream material is aluminum alloy.

[0003] As the energy density and power requirements of existing power battery packs increase, different pallets are required to be lightweight while also taking into account their own load-bearing strength, including the compatibility of different brands of battery cells and the convenience of pallet transportation and hoisting. Existing pallets cannot fully meet all of the above conditions. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this invention is to provide a lightweight and high-strength battery tray to solve one or more problems in the prior art.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: A lightweight and high-strength battery tray, comprising: A base plate, wherein a first welding plate is provided on both sides of the base plate, and the first welding plate forms a step shape with the side wall of the base plate; Side beams are connected to both sides of the base plate, and the side beams are provided with second welding plates that cooperate with the first welding plate; The front beam and the rear beam are both connected to the side beam to form a frame. A crossbeam is detachably connected to the side beam, and the crossbeam can slide on the side beam.

[0006] Using the above technical solution, the first welding plate of the base plate is welded to the second welding plate of the side beam, thereby connecting the base plate and the side beam. Both the first and second welding plates are stepped, resulting in good welding effect and high stability of the battery box. The base plate is made of aluminum extruded profile with a hollow cavity to reduce weight. The thickness of each single layer is controlled to reduce the risk of weld burn-through caused by differences in welding current between thick and thin plates. The front beam, side beam, and rear beam are connected to form a frame, and the battery pack is installed in the frame. The crossbeams can slide within the frame to adjust their position, thus accommodating battery packs of different sizes.

[0007] Furthermore, the bottom end of the side beam is connected to the connecting plate via an inclined plate, and the connection points between the inclined plate and the side beam and the connecting plate are all rounded. Water holes are opened on the upper surface of the connecting plate. The second welding plate is disposed on the connecting plate. The top end of the second welding plate is connected to the top end of the first welding plate by a lap joint, and the bottom end of the second welding plate is connected to the bottom end of the first welding plate by a lap joint.

[0008] The above technical solution incorporates rounded corners on the inclined plate, protecting the edges and corners of the battery pack when it is installed in the battery housing and preventing damage from collisions. The first and second welding plates are joined together via overlapping and lap welding, increasing welding strength and ensuring both lightweight and high strength of the battery housing.

[0009] Furthermore, two side beams are provided, and the two side beams are respectively connected to the bottom plate through the connecting plate. A groove is opened at the top of the side beam along its length.

[0010] Furthermore, first screw holes are opened at both ends of the top of the crossbeam, and the crossbeam is threadedly connected to the side beam by bolts inserted into the first screw holes and the sliding groove in sequence.

[0011] Using the above technical solution, the top of the crossbeam rests on the top of the side beam, and the crossbeam slides within the frame to determine its position, so as to be suitable for battery packs of different sizes. The crossbeam is then fixed with bolts, and the crossbeam is adjusted to make the battery box highly compatible.

[0012] Furthermore, a groove is formed in the middle of the base plate along its length, and a second screw hole is formed in the middle of the bottom end of the crossbeam. The cross-section of the groove and the cross-section of the second screw hole are located in the same plane. A protective plate is connected to the lower surface of the base plate, and the protective plate covers the settling tank.

[0013] To improve the stability of the crossbeam by adopting the above technical solution, bolts can be inserted into the sink and the second screw hole in sequence to connect with the crossbeam threadedly. After the crossbeam is fixed, a protective plate is installed to ensure the sealing of the battery box and protect the bolts.

[0014] Furthermore, the inner wall of the side beam has multiple through grooves along its length, the outer wall of the side beam has multiple lifting lugs along its length, and the bottom end of the side beam has multiple anti-slip grooves along its length.

[0015] Using the above technical solution, the through slot is connected to the inside of the side beam. When the battery box is in use, the heat inside the side beam can be discharged through the through slot, achieving a heat dissipation effect. The lifting lugs are integrally extruded with high strength, facilitating pallet transport and lifting.

[0016] Furthermore, the top of the crossbeam is provided with multiple mounting holes, and the bottom two sides of the crossbeam are chamfered.

[0017] Using the above technical solution, the crossbeam is connected to the top cover and pressure plate through mounting holes to achieve the encapsulation of the battery box. The chamfering of the crossbeam can prevent damage caused by impact with the battery pack.

[0018] Furthermore, the connecting plate is connected to the water nozzle, and the water nozzle is in communication with the water hole.

[0019] Using the above technical solution, the water nozzle is used to ensure the liquid cooling cycle of the battery tray, dissipate heat for it and enable it to operate normally, and the coolant enters the battery box from the water nozzle and water hole.

[0020] Furthermore, both the front beam and the rear beam have multiple foam blocks arranged along their length at their bottom ends.

[0021] Using the above technical solution, the foam block acts as a buffer and shock absorber for the battery tray, preventing the battery tray from being damaged by impact.

[0022] Furthermore, reinforcing plates are provided at the connection points between the side beam and the front beam and the rear beam.

[0023] With the above technical solution, reinforcing plates are connected to the four corners of the frame. The reinforcing plates are used to further connect the side beams and the front beam, and the side beams and the rear beam, thereby improving the overall strength of the battery tray.

[0024] Compared with the prior art, the beneficial technical effects of the present invention are as follows: (i) This invention connects the base plate and the side beam by welding the first welding plate of the base plate to the second welding plate of the side beam. Both the first and second welding plates are stepped, resulting in good welding effect and high stability of the battery box. The base plate is made of aluminum extruded profile with a hollow cavity to reduce weight. The thickness of each single layer is controlled to reduce the risk of weld burn-through due to differences in welding current between thick and thin plates. The front beam, side beam, and rear beam are connected to form a frame, and the battery pack is installed in the frame. The crossbeam can slide within the frame to adjust its position, thus accommodating battery packs of different sizes.

[0025] (ii) The present invention uses a crossbeam with its top end resting on the top end of the side beam. The crossbeam is slidable within the frame to determine its position, making it suitable for battery packs of different sizes. The crossbeam is then fixed with bolts and adjusted to ensure high compatibility of the battery box. Attached Figure Description

[0026] Figure 1 A schematic diagram of the structure of a lightweight and high-strength battery tray according to the present invention is shown; Figure 2 for Figure 1 Another perspective view; Figure 3 A schematic diagram of the side beam and connecting plate of the present invention is shown; Figure 4 for Figure 1Enlarged view of point A; Figure 5 A schematic diagram of the structure of the base plate of the present invention is shown; Figure 6 A schematic diagram of the crossbeam structure of the present invention is shown; Figure 7 for Figure 6 Another perspective view.

[0027] The following are labels in the attached diagram: 1. Base plate; 11. First welded plate; 12. Sink; 13. Guard plate; 2. Side beam; 21. Slide groove; 22. Through groove; 23. Lifting lug; 24. Anti-slip groove; 3. Connecting plate; 31. Second welded plate; 32. Water hole; 33. Inclined plate; 34. Rounded corner; 4. Crossbeam; 41. First screw hole; 42. Second screw hole; 43. Mounting hole; 44. Bolt; 45. Chamfer; 5. Front beam; 51. Reinforcing plate; 52. Water nozzle; 53. Foam block; 6. Rear beam. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer, the device proposed by this invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of this invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, only for the purpose of conveniently and clearly illustrating the embodiments of this invention. Please refer to the drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives achieved by this invention, should still fall within the scope of the technical content disclosed in this invention.

[0029] Correspondingly, such as Figures 1-7 As shown, this embodiment also provides a lightweight and high-strength battery tray, including: a base plate 1, side beams 2, crossbeams 4, a front beam 5 and a rear beam 6. The side beams 2 are connected to both sides of the base plate 1. Two side beams 2 are provided and are arranged opposite to each other. The front beam 5 and the rear beam 6 are both connected to the two ends of the side beams 2 to form a frame.

[0030] Among them, such as Figure 5 As shown, a first welding plate 11 is provided on both sides of the base plate 1. The first welding plate 11 forms a step shape with the side wall of the base plate 1. The first welding plate 11 is located at the top of the base plate 1 and extends along the width direction of the base plate 1 in a convex shape. The upper surface of the base plate 1 is coated with an insulating coating of epoxy powder with a thickness of 100um~450um.

[0031] like Figure 3 As shown, the side beam 2 is equipped with a second welding plate 31 that cooperates with the first welding plate 11. Specifically, the bottom end of the side beam 2 is connected to the connecting plate 3 via an inclined plate 33, and the second welding plate 31 is disposed on the connecting plate 3. The side beam 2 is vertically arranged, while the connecting plate 3 and the bottom plate 1 are both horizontally arranged. The top end of the second welding plate 31 is connected to the top end of the first welding plate 11 via a butt joint, and the bottom end of the second welding plate 31 is connected to the bottom end of the first welding plate 11 via a lap-welded butt joint. The first welding plate 11 and the second welding plate 31 are welded together via butt joints and lap-welded butt joints to improve the welding strength and ensure that the battery box is lightweight while maintaining high strength.

[0032] In this embodiment, the base plate 1 is made of aluminum extruded profile with a hollow cavity to reduce weight. The thickness of a single layer is controlled to reduce the risk of weld burn-through caused by the difference in welding current between thick and thin plates. The first welding plate 11 of the base plate 1 is welded to the second welding plate 31 of the side beam 2, thereby connecting the base plate 1 and the side beam 2. Both the first welding plate 11 and the second welding plate 31 are stepped, resulting in good welding effect and high stability of the battery box.

[0033] like Figure 4 As shown, the crossbeam 4 and the side beam 2 are detachably connected. The crossbeam 4 can slide on the side beam 2. The front beam 5, side beam 2, and rear beam 6 are connected to form a frame. The battery pack is installed in the frame. The crossbeam 4 can slide within the frame to adjust its position, thus adapting to battery packs of different sizes. Specifically, the two side beams 2 are connected to the base plate 1 via connecting plates 3. The top of the side beam 2 has a groove 21 along its length. The top of the crossbeam 4 has first screw holes 41 at both ends. The crossbeam 4 is threaded to the side beam 2 by bolts 44 inserted into the first screw holes 41 and the groove 21 in sequence. The top of the crossbeam 4 rests on the top of the side beam 2. The crossbeam 4 slides within the frame to determine its position, adapting to battery packs of different sizes. The crossbeam 4 is then fixed with bolts 44. Adjusting the crossbeam 4 ensures high compatibility of the battery pack.

[0034] Continue to refer to Figure 5 A groove 12 is formed in the middle of the base plate 1 along its length, such as... Figure 7 As shown, a second screw hole 42 is opened at the middle of the bottom end of the crossbeam 4. The cross-section of the sink 12 and the cross-section of the second screw hole 42 are located on the same plane. To improve the stability of the crossbeam 4, bolts 44 can be inserted into the sink 12 and the second screw hole 42 in sequence to connect with the crossbeam 4 by thread. A protective plate 13 is connected to the lower surface of the base plate 1. The protective plate 13 covers the sink 12. After the crossbeam 4 is fixed, the protective plate 13 is installed to ensure the sealing of the battery box and protect the bolts 44. The protective plate 13 is laser-welded with filler wire, with a welding power of 700W, a welding speed of 60cm / min, and a wire feeding speed of 85cm / min.

[0035] Continue to refer to Figure 3Multiple through slots 22 are formed along the length of the inner wall of the side beam 2, and multiple lifting lugs 23 are formed along the length of the outer wall of the side beam 2. Multiple anti-slip grooves 24 are formed along the length of the bottom end of the side beam 2. The through slots 22 are connected to the interior of the side beam 2, and when the battery box is in use, the heat inside the side beam 2 can be discharged through the through slots 22 to achieve the effect of heat dissipation. The lifting lugs 23 are integrally extruded with high strength, which is convenient for pallet transportation and hanging. The lifting lugs 23 are made of AL6061-T6 material with a tensile strength greater than 290MPa, a yield strength greater than 240MPa, an elongation after fracture A ≥ 10%, and a Brinell hardness ≥ 95HBW.

[0036] like Figure 6 As shown, the top of the crossbeam 4 is also provided with multiple mounting holes 43, and the bottom of the crossbeam 4 is provided with chamfers 45 on both sides. The crossbeam 4 is connected to the top cover and pressure plate through the mounting holes 43 to realize the encapsulation of the battery box. The chamfers 45 on the crossbeam 4 can prevent damage caused by impact with the battery pack.

[0037] Continue to refer to Figure 3 The inclined plate 33 has rounded corners 34 at its connection with the side beam 2 and the connecting plate 3. Water holes 32 are formed on the upper surface of the connecting plate 3. The connecting plate 3 is connected to a water nozzle 52, which communicates with the water hole 32. The water nozzle 52 is located at one end near the front beam 5. The rounded corners 34 on the inclined plate 33 protect the edges and corners of the battery pack when it is installed in the battery box, preventing damage from collisions with the battery box. The first welding plate 11 and the second welding plate 31 are welded together using overlapping and lap welding techniques to improve welding strength and ensure both lightweight and high strength of the battery box. The water nozzle 52 ensures liquid cooling circulation for the battery tray, dissipating heat and enabling normal operation. Coolant enters the battery box through the water nozzle 52 and the water hole 32.

[0038] like Figure 2 As shown, multiple foam blocks 53 are provided along the length of the bottom of both the front beam 5 and the rear beam 6. The foam blocks 53 are made of PU material and are located on both sides of the anti-slip groove 24. The foam blocks 53 serve as a buffer and shock absorber for the battery tray, preventing it from being damaged by impact. Reinforcing plates 51 are provided at the connection points between the side beam 2 and the front beam 5 and the rear beam 6. Reinforcing plates 51 are also connected to the four corners of the frame. The reinforcing plates 51 are used to further connect the side beam 2 and the front beam 5, and the side beam 2 and the rear beam 6, improving the overall strength of the battery tray.

[0039] In summary, this invention connects the base plate 1 and the side beam 2 by welding the first welding plate 11 of the base plate 1 to the second welding plate 31 of the side beam 2. Both the first welding plate 11 and the second welding plate 31 are stepped, resulting in good welding effect and high stability of the battery box. The base plate 1 is made of aluminum extruded profile with a hollow cavity to reduce weight. The single-layer plate thickness is controlled to reduce the risk of weld burn-through caused by the difference in welding current between thick and thin plates. The front beam 5, the side beam 2, and the rear beam 6 are connected to form a frame, in which the battery pack is installed. The crossbeam 4 can slide within the frame to adjust its position, thus adapting to battery packs of different sizes.

[0040] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0041] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A lightweight and high-strength battery tray, characterized in that, include: The base plate (1) has a first welding plate (11) on both sides, and the first welding plate (11) forms a step shape with the side wall of the base plate (1); Side beam (2), the side beam (2) is connected to both sides of the bottom plate (1), and the side beam (2) is provided with a second welding plate (31) that cooperates with the first welding plate (11). The front beam (5) and the rear beam (6) are both connected to the side beam (2) to form a frame. A crossbeam (4) is detachably connected to the side beam (2), and the crossbeam (4) can slide on the side beam (2).

2. The lightweight and high-strength battery tray as described in claim 1, characterized in that: The bottom end of the side beam (2) is connected to the connecting plate (3) by an inclined plate (33). The connection between the inclined plate (33) and the side beam (2) and the connecting plate (3) is provided with rounded corners (34). Water holes (32) are opened on the upper surface of the connecting plate (3). The second welding plate (31) is disposed on the connecting plate (3). The top end of the second welding plate (31) is connected to the top end of the first welding plate (11) by a tack joint, and the bottom end of the second welding plate (31) is connected to the bottom end of the first welding plate (11) by a tack joint.

3. The lightweight and high-strength battery tray as described in claim 2, characterized in that: Two side beams (2) are provided, and the two side beams (2) are respectively connected to the bottom plate (1) through the connecting plate (3). The top of the side beam (2) has a groove (21) along its length direction.

4. The lightweight and high-strength battery tray as described in claim 3, characterized in that: The top two ends of the crossbeam (4) are provided with first screw holes (41). The crossbeam (4) is then connected to the side beam (2) by bolts (44) inserted into the first screw holes (41) and the slide groove (21) in sequence.

5. The lightweight, high-strength battery tray as described in claim 1, characterized in that: A groove (12) is formed in the middle of the base plate (1) along its length direction, and a second screw hole (42) is formed in the middle of the bottom end of the crossbeam (4). The cross section of the groove (12) and the cross section of the second screw hole (42) are located in the same plane. The lower surface of the base plate (1) is connected to a guard plate (13), which covers the sinkhole (12).

6. The lightweight and high-strength battery tray as described in claim 1, characterized in that: The inner wall of the side beam (2) has multiple through grooves (22) along its length, the outer wall of the side beam (2) has multiple lifting lugs (23) along its length, and the bottom end of the side beam (2) has multiple anti-slip grooves (24) along its length.

7. The lightweight, high-strength battery tray as described in claim 1, characterized in that: The top of the crossbeam (4) is provided with multiple mounting holes (43), and the bottom of the crossbeam (4) is provided with chamfers (45) on both sides.

8. The lightweight and high-strength battery tray as described in claim 2, characterized in that: The connecting plate (3) is connected to the water nozzle (52), and the water nozzle (52) is connected to the water hole (32).

9. The lightweight, high-strength battery tray as described in claim 1, characterized in that: Both the front beam (5) and the rear beam (6) have multiple foam blocks (53) arranged along their length at their bottom ends.

10. The lightweight, high-strength battery tray as described in claim 1, characterized in that: Reinforcing plates (51) are provided at the connection points between the side beam (2) and the front beam (5) and the rear beam (6).

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