A new energy vehicle battery lower tray

Abstract

The utility model discloses a lower tray for a new energy vehicle battery, comprising two first support beams arranged in parallel with each other, a second support beam fixedly connected between the corresponding ends of the two first support beams, so that the two first support beams and the two second support beams together form a square frame, and a groove is formed inside the frame; the frame, the first reinforcement beam and the second reinforcement beam together form a frame, and a coating layer is provided on the outer surface of the frame and the bottom of the inner wall of the groove, so that the first support beam, the second support beam, the first reinforcement beam and the second reinforcement beam are all fixedly connected through the coating layer. The utility model is integrally formed in structure, which eliminates the welding step and will not cause welding defects. The absence of welding seams makes the sealing strong, improves the flatness and precision of the lower tray structure, and has excellent mechanical properties, and is more solid as a whole. At the same time, the hollow structure design makes the finished product lighter.

Description

Technical Field

[0001] The utility model relates to the technical field of battery lower tray production, in particular to a new energy vehicle battery lower tray. Background Art

[0002] Electric vehicles have solved the energy crisis and environmental pollution. Currently, lightweight and low cost are the important directions for the development of electric vehicles. Batteries are important components of electric vehicles and are installed and fixed by battery trays.

[0003] At present, the lower tray of new energy vehicle batteries on the market is usually made of high-strength steel or aluminum alloy. Compared with the die-casting and stamping of high-strength steel, the mainstream process of current battery boxes is to extrude aluminum into profiles and then weld them. Different needs can be met through the splicing and processing of profiles, which has the advantages of flexible design, convenient processing, and easy modification. In terms of performance, the extruded aluminum alloy battery tray has high rigidity, vibration resistance, extrusion resistance and impact resistance, and the density of the high-strength steel used is usually 7.5g / cm 3 The density of the aluminum alloy used is usually 2.75g / cm 3 Aluminum alloy materials are lighter, so aluminum alloys have gradually replaced high-strength steel to become the main material for manufacturing battery trays.

[0004] However, the lower tray structure currently made of aluminum alloy material is welded together after the aluminum is extruded into profiles. Traditional fusion welding causes problems such as material deformation, pores and low welding joint coefficient due to the large heat input, resulting in insufficient flatness and precision of the existing lower tray structure, affecting the installation and use of the battery. Utility Model Content

[0005] The purpose of the utility model is to provide a lower tray for a new energy vehicle battery, so as to solve the technical problem that the lower tray made of aluminum alloy material in the prior art has poor flatness and precision due to the need for welding.

[0006] In order to solve the above technical problems, the utility model specifically provides the following technical solutions:

[0007] A new energy vehicle battery lower tray comprises two first support beams arranged parallel to each other, a second support beam is fixedly connected between the corresponding ends of the two first support beams, so that the two first support beams and the two second support beams together form a square frame, and a groove is formed inside the frame;

[0008] At least one first reinforcing beam arranged in parallel with the first supporting beam is provided inside the groove, and at least one second reinforcing beam arranged in parallel with the second supporting beam is provided, so that the first reinforcing beam is arranged perpendicularly to the second reinforcing beam;

[0009] The frame body, the first reinforcement beam and the second reinforcement beam together form a frame, and a coating layer is provided on the outer surface of the frame and the bottom of the inner wall of the groove, so that the first support beam, the second support beam, the first reinforcement beam and the second reinforcement beam are fixedly connected by the coating layer.

[0010] As a preferred solution of the utility model, hollow grooves are provided inside the first support beam, the second support beam, the first reinforcement beam and the second reinforcement beam, and reinforcement ribs are fixedly connected inside the hollow grooves.

[0011] As a preferred solution of the utility model, notches are provided at both ends of the second support beam close to the first support beam, so that baffles remain on one side of the notches at both ends of the second support beam, so that the baffles match the vertical section of the first support beam.

[0012] As a preferred solution of the utility model, the first reinforcing beam and the second reinforcing beam are both provided with a clamping groove at the position where they contact each other, so that the first reinforcing beam and the second reinforcing beam are clamped and fixed in position by the clamping groove.

[0013] Compared with the prior art, the utility model has the following beneficial effects:

[0014] The utility model is formed in one piece in structure, thus eliminating the welding step and preventing welding defects. The absence of welding seams makes the sealing strong, improves the flatness and precision of the lower tray structure, and has excellent mechanical properties, making the whole structure more solid. At the same time, the design of the hollow structure reduces the weight of the finished product by half under the same volume. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the implementation of the utility model or the technical solution in the prior art, the following is a brief introduction to the drawings required for the implementation or the prior art description. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0016] Figure 1 The overall structural diagram provided by the utility model;

[0017] Figure 2 This is a schematic diagram of the structure of the utility model after the coating layer is removed;

[0018] Figure 3 This is an exploded view of the frame in the utility model;

[0019] Figure 4 This is a schematic diagram of the structure of the second support beam in the utility model;

[0020] Figure 5 It is a structural schematic diagram of the tooling structure in the utility model;

[0021] Figure 6 It is a schematic diagram of the connection structure between the extrusion plate and the cylinder in the utility model.

[0022] The numbers in the figure represent the following:

[0023] 01-first support beam; 02-second support beam; 03-frame; 04-groove; 05-first reinforcement beam; 06-second reinforcement beam; 07-frame; 08-cladding layer; 09-hollow groove; 010-reinforcement rib; 011-notch; 012-baffle; 013-slot;

[0024] 1-bottom plate; 2-placement groove; 3-placement plate; 4-positioning plate; 5-first push plate; 6-extrusion plate; 7-second push plate; 8-cylinder; 9-roller; 10-liquid outlet; 11-extrusion block; 12-vertical plate; 13-slide rod; 14-first spring; 15-push rod; 16-second spring. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0026] like Figure 1 and Figure 2 As shown, the present invention provides a new energy vehicle battery lower tray, which mainly uses a coating layer 08 to fix the frame 07 to avoid the influence caused by welding.

[0027] The lower tray of the new energy vehicle battery includes two first support beams 01 arranged in parallel with each other, and a second support beam 02 is fixedly connected between the corresponding ends of the two first support beams 01, so that the two first support beams 01 and the two second support beams 02 together form a square frame 03, and a groove 04 is formed inside the frame 03;

[0028] At least one first reinforcing beam 05 is provided in parallel with the first supporting beam 01, and at least one second reinforcing beam 06 is provided in parallel with the second supporting beam 02, so that the first reinforcing beam 05 and the second reinforcing beam 06 are arranged perpendicularly;

[0029] The frame body 03, the first reinforcing beam 05 and the second reinforcing beam 06 together form a frame 07, and a coating layer 08 is provided on the outer surface of the frame 07 and the bottom of the inner wall of the groove 04, so that the first support beam 01, the second support beam 02, the first reinforcing beam 05 and the second reinforcing beam 06 are fixedly connected by the coating layer 08.

[0030] At present, the lower tray structure is made of aluminum alloy. After the aluminum is extruded into profiles, the profiles are spliced ​​by welding. Traditional fusion welding causes problems such as material deformation, pores and low welding joint coefficient due to the large heat input. As a result, the flatness and precision of the existing lower tray structure are insufficient, affecting the installation and use of the battery.

[0031] Specifically, 1. The deformation of the tray caused by welding makes it impossible for the lower tray to match the hole position of its upper sealing cover.

[0032] 2. The air holes caused by welding will lead to poor air tightness of the battery box. Battery packs that do not meet the sealing requirements will be scrapped as a whole, otherwise it will directly affect driving safety.

[0033] 3. The low dimensional accuracy of the lower tray caused by welding will result in the layout of the internal battery cells, motors, and cables requiring more floating space to be reserved for the lower tray, or normal assembly will be impossible due to interference.

[0034] 4. The lack of flatness of the lower tray structure caused by welding will seriously affect the effectiveness of the sealing strip.

[0035] In summary, there are many problems caused by welding, so it is necessary to develop a lower tray that does not require welding.

[0036] The lower tray structure provided in the present application is integrally formed in structure, eliminating the welding step and preventing welding defects. The absence of welding seams ensures strong sealing, improves the flatness and precision of the lower tray structure, and has excellent mechanical properties, making the structure more solid overall.

[0037] As a preferred embodiment of this embodiment, the first support beam 01, the second support beam 02, the first reinforcement beam 05 and the second reinforcement beam 06 are all provided with hollow grooves 09, and reinforcement ribs 010 are fixedly connected inside the hollow grooves 09. The design of the hollow structure reduces the weight of the finished product by half under the same volume, reduces the amount of raw materials used in production, reduces costs, and through the design of the internal reinforcement ribs 010, ensures that the support of the pultruded beam is not affected after the processing of the tray assembly hole.

[0038] Furthermore, in order to provide overall firmness, notches 011 are provided at both ends of the second support beam 02 near the first support beam 01, so that baffles 012 remain on one side of the notches 011 at both ends of the second support beam 02, so that the baffles 012 match the vertical section of the first support beam 01. During installation, the first support beam 01 is matched with the notches 011 to limit and fix the first support beam 01 and the second support beam 02, thereby improving the connection stability of the frame 07 and preparing for subsequent layer laying.

[0039] Furthermore, in order to improve the connection firmness between the first reinforcing beam 05 and the second reinforcing beam 06, the first reinforcing beam 05 and the second reinforcing beam 06 are provided with a clamping groove 013 at the position where they contact each other, so that the first reinforcing beam 05 and the second reinforcing beam 06 are fixed in position by clamping the clamping groove 013. During installation, the first reinforcing beam 05 and the second reinforcing beam 06 are fixed in position by clamping the clamping groove 013 on the first reinforcing beam 05 with the clamping groove 013 on the second reinforcing beam 06.

[0040] In the present application, there is no fixed limiting structure between the reinforcing beam and the supporting beam, and they are only fixed by laying layers, which can minimize the error and improve the flatness and accuracy of the lower pallet of the finished product.

[0041] The molding process of the lower tray of the new energy vehicle battery is as follows: Figure 5-6 shown.

[0042] The following steps are involved:

[0043] Preparation of pultruded beams: pultruding the resin-based composite material through a pultrusion device to form a hollow pultruded beam;

[0044] Frame 07 is installed, the hollow pultruded beam prepared above is cut to form a plurality of profiles, and the plurality of profiles are combined and spliced ​​by tooling to form frame 07;

[0045] Coating the layer, coating the frame 07 with a resin-based composite material prepreg sheet;

[0046] Hot pressing and curing: the resin-based composite material prepreg sheets after the layering are hot pressed and cured by a press and a mold, so that a coating layer 08 is formed on the outer surface of the frame 07, so that the multiple profiles on the frame 07 are fixedly connected by the coating layer 08;

[0047] The frame 07 coated with the coating layer 08 is punched and deburred to form a lower tray.

[0048] Composite materials are currently an emerging material market. Composite materials perform well in environmental tests such as high temperature and humidity, temperature shock, low temperature dry state, and high temperature wet state. At the same time, they are almost unaffected by salt spray, electrolyte, engine oil, acidic and alkaline environments. It is difficult for metal materials to maintain their original material state in corrosion resistance and aging resistance tests. Therefore, there are also studies in the existing technology to produce lower pallets through composite materials, but they all have defects in use and are not widely used at present, such as:

[0049] 1. The lower tray formed of composite materials by SMC process has the defects of poor overall mechanical properties and low lightweight.

[0050] 2. The lower tray made of steel frame and composite materials has defects such as overall heavy weight, complex process and poor electrical performance.

[0051] Therefore, using emerging composite materials to produce lower trays with excellent performance has become a difficulty in current research.

[0052] The pallet provided in this embodiment is structurally formed as an integral piece through the coating layer 08, eliminating the welding step, thereby avoiding potential defects caused by welding, achieving a seamless integrated structure, significantly enhancing the sealing performance, and improving the overall quality of the product. At the same time, it has a high degree of lightweight. Under the premise of maintaining the same volume, a composite material with a hollow tube beam structure is used, which achieves a weight reduction effect of up to 50% compared with traditional aluminum pallets.

[0053] The purpose of sealing the lower tray is to ensure the safe use of the battery pack and prevent the intrusion of foreign substances and internal current leakage. The sealing of the battery pack directly affects the safety of the battery system, and therefore also affects the safety of the entire vehicle. The lower tray prepared by this process is one-piece molded without welding seams and will not have pores. The molded one-piece surface can ensure a smooth surface. Combined with high-precision machining methods, the battery box and the sealing strip structure can be perfectly combined to ensure the safety of the battery pack and increase its service life.

[0054] The resin in the resin-based composite material is a thermosetting resin-based resin, and the reinforcing material in the resin-based composite material is glass fiber;

[0055] The glass fibers are unidirectional fiber bundles.

[0056] In the above-mentioned coating and laying process, the thickness of the resin-based composite material prepreg sheet is between 1.5 and 4.5 mm, and the continuity of the fibers in the prepreg sheet is retained;

[0057] When the prepreg sheets overlap, the overlap distance is greater than 300 mm.

[0058] Unidirectional tows can effectively transfer and disperse stress, significantly improving the strength and stiffness of the material in the load direction.

[0059] The curing temperature of the resin-based composite material prepreg sheet after layering is 140-155°C, and the curing time is 360-480s.

[0060] The draft angle on the mold is ≥1.5°, and the mold temperature is: 130℃~170℃; the mold pressure is selected according to the mold projection area, and the specific mold pressure is based on the formula T=S*F1*F2 / F table, where T represents: the tonnage of the press; S represents: the horizontal projection area of ​​the product; F1 represents: the unit pressure required by the product; F2 represents: the rated gauge pressure of the press; F table represents: molding pressure, that is, gauge pressure.

[0061] A plurality of reinforcing ribs 010 are arranged inside the hollow pultruded beam, so that a plurality of hollow grooves 09 are formed inside the profile.

[0062] The profile obtained by cutting the hollow pultruded beams includes a plurality of first support beams 01, second support beams 02, first reinforcement beams 05 and second reinforcement beams 06;

[0063] Notches 011 are provided at both ends of the second support beam 02 near the first support beam 01, so that baffles 012 remain on one side of the notches 011 at both ends of the second support beam 02, so that the baffles 012 match the vertical section of the first support beam 01;

[0064] The first reinforcing beam 05 and the second reinforcing beam 06 are both provided with a clamping groove 013 at the position where they contact each other, so that the first reinforcing beam 05 and the second reinforcing beam 06 are clamped and fixed in position through the clamping groove 013 .

[0065] In order to reduce errors and improve the flatness and accuracy of the lower pallet of the finished product, there is no fixed limiting structure between the reinforcing beam and the supporting beam, and they are only fixed by laying layers.

[0066] Since there is no fixed limiting structure between the reinforcing beam and the supporting beam, tooling is required for positioning and assembly to ensure that the lower pallet frame 07 has a certain stability to prevent it from falling apart during the subsequent laying process.

[0067] The two first support beams 01, the two second support beams 02, at least one first reinforcement beam 05 and at least one second reinforcement beam 06 are assembled and spliced ​​together by tooling to form a frame 07;

[0068] Among them, the two first support beams 01 inside the frame 07 are arranged in parallel, the two second support beams 02 are arranged in parallel, and the two first support beams 01 and the two second support beams 02 together form a square frame body 03, and a groove 04 is formed inside the frame body 03. At the same time, the first reinforcement beam 05 and the second reinforcement beam 06 are limited inside the frame body 03, and the first reinforcement beam 05 and the second reinforcement beam 06 are arranged vertically.

[0069] The specific steps of combining and splicing two first support beams 01, two second support beams 02, at least one first reinforcement beam 05 and at least one second reinforcement beam 06 to form a frame 07 by means of tooling are as follows:

[0070] Place the second reinforcement beam 06 in a fixed position on the tooling;

[0071] The clamping groove 013 on the first reinforcing beam 05 is clamped with the clamping groove 013 on the second reinforcing beam 06, so that the first reinforcing beam 05 is connected with the second reinforcing beam 06;

[0072] The first support beam 01 is pushed to move toward the first reinforcement beam 05 by the power mechanism on the tooling, and the first support beam 01 is positioned at the same time, and a layer of structural adhesive is applied on both sides of the first support beam 01;

[0073] The second support beam 02 is pushed toward the first reinforcing beam 05 by the power mechanism on the tooling, and the second support beam 02 is positioned at the same time, and the baffles 012 on both sides of the second support beam 02 are fixedly connected to both sides of the first support beam 01 by structural adhesive.

[0074] The tooling structure for realizing the assembly of the frame 07 includes a bottom plate 1, a placement groove 2 for placing the second reinforcing beam 06 is opened on the top of the bottom plate 1, and a placement plate 3 is slidably connected to the inside of the placement groove 2;

[0075] A group of first positioning components are fixedly connected to both sides of the top of the bottom plate 1, and each group of the first positioning components includes two positioning plates 4 and a first push plate 5. The first push plate 5 is arranged between the two positioning plates 4, and the end of the positioning plate 4 close to the placement groove 2 is inclined toward the first push plate 5;

[0076] Two groups of symmetrically arranged second positioning components are provided between the two groups of the first positioning components, and each group of the second positioning components includes two squeezing plates 6 and a second push plate 7 provided between the two squeezing plates 6, and the squeezing plate 6 is inclined toward the second push plate 7 at one end close to the placement slot 2;

[0077] The first push plate 5 is away from the side of the placement groove 2, the second push plate 7 is away from the side of the placement groove 2 and the bottom of the placement plate 3 are all provided with a power mechanism, so that the first push plate 5 and the second push plate 7 move toward the placement groove 2, and the placement plate 3 moves up and down;

[0078] Among them, a cylinder 8 filled with glue is provided on the side of the extrusion plate 6 away from the second push plate 7, and a roller 9 rotatably connected to the bottom plate 1 is provided on the side of the extrusion plate 6 close to the placement groove 2, and a liquid outlet 10 is provided between the cylinder 8 and the roller 9. When the second push plate 7 pushes the first support beam 01 to move toward the placement groove 2, the end of the first support beam 01 squeezes the extrusion plate 6, so that the extrusion plate 6 squeezes the cylinder 8 and deforms it, thereby squeezing the glue inside the cylinder 8 from the liquid outlet 10 and smearing it on the roller 9, and as the movement of the first support beam 01 drives the roller 9 to rotate, the glue on the roller 9 is transferred to the two end surfaces of the first support beam 01.

[0079] It is more time-saving and labor-saving to install the frame 07 through tooling, and the error is smaller. First, place the second reinforcing beam 06 inside the placement groove 2, and then push the second support beam 02 and the first support beam 01 through the first push plate 5 and the second push plate 7, and apply glue to the two end surfaces of the first support beam 01 through the roller 9. The extrusion plate 6 not only limits the moving first support beam 01, but also can extrude the cylinder 8 and apply the glue on the roller 9.

[0080] The height of the liquid outlet nozzle 10 is less than or equal to the height of the drum 9, and the height of the liquid outlet nozzle 10 is greater than or equal to the height of the first support beam 01;

[0081] The shortest distance between each group of positioning plates 4 is equal to the length of the second support beam 02;

[0082] The shortest distance between each group of extrusion plates 6 is less than the length of the first support beam 01;

[0083] The extrusion plate 6 is fixedly connected to the side close to the cylinder 8 with an extrusion block 11, and the cylinder 8 is provided with a vertical plate 12 fixedly connected to the bottom plate 1 on the side away from the extrusion plate 6. The extrusion plate 6 is fixedly connected to the side close to the vertical plate 12 with a sliding rod 13, and the sliding rod 13 is slidably connected to the vertical plate 12.

[0084] A first spring 14 is fixedly connected between the extrusion plate 6 and the vertical plate 12 , so that the extrusion plate 6 returns to its original position under the rebound force of the first spring 14 .

[0085] The slide bar 13 passes through the vertical plate 12 and extends. A push rod 15 is provided on the side of the drum 9 close to the liquid outlet 10. The push rod 15 is arranged parallel to the slide bar 13. The push rod 15 and the slide bar 13 are fixedly connected by a connecting rod.

[0086] The push rod 15 is fixedly connected to the second spring 16 at one end close to the roller 9. When the extrusion plate 6 is squeezed and moves toward the cylinder 8, the push rod 15 is driven to move away from the roller 9 through the slide bar 13. When the extrusion plate 6 loses the extrusion force, under the action of the rebound force of the first spring 14, the second spring 16 on the push rod 15 is driven to move toward the roller 9 through the slide bar 13, and the roller 9 is rotated to turn the side coated with glue toward the first support beam 01.

[0087] The distance between the roller 9 and the end of the extrusion plate 6 is greater than the width of the first support beam 01 .

[0088] To prevent the glue from drying, when the first support beam 01 moves to one side of the roller 9, it breaks contact with the extrusion plate 6, and the connecting rod pushes the roller 9 to rotate due to the rebound force of the first spring 14, so that the side with glue just moves to the side of the first support beam 01. The force mechanism can be a hydraulic rod or a telescopic rod.

[0089] The above embodiments are only exemplary embodiments of the present application and are not intended to limit the present application. The protection scope of the present application is defined by the claims. Those skilled in the art may make various modifications or equivalent substitutions to the present application within the essence and protection scope of the present application, and such modifications or equivalent substitutions shall also be deemed to fall within the protection scope of the present application.

Claims

1. A new energy vehicle battery lower tray, characterized in that: It comprises two first support beams (01) arranged parallel to each other, and a second support beam (02) is fixedly connected between the corresponding ends of the two first support beams (01), so that the two first support beams (01) and the two second support beams (02) together form a square frame (03), and a groove (04) is formed inside the frame (03); At least one first reinforcing beam (05) is provided inside the groove (04) and is arranged parallel to the first supporting beam (01), and at least one second reinforcing beam (06) is provided and is arranged parallel to the second supporting beam (02), so that the first reinforcing beam (05) and the second reinforcing beam (06) are arranged perpendicularly; The frame body (03), the first reinforcing beam (05) and the second reinforcing beam (06) together form a frame (07), and a coating layer (08) is provided on the outer surface of the frame (07) and the bottom of the inner wall of the groove (04), so that the first support beam (01), the second support beam (02), the first reinforcing beam (05) and the second reinforcing beam (06) are fixedly connected via the coating layer (08).

2. A new energy vehicle battery lower tray according to claim 1, characterized in that: The first support beam (01), the second support beam (02), the first reinforcement beam (05) and the second reinforcement beam (06) are all provided with hollow grooves (09) inside, and reinforcement ribs (010) are fixedly connected inside the hollow grooves (09).

3. A new energy vehicle battery lower tray according to claim 2, characterized in that: Notches (011) are provided at both ends of the second support beam (02) on one side close to the first support beam (01), so that baffles (012) remain on one side of the notches (011) at both ends of the second support beam (02), so that the baffles (012) match the vertical section of the first support beam (01).

4. A new energy vehicle battery lower tray according to claim 3, characterized in that: The first reinforcing beam (05) and the second reinforcing beam (06) are both provided with a clamping groove (013) at the position where they contact each other, so that the first reinforcing beam (05) and the second reinforcing beam (06) are clamped and fixed in position through the clamping groove (013).

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