Highly integrated light-weight battery tray structure, exchanger and battery pack

Abstract

The utility model relates to the technical field of battery pack heat exchangers, in particular to a highly-integrated light-weight battery tray structure which comprises an upper-layer plate, and the periphery of the upper-layer plate is provided with an inner-layer flange formed by bending perpendicular to one side of an upper-layer plate main body; the periphery of the lower-layer plate is provided with an outer-layer flange formed by bending perpendicular to one side of a lower-layer plate main body; the upper-layer plate is installed in the inner-layer turnup of the lower-layer plate, a main body of the upper-layer plate is attached to a main body of the lower-layer plate, the inner-layer turnup and the outer-layer turnup are arranged at intervals, and the upper-layer plate and the lower-layer plate form a water channel plate assembly; the bottom protection plates are arranged in the width direction or the length direction of the water channel plate assembly, and the two ends of each bottom protection plate are connected to the bottom face of the lower layer plate and correspond to the interval between the inner layer flanging and the outer layer flanging. According to the battery tray structure, the traditional relatively complicated box body tailor-welded frame process is changed, and the purposes of process manufacturing optimization and structure optimization are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of battery pack heat exchangers, and in particular to a highly integrated lightweight battery tray structure, an exchanger and a battery pack. Background Art

[0002] At present, the battery pack box structure is relatively conventional, usually the water-cooling plate is brazed separately, and the box frame is welded and then assembled and connected with the water-cooling plate and the box frame by FDS nails or stir friction welding. This production method is relatively complicated in terms of process route, cumbersome procedures and it is difficult to ensure the airtight performance after the overall assembly. Today, the conventional solutions mentioned above are no longer sufficient to cope with the rapid development pace and cost control concept of the battery pack industry in terms of process production methods, assembly structure and lightweight. Utility Model Content

[0003] To solve the above problems, the utility model proposes a highly integrated lightweight battery tray structure, which changes the traditional complex box welding frame process, achieves the purpose of process manufacturing optimization and structural optimization. The utility model also proposes a related switch and battery pack.

[0004] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0005] In the first technical solution, a highly integrated lightweight battery tray structure includes

[0006] The upper plate has inner flanges formed by bending perpendicularly to one side of the upper plate body on all sides;

[0007] The lower plate has outer flanges formed by bending perpendicularly to one side of the lower plate body on all sides;

[0008] The upper plate is installed in the inner flange of the lower plate, and the main body of the upper plate is in contact with the main body of the lower plate, and the inner flange is spaced apart from the outer flange, and the upper plate and the lower plate form a waterway plate assembly;

[0009] There are several bottom guard plates, and the bottom guard plates are arranged along the width direction or length direction of the waterway plate assembly. The two ends of the bottom guard plates are connected to the bottom surface of the lower plate and correspond to the interval between the inner flange and the outer flange.

[0010] In the first technical solution, as a preference, the bottom guard plate includes

[0011] The rear bottom guard plate is installed at the rear of the bottom surface of the lower plate;

[0012] There are several intermediate bottom guard plates installed at intervals in the middle of the bottom surface of the lower plate;

[0013] The front bottom guard plate is installed at the front part of the bottom surface of the lower plate.

[0014] In the first technical solution, preferably, a flange metal joint is installed at the front of the waterway plate assembly, and the front bottom guard plate extends forward to form a joint protection structure, which is used to protect the flange metal joint.

[0015] In the first technical solution, preferably, a water channel is formed between the upper plate and the lower plate, and a flange connection block is installed on the top surface of the upper plate near the front end.

[0016] In the first technical solution, preferably, a welded side beam is installed at the interval between the outer flange and the inner flange.

[0017] In the first technical solution, preferably, the welding side beam and the contact surface of the inner flange of the upper plate are welded and connected.

[0018] In the first technical solution, preferably, the inner flange is provided with a plurality of groups of mounting holes, each group of mounting hole pairs has a single or multiple corresponding hollowings along the width direction or the length direction, and the inner flange is provided with a plurality of cross beams, and the two ends of the cross beams are inserted in two hollowings separately inserted in a group of mounting hole pairs.

[0019] In the first technical solution, preferably, there are a plurality of cross beams, which are respectively arranged at the front, middle and rear of the upper plate.

[0020] In a second technical solution, a switch includes a battery tray structure, wherein the battery tray structure is a highly integrated lightweight battery tray structure as described in any one of the first technical solutions.

[0021] In a third technical solution, a battery pack includes a battery tray structure, and the battery tray structure is a highly integrated lightweight battery tray structure as described in any one of the first technical solutions.

[0022] The beneficial effects of using the utility model are:

[0023] The installation frame is highly integrated, and the bottom guard plate is installed after the cold plate is welded as a whole, which changes the traditional more complicated box welding frame process and achieves the purpose of process manufacturing optimization and structural optimization; at the same time, the installation frame and the cold plate are highly integrated with the lightweight battery tray structure. The process optimization eliminates the previous FDS nail connection or stir friction welding process between the box and the water-cooled plate, and eliminates the production process of the sealing ring, sealing structural adhesive and sealing glue between the cold plate and the lower box. The process route is greatly optimized, reducing the investment in manufacturing equipment and greatly saving the product manufacturing cycle; the water inlet and outlet of the cold plate are designed as outward-extending flange metal joints, which are connected to the upper plate through the flange connection block, which greatly ensures the sealing of the installation frame and the cold plate highly integrated lightweight battery tray structure; the overall brazing of the integrated cold plate assembly is not limited by the box frame structure, and multi-region battery modules can be arranged on the upper flat plate to meet the battery cell layout strategies of different customers, greatly saving design and development resources and cycles.

[0024] In addition, the application scope of the embodiments of the utility model is not limited to a specific battery pack, and can be applied to automotive power battery packs, energy storage battery packs, heat dissipation modules of large cooling system units, battery pack heat dissipation modules in other fields, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is an exploded view of the highly integrated lightweight battery tray structure of the utility model.

[0026] Figure 2 It is an axonometric diagram of the highly integrated lightweight battery tray structure of the utility model.

[0027] Figure 3 This is a schematic diagram of the bottom of the highly integrated lightweight battery tray structure of the utility model.

[0028] Figure 4 This is a partial cross-sectional view of the highly integrated lightweight battery tray structure of the utility model along the long welded side beam.

[0029] Reference numerals include:

[0030] 1-box cover, 2-battery core, 3-rear cross beam, 4-upper plate, 41-inner flange, 5-short welded side beam, 6-long welded side beam, 7-lower plate, 71-outer flange, 8-rear bottom guard plate, 9-middle cross beam, 10-middle bottom guard plate, 11-front bottom guard plate, 111-joint protection structure, 12-front cross beam, 13-flange connection block, 14-flange metal joint. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the technical solution more clear, the technical solution is further described in detail below in conjunction with specific implementation methods. It should be understood that these descriptions are only exemplary and are not intended to limit the scope of the technical solution.

[0032] like Figure 1 As shown, in the highly integrated lightweight battery tray structure proposed in this embodiment, the tray structure is used to support the bottom of the battery core 2. After the top surface of the tray structure and the battery core 2 are installed with each other, since the top main extension surface of the tray structure is against the bottom surface of the battery core 2, the cooling fluid circulates inside the tray structure, so the battery tray structure can dissipate heat for the battery core 2, and the box cover 1 covers the top surface of the battery core 2, playing a certain protective role.

[0033] In this embodiment, the upper plate 4 and the lower plate 7 are both made of metal materials. Figure 4 As shown, the four sides of the upper plate 4 are bent upward to form the inner flange 41, and the four sides of the lower plate 7 are bent upward to form the outer flange 71. Since the area of ​​the main extension surface of the upper plate 4 is greater than the area of ​​the main extension surface of the lower plate 7, the upper plate 4 and the inner side of the outer flange 71 nested and installed around the lower plate 7, after the main extension surfaces of the upper plate 4 and the lower plate 7 are attached, a channel for the circulation of cooling liquid is formed between the upper plate 4 and the lower plate 7. The spacing between the inner flange 41 and the outer flange 71 is consistent, and the short welding side beam 5 and the long welding side beam 6 are installed between the inner flange 41 and the outer flange 71. Since the main extension surfaces of the upper plate 4 and the lower plate 7 in this embodiment are rectangular structures, there are two short welding side beams 5 and two long welding side beams 6 respectively and they are combined into a rectangular frame structure. The rectangular frame structure composed of the short welding side beams 5 and the long welding side beams 6 can be embedded in the interval between the inner flange 41 and the outer flange 71 to increase the strength. The short welding side beam 5 and the long welding side beam 6 are both provided with rivet nut mounting holes for mounting rivet nuts of the box cover 1. The welding side beam is an aluminum profile structure.

[0034] like Figure 2 As shown, the upper plate is provided with a beam penetration mounting hole and a flange connection block 13 mounting hole, and the lower plate 7 is provided with a rivet nut mounting hole for installing the bottom guard plate rivet nuts. The upper plate 4 and the lower plate 7 are aluminum plate structures.

[0035] The inner flange 41 is provided with several groups of mounting holes, each group of mounting hole pairs has a single or multiple narrow sides or corresponding hollows in the length direction, and the inner flange 41 is provided with several crossbeams, and the two ends of the crossbeams are inserted in two hollows separately inserted in a group of mounting hole pairs. In this embodiment, the crossbeams include a front crossbeam 12, an intermediate crossbeam 9 and a rear crossbeam 3, and the two ends of the crossbeams pass through the upper plate 4 and overlap and braze with the welding side beams as a whole. The crossbeams are provided with rivet nut installation holes for installing the rivet nuts of the battery module, and the crossbeams are solid aluminum structures.

[0036] like Figure 3 As shown, a flange metal joint 14 is installed at the front of the waterway plate assembly, and the front bottom guard plate 11 extends forward to form a joint protection structure 111, which is used to protect the flange metal joint 14. Specifically, the bottom guard plate includes a front bottom guard plate 11, an intermediate bottom guard plate 10 and a rear bottom guard plate 8. The bottom guard plate is assembled with the integrated water-cooling plate by bolts after brazing. The front bottom guard plate 11 has a structure to protect the flange metal joint 14 to prevent the flange metal joint 14 from being damaged during production and transportation. The two ends of the bottom guard plate are designed with overlapping planes of the integrated water-cooling plate assembly and the customer installation interface, and the bottom guard plate is a stamped steel plate structure.

[0037] The flange connection block 13 is brazed and connected to the upper plate 4. After the flange metal joint 14 is installed and connected to the flange connection block 13, a sealing gasket on the flange is used to seal the flange to ensure the air tightness of the overall integrated water-cooled plate assembly after the box cover 1 is installed. The flange connection block 13 and the flange metal joint 14 are made of aluminum.

[0038] The installation frame is highly integrated, and the bottom guard plate is installed after the cold plate is welded as a whole, which changes the traditional relatively complicated box welding frame process and achieves the purpose of process manufacturing optimization and structural optimization; at the same time, the installation frame and the cold plate are highly integrated with the lightweight battery tray structure. The process optimization eliminates the previous FDS nail connection or stir friction welding process between the box and the water-cooled plate, and eliminates the production process of the sealing ring, sealing structural adhesive and sealing glue between the cold plate and the lower box. The process route is greatly optimized, reducing the investment in manufacturing equipment and greatly saving the product manufacturing cycle; the water inlet and outlet of the cold plate are designed as outward-extending flange metal joints 14, which are connected to the upper plate 4 through the flange connection block 13 inside, which greatly ensures the sealing of the installation frame and the cold plate highly integrated lightweight battery tray structure; the overall brazing of the integrated cold plate assembly is not limited by the box frame structure, and multi-region battery cell modules can be arranged on the upper flat plate to meet the battery cell layout strategies of different customers, greatly saving design and development resources and cycles.

[0039] In addition, the application scope of the embodiments of the utility model is not limited to a specific battery pack, and can be applied to automotive power battery packs, energy storage battery packs, heat dissipation modules of large cooling system units, battery pack heat dissipation modules in other fields, etc.

[0040] The above contents are only preferred embodiments of the present invention. For ordinary technicians in this field, many changes can be made in the specific implementation methods and application scopes based on the ideas of the present technical content. As long as these changes do not deviate from the concept of the present invention, they all fall within the scope of protection of this patent.

Claims

1. A highly integrated lightweight battery tray structure, characterized in that: include The upper plate has inner flanges formed by bending perpendicularly to one side of the upper plate body on all sides; The lower plate has outer flanges formed by bending perpendicularly to one side of the lower plate body on all sides; The upper plate is installed in the inner flange of the lower plate, and the main body of the upper plate is in contact with the main body of the lower plate, and the inner flange is spaced apart from the outer flange, and the upper plate and the lower plate form a waterway plate assembly; There are several bottom guard plates, and the bottom guard plates are arranged along the width direction or length direction of the waterway plate assembly. The two ends of the bottom guard plates are connected to the bottom surface of the lower plate and correspond to the interval between the inner flange and the outer flange.

2. The highly integrated lightweight battery tray structure according to claim 1, characterized in that: The bottom guard plate includes The rear bottom guard plate is installed at the rear of the bottom surface of the lower plate; There are several intermediate bottom guard plates installed at intervals in the middle of the bottom surface of the lower plate; The front bottom guard plate is installed at the front part of the bottom surface of the lower plate.

3. The highly integrated lightweight battery tray structure according to claim 2, characterized in that: A flange metal joint is installed at the front of the waterway plate assembly, and the front bottom guard plate extends forward to form a joint protection structure, which is used to protect the flange metal joint.

4. The highly integrated lightweight battery tray structure according to claim 1, characterized in that: A water channel is formed between the upper plate and the lower plate, and a flange connection block is installed on the top surface of the upper plate near the front end.

5. The highly integrated lightweight battery tray structure according to claim 1, characterized in that: A welded side beam is installed at the interval between the outer flange and the inner flange.

6. The highly integrated lightweight battery tray structure according to claim 5, characterized in that: The welding side beam is connected to the contact surface of the inner flange of the upper plate by welding.

7. The highly integrated lightweight battery tray structure according to claim 1, characterized in that: The inner flange is provided with a plurality of groups of mounting holes, each group of mounting hole pairs has a single or multiple corresponding hollowings along the width direction or the length direction, and the inner flange is provided with a plurality of cross beams, both ends of the cross beams are inserted in two hollowings separately inserted in a group of mounting hole pairs.

8. The highly integrated lightweight battery tray structure according to claim 7, characterized in that: There are a plurality of cross beams, which are respectively arranged at the front, middle and rear of the upper plate.

9. A switch, characterized in that: It comprises a battery tray structure, and the battery tray structure is a highly integrated lightweight battery tray structure as described in any one of claims 1-8.

10. A battery pack, characterized in that: It comprises a battery tray structure, and the battery tray structure is a highly integrated lightweight battery tray structure as described in any one of claims 1-8.

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