Lightweight battery pack lower box frame structure

Abstract

The utility model discloses a lower box body frame structure of a light-weight battery pack. The lower box body frame structure comprises four frame beams which are fixedly welded, the frame beam comprises a frame beam supporting frame, and a frame beam upper cover and a frame beam lower cover which are respectively welded and fixed at the upper end and the lower end of the frame beam supporting frame; the frame beam supporting frame is provided with a metal sectional material and a plurality of plastic filling pieces which are arranged in the metal sectional material in an array mode. According to the frame structure, the metal forming base body and the plastic filling piece are combined to form a composite structure, and the purpose of reducing the weight of the battery pack box body is achieved on the basis that the structural strength of the box body is guaranteed.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicle batteries, and in particular to a lower box frame structure of a lightweight battery pack. Background Art

[0002] Since the development of new energy vehicles, the three-electric field has always been the key to promoting its development. As a key link in the field of three-electric technology, batteries are the energy supply unit of electric vehicles in new energy vehicles, and determine many performance parameters of electric vehicles such as endurance and safety. The endurance of electric vehicles depends on the energy density of their cells at the cell level, and also on the energy density of the entire battery pack at the battery pack level. The higher the energy density of the battery pack that can provide to the electric vehicle, the longer the endurance of the vehicle will be, which is beneficial and necessary for the development of electric vehicles as a whole.

[0003] Generally speaking, the mechanical components in a battery pack account for 15% to 30% of the mass of the entire pack. These mechanical components mainly include the battery pack upper cover, lower box and other mechanical parts. If the mass of the battery pack mechanical components can be reduced at the structural level, making the entire pack lighter, it will be beneficial to improve the energy density of the entire pack.

[0004] Therefore, based on the above technical problems, technicians in this field urgently need to develop a lightweight battery pack lower box frame structure. Utility Model Content

[0005] The purpose of the utility model is to provide a lightweight battery pack lower box frame structure, which combines a metal molded base and a plastic filler to form a composite structure, which can reduce the weight of the battery pack box while ensuring the strength of the box structure.

[0006] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0007] The utility model discloses a lightweight battery pack lower box frame structure, which comprises:

[0008] four welded fixed frame beams;

[0009] The frame beam comprises:

[0010] frame beam support brackets; and

[0011] A frame beam upper cover and a frame beam lower cover respectively welded and fixed to the upper end and the lower end of the frame beam support frame;

[0012] The frame beam support frame comprises a metal profile and a plurality of plastic filling pieces arranged in an array and disposed inside the metal profile.

[0013] Furthermore, the frame beam upper cover and the frame beam lower cover are both thin plate structures formed by metal stamping;

[0014] The frame beam support frame is an H-shaped profile formed by metal extrusion.

[0015] Furthermore, the frame beam support frame includes:

[0016] a profile body configured in an H-shape; and

[0017] A plurality of protruding beams protruding inwardly and formed on the inner side surfaces of the two large surfaces of the profile body and arranged at intervals;

[0018] The protruding beam inside the profile body is formed into a plurality of protruding beam parts arranged in an array by milling, and injection flow holes are processed on the protruding beam parts.

[0019] Furthermore, the frame beam support frame is provided with a plurality of the plastic filling pieces along its length direction;

[0020] The plastic filler is connected to the profile body through a group of protruding beams along the width direction of the frame beam support frame.

[0021] Furthermore, the plastic filling piece is injection molded at a group of protruding beam parts corresponding to the profile body through a plastic injection mold.

[0022] Furthermore, the plastic part injection mold comprises:

[0023] left template and right template;

[0024] The top of the left template is provided with a mold top plate, and one side of the mold top plate is provided with an injection molding inlet, and the other side of the mold top plate is provided with an injection molding outlet;

[0025] The left template surface has a convex mold, and the right template surface has a concave mold;

[0026] Grooves matching the protruding beam split are arranged on both sides of the left template and the right template, and the protruding beam split is embedded in the corresponding grooves.

[0027] In the above technical solution, the utility model provides a lightweight battery pack lower box frame structure, which has the following beneficial effects:

[0028] The frame structure of the utility model is combined with a metal forming matrix and a plastic filling piece to form a composite structure, which can reduce the weight of the battery pack box body while ensuring the strength of the box body structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present utility model. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0030] Figure 1 A schematic structural diagram of a lower box frame structure of a lightweight battery pack disclosed in an embodiment of the present application;

[0031] Figure 2 A schematic structural diagram of a frame beam of a lower box frame structure of a lightweight battery pack disclosed in an embodiment of the present application;

[0032] Figure 3 It is a structural explosion diagram of a frame beam of a lightweight battery pack lower box frame structure disclosed in an embodiment of the present application;

[0033] Figure 4 It is a structural schematic diagram of a frame beam support frame of a lightweight battery pack lower box frame structure disclosed in an embodiment of the present application during extrusion molding;

[0034] Figure 5 A schematic diagram of a structure in which a frame beam support frame of a lightweight battery pack lower box frame structure disclosed in an embodiment of the present application is milled with multiple protruding beam parts and injection molding flow holes are processed;

[0035] Figure 6 It is a structural schematic diagram of a lightweight battery pack lower box frame structure disclosed in an embodiment of the present application during an injection molding operation of a plastic part injection mold;

[0036] Figure 7 This is a structural schematic diagram of a plastic part injection mold of a lightweight battery pack lower box frame structure disclosed in an embodiment of the present application;

[0037] Figure 8 It is a structural schematic diagram of a left template of a lower box frame structure of a lightweight battery pack disclosed in an embodiment of the present application;

[0038] Fig. 9 It is a structural schematic diagram of a right template of a lower box frame structure of a lightweight battery pack disclosed in an embodiment of the present application;

[0039] Fig.10 A schematic structural diagram of a plastic filling member of a lower box frame structure of a lightweight battery pack disclosed in an embodiment of the present application;

[0040] Fig.11 This is a structural schematic diagram of a plastic filling piece of a lightweight battery pack lower box frame structure placed in a frame beam support frame disclosed in an embodiment of the present application.

[0041] Description of reference numerals:

[0042] 10. Lower box frame structure; 20. Welding seam;

[0043] 1. Frame beam; 2. Plastic filling parts; 3. Plastic injection mold;

[0044] 101. frame beam support frame; 102. frame beam upper cover; 103. frame beam lower cover; 104. protruding beam; 105. protruding beam split; 106. injection flow hole;

[0045] 301, left template; 302, right template; 303, injection molding inlet; 304, injection molding outlet; 305, punch; 306, die; 307, groove. DETAILED DESCRIPTION

[0046] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings.

[0047] See also Figures 1 to 11 As shown;

[0048] This embodiment discloses a lightweight battery pack lower box frame structure, the lower box frame structure 10 includes:

[0049] Four welded fixed frame beams 1;

[0050] The frame beam 1 comprises:

[0051] Frame beam support frame 101; and

[0052] A frame beam upper cover 102 and a frame beam lower cover 103 are respectively welded and fixed to the upper and lower ends of the frame beam support frame 101;

[0053] The frame beam support frame 101 has a metal profile and a plurality of plastic filling members 2 arranged in an array and disposed inside the metal profile.

[0054] Specifically, the present embodiment discloses a battery pack lower box frame structure 10 that meets the requirements of lightweight design and strength; the structure is a quadrilateral frame structure as a whole, and its four faces, front, back, left and right, are all frame beams 1. The four frame beams 1 of the present embodiment are welded together by brazing or other welding methods; the frame beam 1 of the present embodiment includes a frame beam support frame 101, a frame beam upper cover 102 and a frame beam lower cover 103. Similarly, the frame beam upper cover 102 and the frame beam lower cover 103 of the present embodiment are also welded together with the frame beam support frame 101 by brazing or other welding methods.

[0055] The frame beam support frame 101 of the present embodiment adopts a composite structure in which a plurality of plastic fillers 2 are arranged inside a metal profile. This structural method can further reduce the overall weight while ensuring the structural strength, thereby meeting the lightweight design requirements.

[0056] Preferably, the frame beam upper cover 102 and the frame beam lower cover 103 of this embodiment are both thin plate structures formed by metal stamping; secondly, the frame beam support frame 101 of this embodiment is an H-shaped profile piece formed by metal extrusion. First, the metal profile part of the frame beam 1 of this embodiment is formed. The frame beam upper cover 102 and the frame beam lower cover 103 of this embodiment are both thin plates formed by metal stamping, which can be directly welded to the upper and lower ends of the frame beam support frame 101. The frame beam support frame 101 is processed into an H-shaped profile by extrusion molding. And a plurality of protruding beams 104 are formed inside, which are formed into a semi-hollow cross-section in this way, ensuring the structural strength of the parts and reducing the mold cost. While ensuring the structural strength, the protruding beams 104 of this embodiment can also provide convenient conditions for the complete integration of the plastic filler 2 and the metal matrix.

[0057] See also Figure 4 As shown, preferably, the frame beam support frame 101 of this embodiment includes:

[0058] a profile body, the profile body being configured in an H-shape; and

[0059] A plurality of protruding beams 104 protruding inwardly and formed on the inner side surfaces of the two large surfaces of the profile body and arranged at intervals;

[0060] See also Figure 5 As shown, the protruding beam 104 inside the profile body is formed into a plurality of protruding beam segments 105 arranged in an array by milling, and injection flow holes 106 are processed on the protruding beam segments 105.

[0061] After the frame beam support frame 101 of the present embodiment is extruded, a plurality of protruding beam segments 105 are first formed by milling. Figure 5 As shown, a hole 106 for injection liquid flow is formed by drilling on the protruding beam split body 105 .

[0062] Preferably, the frame beam support frame 101 of this embodiment is provided with a plurality of plastic filling members 2 along its length direction;

[0063] The plastic filler 2 is connected to the profile body through a group of protruding beam segments 105 along the width direction of the frame beam support frame 101.

[0064] See also Figure 6As shown, in order to form the plastic filling piece 2 of this embodiment, the plastic filling piece 2 of this embodiment is injection molded at a group of protruding beam segments 105 corresponding to the profile body through a plastic part injection mold 3.

[0065] When injection molding is performed through the mold, the plastic filler 2 can wrap up the protruding beam segment 105 on the metal substrate through the injection flow hole 106, so that the strength of the entire structure can meet the requirements.

[0066] See also Figures 7 to 9 As shown, the plastic part injection mold 3 of this embodiment includes:

[0067] A left template 301 and a right template 302;

[0068] The left template 301 has a mold top plate on its top, and an injection molding inlet 303 is opened on one side of the mold top plate, and an injection molding outlet 304 is opened on the other side;

[0069] The surface of the left template 301 has a convex mold 305, and the surface of the right template 302 has a concave mold 306;

[0070] Grooves 307 matching the protruding beam split 105 are provided on both sides of the left template 301 and the right template 302 , and the protruding beam split 105 is embedded in the corresponding grooves 307 .

[0071] This embodiment further defines the structure of the plastic part injection mold 3, and the specific method of injection molding the plastic filler 2 required by this embodiment inside the frame beam support frame 101 based on the plastic part injection mold 3. First, the plastic part injection mold 3 of this embodiment includes a left template 301 and a right template 302. The injection flow hole 106 is processed correspondingly on the protruding beam split 105 of this embodiment, and the left template 301 of this embodiment is processed with an injection inlet 303 and an injection outlet 304. When the mold is closed, the injection inlet 303 injects the filling liquid, and after filling the internal space, it is discharged from the injection outlet 304, so as to achieve the purpose of filling the entire mold cavity with plastic filler. And the plastic filler 2 molded in this way can be fully matched with the frame beam support frame 101 of this embodiment and the internal protruding beam split 105, so as to achieve a perfect combination of the plastic filler 2 and the metal matrix.

[0072] In the above technical solution, the utility model provides a lightweight battery pack lower box frame structure, which has the following beneficial effects:

[0073] The frame structure of the utility model is combined with the metal forming matrix and the plastic filling member 2 to form a composite structure, which can reduce the weight of the battery pack box while ensuring the strength of the box structure.

[0074] The above only describes some exemplary embodiments of the present invention by way of illustration. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A lightweight battery pack lower box frame structure, characterized in that: The lower box frame structure (10) comprises: Four welded fixed frame beams (1); The frame beam (1) comprises: A frame beam support frame (101); and A frame beam upper cover (102) and a frame beam lower cover (103) respectively welded and fixed to the upper and lower ends of the frame beam support frame (101); The frame beam support frame (101) comprises a metal profile and a plurality of plastic filling pieces (2) arranged in an array and disposed inside the metal profile.

2. The lightweight battery pack lower box frame structure according to claim 1, characterized in that: The frame beam upper cover (102) and the frame beam lower cover (103) are both thin plate structures formed by metal stamping; The frame beam support frame (101) is an H-shaped profile formed by metal extrusion.

3. A lightweight battery pack lower box frame structure according to claim 1 or 2, characterized in that: The frame beam support frame (101) comprises: a profile body configured in an H-shape; and A plurality of protruding beams (104) protruding inwardly and formed on the inner side surfaces of the two large surfaces of the profile body and arranged at intervals; The protruding beam (104) inside the profile body is formed into a plurality of protruding beam segments (105) arranged in an array by milling, and injection flow holes (106) are processed on the protruding beam segments (105).

4. The lightweight battery pack lower box frame structure according to claim 3 is characterized in that: The frame beam support frame (101) is provided with a plurality of plastic filling pieces (2) arranged along its length direction; The plastic filler (2) is connected to the profile body via a group of protruding beam segments (105) along the width direction of the frame beam support frame (101).

5. The lightweight battery pack lower box frame structure according to claim 4, characterized in that: The plastic filling piece (2) is injection molded at a group of protruding beam parts (105) corresponding to the profile body by a plastic part injection mold (3).

6. A lightweight battery pack lower box frame structure according to claim 5, characterized in that: The plastic part injection mold (3) comprises: A left template (301) and a right template (302); The left template (301) has a mold top plate at the top, and an injection molding inlet (303) is opened on one side of the mold top plate, and an injection molding outlet (304) is opened on the other side; The surface of the left template (301) has a convex mold (305), and the surface of the right template (302) has a concave mold (306); Both sides of the left template (301) and the right template (302) are provided with grooves (307) matching the protruding beam split (105), and the protruding beam split (105) is embedded in the corresponding grooves (307).

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