Light battery box body of new energy electric vehicle

Abstract

The utility model discloses a new energy electric automobile light battery box, which comprises an upper box body, a lower box body and a plurality of connecting parts, the upper box body and the lower box body are hollow square structures and are the same in size, the contact sides of the upper box body and the lower box body are opened, the number of the connecting parts is multiple, and the connecting parts are connected with the upper box body and the lower box body. The connecting components are arranged on the outer side wall of the upper box body and the outer side wall of the lower box body at intervals, the upper box body and the lower box body are connected through the connecting components, the upper box body and the lower box body sequentially comprise an energy absorption layer, a structural layer and a contact layer from outside to inside, the thickness ratio of the structural layer to the contact layer is 2, and the thickness ratio of the energy absorption layer to the contact layer is 1.5. The lower box body comprises the energy absorption layer, the structural layer and the contact layer, the energy absorption layer, the structural layer and the contact layer are arranged according to a specific thickness ratio, the thickness ratio of the energy absorption layer to the contact layer is 1.5, the thickness ratio of the structural layer to the contact layer is 2, and the purpose of weight reduction is achieved while the strength of the lower box body is ensured.

Description

Technical Field

[0001] The utility model relates to the technical field of battery boxes, in particular to a lightweight battery box for a new energy electric vehicle. Background Art

[0002] The automotive industry urgently needs to carry out lightweight research. Carbon fiber, aluminum alloy and foam aluminum have excellent weight reduction effects and load-bearing performance. Through reasonable combination and use, we can further explore the advantages of different materials in performance, weight reduction and cost, and promote the application of multi-material lightweight materials in lightweight automotive design. In recent years, the problem of battery box compression or puncture after tram collision, resulting in short circuit, battery fire or thermal runaway, has gradually become a social pain point. It can be seen that in the research of trams, the energy absorption, anti-collision and anti-puncture performance of the battery box are greatly tested.

[0003] The battery case is an important component for protecting and fixing the battery pack, and its design and manufacturing directly affect the safety of the vehicle. At present, electric vehicles generally use metal materials, such as steel, aluminum alloy, etc. These metals have excellent performance in impact resistance and heat conduction, but their mass is large and cannot meet the design concept of lightweight vehicles. If composite materials are used to replace the metal materials currently used in the battery case, it can not only reduce the weight of the electric vehicle, but also improve the safety of the electric vehicle. Therefore, it is urgent to use multiple lightweight materials to carry out lightweight design of automobiles according to actual needs, and better seek a balance between material cost, mechanical properties and weight reduction advantages; and the stability of the connection between the upper cover and the lower cover of the battery case is also related to the safety of new energy vehicles. Utility Model Content

[0004] The purpose of the utility model is to overcome the deficiencies in the above-mentioned prior art and to provide a lightweight battery case for a new energy electric vehicle, comprising an energy absorbing layer, a structural layer and a contact layer, wherein the energy absorbing layer, the structural layer and the contact layer are arranged in a specific thickness ratio, the thickness ratio of the energy absorbing layer to the contact layer is 1.5, and the thickness ratio of the structural layer to the contact layer is 2, thereby achieving the purpose of weight reduction while ensuring the strength of the lower case.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the utility model is: a lightweight battery box for a new energy electric vehicle, comprising an upper box, a lower box and a connecting component, the upper box and the lower box are both hollow square structures and have the same size, the sides of the upper box and the lower box that are in contact are both open, there are multiple connecting components, and the multiple connecting components are spaced apart on the outer side walls of the upper box and the lower box, the upper box and the lower box are connected by the connecting component, and the upper box and the lower box are respectively an energy absorption layer, a structural layer and a contact layer from the outside to the inside, the thickness ratio of the structural layer to the contact layer is 2, and the thickness ratio of the energy absorption layer to the contact layer is 1.5.

[0006] Preferably, the number of connecting components arranged on each outer side wall of the upper box body and the lower box body along the length direction is the same, and the number of connecting components arranged on each outer side wall of the upper box body and the lower box body along the width direction is the same.

[0007] Preferably, the positions of the multiple connecting parts of the upper box body correspond one-to-one with the positions of the multiple connecting parts of the lower box body, so as to facilitate the fastening connection between the upper box body and the lower box body.

[0008] Preferably, the cross-section of each of the connecting components is trapezoidal.

[0009] Preferably, the energy absorbing layer has a density of 1750 kg / m 3 And the thickness of the carbon fiber reinforced composite material is 1.5mm.

[0010] Preferably, the structural layer has a density of 510 kg / m 3 And the thickness of the foamed aluminum is 2.5mm.

[0011] Preferably, the contact layer has a density of 2698 kg / m 3 And the thickness of aluminum alloy is 1mm.

[0012] Preferably, the energy absorbing layer, the structural layer and the contact layer are integrally formed using hot film pressing technology.

[0013] Preferably, the contact layer is made of 4032 aluminum alloy.

[0014] Compared with the prior art, the utility model has the following advantages:

[0015] 1. The utility model includes an energy absorbing layer, a structural layer and a contact layer, and the energy absorbing layer, the structural layer and the contact layer are arranged in a specific thickness ratio. The thickness ratio of the energy absorbing layer to the contact layer is 1.5, and the thickness ratio of the structural layer to the contact layer is 2, so as to achieve the purpose of weight reduction while ensuring the strength of the upper box body and the lower box body.

[0016] 2. The lower box body and the upper box body of the utility model are connected by multiple connecting parts arranged on the outer side walls. The connecting parts on the outer side walls of the upper box body are at the same height as the upper box body, and the connecting parts on the outer side walls of the lower box body are at the same height as the lower box body, thereby achieving complete connection between the lower box body and the upper box body and improving the stability of the connection between the upper box body and the lower box body.

[0017] 3. The energy-absorbing layer of the utility model has excellent energy absorption capacity, which can effectively disperse and absorb the impact force when the vehicle collides, protect the battery pack from damage, and improve the overall safety of the vehicle; at the same time, the specific thickness ratio design ensures the maximization of the energy absorption effect without excessively increasing the overall weight; the structural layer adopts foam aluminum material, which provides the necessary structural support for the box with good mechanical properties and cost-effectiveness; the contact layer uses high-strength aluminum alloy to ensure that the contact surface with the battery module has good thermal conductivity and durability; this material combination balances the relationship between performance and cost.

[0018] 4. The upper box and the lower box of the utility model are connected by a detachable connecting part. This design makes the maintenance of the battery box and the replacement or upgrade of the internal battery pack more convenient and quick; the necessary maintenance work can be carried out without completely disassembling the entire box, which reduces maintenance costs and time.

[0019] The present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0021] Figure 2 It is a cross-sectional view of the lower box of the utility model;

[0022] Figure 3 for Figure 2 A magnified view of the structure at center.

[0023] Description of reference numerals:

[0024] 1—upper box; 2—lower box; 3—connecting parts;

[0025] 4—energy absorbing layer; 5—structural layer; 6—contact layer;

[0026] 7—Longitudinal beam. DETAILED DESCRIPTION

[0027] like Figures 1 to 3 As shown, the utility model discloses a lightweight battery box for a new energy electric vehicle, comprising an upper box 1, a lower box 2 and a connecting component 3. The upper box 1 and the lower box 2 are both hollow square structures and have the same size. The sides where the upper box 1 and the lower box 2 contact each other are both open. There are multiple connecting components 3, and the multiple connecting components 3 are arranged at intervals on the outer side walls of the upper box 1 and the lower box 2. The upper box 1 and the lower box 2 are connected by the connecting component 3. The upper box 1 and the lower box 2 are respectively an energy absorption layer 4, a structural layer 5 and a contact layer 6 from the outside to the inside. The thickness ratio of the structural layer 5 to the contact layer 6 is 2, and the thickness ratio of the energy absorption layer 4 to the contact layer 6 is 1.5.

[0028] In this embodiment, the lower box body 2 and the upper box body 1 have the same size, which is convenient for using batteries of uniform size, and the upper box body 1 and the lower box body 2 of the same size are more conducive to production and assembly; the upper box body 1 opens downward, and the lower box body 2 opens upward. The inner sides of the bottoms of the upper box body 1 and the lower box body 2 are provided with longitudinal beams 7 arranged along the width direction of the boxes. The longitudinal beams 7 enable the upper box body 1 and the lower box body 2 to form a smooth impact force transmission path, thereby improving the bending strength of the battery box. The edges of the upper box body 1 and the lower box body 2 along the height direction are pressed against each other, and the lower box body 2 and the upper box body 1 are connected by the connecting component 3, so that the lower box body 2 and the upper box body 1 are tightly connected to form a battery box. The upper box body 1 and the lower box body 2 of the battery box are designed with a sandwich structure, which includes an outer energy absorption layer 4, a middle structural layer 5 and an inner contact layer 6. The energy absorption layer 4 absorbs energy to protect the battery cells inside the box from external impact; the thickness ratio of the energy absorption layer 4 to the contact layer 6 is set to 1.5, which can ensure that the contact layer 6 has sufficient rigidity and strength while providing more thickness space for the energy absorption layer 4, thereby improving the energy absorption capacity of the energy absorption layer 4; the thickness ratio of the structural layer 5 to the contact layer 6 is 2, so the structural layer 5 is thicker than the contact layer 6 and the energy absorption layer 4. The structural layer 5 serves as the main load-bearing and supporting part of the upper box body 1 and the lower box body 2. Properly increasing the thickness of the structural layer 5 can significantly improve the overall strength of the battery box. The thickness of the contact layer 6 is less than that of the energy absorption layer 4 and the structural layer 5. By optimizing the thickness of the battery box through the contact layer 6, unnecessary weight increase can be reduced. The contact layer 6 and the energy absorption layer 4 jointly provide mechanical support to keep the battery box in its original shape. At the same time, the contact layer 6 and the energy absorption layer 4 also protect the battery pack inside the battery box.

[0029] The number of connecting components 3 provided on each outer side wall of the upper box body 1 and the lower box body 2 along the length direction is the same, and the number of connecting components 3 provided on each outer side wall of the upper box body 1 and the lower box body 2 along the width direction is the same.

[0030] In the present embodiment, three connecting components 3 are arranged on the outer side walls of the upper box body 1 and the lower box body 2 along the length direction. First, a connecting component 3 is arranged in the middle of the upper box body 1 and the lower box body 2 along the length direction, and then a connecting component 3 is arranged at the same distance on the left and right sides of the connecting component 3, respectively. Each connecting component 3 is arranged along the height direction of the upper box body 1 and the lower box body 2, and then the setting of the connecting components 3 of the upper box body 1 and the lower box body 2 along the length direction is completed; two connecting components 3 are arranged on the outer side walls of the upper box body 1 and the lower box body 2 along the width direction. First, the center line of the upper box body 1 and the lower box body 2 in the width direction is found, and then a connecting component 3 is arranged along the center line to the left and right sides at the same distance, respectively. Then the setting of the connecting components 3 of the upper box body 1 and the lower box body 2 along the width direction is completed. Each connecting component 3 adopts hot molding technology to make the connecting component 3 and the upper box body 1 or the lower box body 2 integrally formed.

[0031] Furthermore, according to the size of the upper box body 1 and the lower box body 2, more or fewer connecting components 3 may be arranged on the outer side walls of the upper box body 1 and the lower box body 2, and the distance between each two adjacent connecting components 3 may be equal or unequal.

[0032] The positions of the multiple connecting parts 3 of the upper box body 1 correspond to the positions of the multiple connecting parts 3 of the lower box body 2 one by one, so as to facilitate the fastening connection between the upper box body 1 and the lower box body 2.

[0033] In the present embodiment, since the upper box body 1 and the lower box body 2 have the same size, both the upper box body 1 and the lower box body 2 are hollow square frames with a length of 1600 mm, a width of 1200 mm, and a height of 120 mm, the heights of the connecting parts 3 on the outer walls of the upper box body 1 and the lower box body 2 are consistent, and each connecting part 3 is provided with a threaded hole along its height direction, and the upper box body 1 and the lower box body 2 are fixed by bolts passing through the threaded holes of the connecting parts 3 on the upper box body 1 and then reaching the threaded holes of the connecting parts 3 on the lower box body 2, and the upper box body 1 and the lower box body 2 are both provided with a connecting part 3 in the middle along the length direction, and a connecting part 3 is respectively provided on the left and right sides of the connecting part 3 in the middle at the same distance, thereby improving the stability of the connection between the upper box body 1 and the lower box body 2. The connecting part 3 of the utility model is made of aluminum alloy material, and the strength of the aluminum alloy material is sufficient to ensure that the upper box body 1 and the lower box body 2 are tightly combined.

[0034] The cross section of each connecting member 3 is trapezoidal.

[0035] The cross section of the connecting component 3 is set to be trapezoidal, so as to avoid collision of the connecting component 3 .

[0036] The energy absorbing layer 4 has a density of 1750kg / m 3 And the thickness of the carbon fiber reinforced composite material is 1.5mm.

[0037] In this embodiment, the carbon fiber reinforced composite material uses a carbon fiber-resin composite fiber textile fabric. Compared with traditional metal materials, carbon fiber reinforced composite materials are lighter, have a lower thermal expansion coefficient and are not easily affected by temperature; carbon fiber reinforced composite materials have a longer fatigue life than ordinary metal materials and are more durable and reliable under repeated loading conditions; and the energy absorption performance of carbon fiber reinforced composite materials causes the layers in the carbon fiber reinforced composite materials to separate when the carbon fiber reinforced composite materials are impacted, and this process can dissipate a lot of energy, and the friction between the broken carbon fiber and the matrix and between different layers also helps to further dissipate energy, thereby achieving the purpose of protecting the battery pack in the battery box. The thickness of the carbon fiber reinforced composite material selected by the utility model is 1.5mm, because after the thickness of the carbon fiber reinforced composite material increases to a certain extent, the improvement of its mechanical properties will tend to saturation or even decline, and the thickness of 1.5mm is in the range of more significant performance improvement, which can not only maintain a high tensile strength and modulus, but also will not cause the mechanical properties to decline due to excessive thickness. In addition, the processing technology of carbon fiber reinforced composite materials is complicated. The 1.5mm thick carbon fiber reinforced composite material is easier to control the flow and curing process of the resin during the molding process, and it is easy to achieve uniform arrangement of fibers, which is convenient for cutting and trimming, and helps to improve the overall performance of the carbon fiber reinforced composite material. Therefore, the selected 1.5mm thick carbon fiber reinforced composite material can ensure the structural strength of the battery box while ensuring the mechanical properties.

[0038] The structural layer 5 adopts a density of 510kg / m 3 And the thickness of the foamed aluminum is 2.5mm.

[0039] In the present embodiment, the middle layer of the upper box body 1 and the lower box body 2 are both structural layers 5, and the structural layer 5 is made of foam aluminum with a thickness of 2.5 mm. Since foam aluminum is a material containing a large number of pores inside, these pores make it have a lower density. Compared with traditional metals, it has the characteristics of light weight and high strength. Therefore, while ensuring the strength of the upper box body 1 and the lower box body 2, the weight of the upper box body 1 and the lower box body 2 can be reduced, thereby achieving the purpose of reducing the weight of the battery box. Moreover, foam aluminum also has energy absorption capacity. When the battery case is subjected to external impact or vibration, the pore structure inside the foam aluminum can effectively disperse and absorb energy, so that the foam aluminum as an intermediate layer can buffer the impact on the battery case, and can effectively disperse the impact strength, protect the battery pack in the battery case from external impact, and improve the durability of the battery case in harsh environments and the safety of equipment operation. The utility model selects 2.5mm thick foam aluminum, because 2.5mm thick foam aluminum can achieve a balance between strength and rigidity. Compared with 3mm thick foam aluminum, 2.5mm thick foam aluminum can significantly reduce weight and reduce costs, and the strength gap can be made up through reasonable structural design. Compared with 2mm thick foam aluminum, 2.5mm thick foam aluminum provides better structural stability and durability. In comparison, 2.5mm thick foam aluminum is relatively reasonable in material cost, and will not increase processing difficulty and loss rate due to excessively thin materials, nor will it increase unnecessary material costs due to excessively thick materials.

[0040] The contact layer 6 adopts a density of 2698kg / m 3 And the thickness of aluminum alloy is 1mm.

[0041] In this embodiment, the inner sides of the upper box body 1 and the lower box body 2 are both contact layers 6, and the contact layer 6 is in contact with the battery pack in the battery box. The contact layer 6 is made of aluminum alloy with a thickness of 1 mm. The high strength of aluminum alloy can effectively resist external impact and pressure to prevent the battery pack from being damaged. In addition, aluminum alloy has a low density, so that the overall structure maintains strength without significantly increasing weight. Aluminum alloy will not generate sparks when rubbed or impacted, which can effectively avoid the risk of explosion and fire of the battery pack in the battery box, thereby improving the safety of the battery pack. At the same time, due to the high strength of aluminum alloy, aluminum alloy Gold can also provide sufficient structural support at a thinner thickness, thereby reducing costs. The utility model selects an aluminum alloy with a thickness of 1 mm, because an aluminum alloy with a thickness of 1 mm is light in weight and easy to process, and is sufficient to withstand impact as the contact layer 6 on the inner side of the upper box body 1 and the lower box body 2. Compared with an aluminum alloy with a thickness of 0.5 mm, an aluminum alloy with a thickness of 1 mm can provide better structural stability and load-bearing capacity while still maintaining a relatively light weight. Compared with an aluminum alloy with a thickness of 1.5 mm, an aluminum alloy with a thickness of 1 mm can reduce the overall weight, effectively reduce costs, and achieve the design purpose of a lightweight battery case.

[0042] The energy absorbing layer 4, the structural layer 5 and the contact layer 6 are integrally formed by using hot film pressing technology.

[0043] The bottom and side walls of the upper box body 1 and the lower box body 2 both adopt a sandwich structure, that is, the upper box body 1 and the lower box body 2 both include an energy absorption layer 4, a structural layer 5 and a contact layer 6, and the energy absorption layer 4, the structural layer 5 and the contact layer 6 are tightly combined using resin material, the energy absorption layer 4 is located on the outside, the contact layer 6 is located on the inside, and the structural layer 5 is located between the energy absorption layer 4 and the contact layer 6 to realize the sandwich structure of the battery box, and then hot molding technology is used to form it as one piece.

[0044] The contact layer 6 is made of 4032 aluminum alloy.

[0045] Furthermore, the contact layer 6 may also be made of A5052-H32 aluminum plate, 5052 aluminum alloy, 5083 aluminum alloy, or 6063 aluminum alloy.

[0046] When in use, the energy absorption layer 4 of the upper box body 1 and the lower box body 2 are made of 1.5mm thick carbon fiber reinforced composite material, the structural layer 5 is made of 2.5mm thick foam aluminum, and the contact layer 6 is made of 1mm thick aluminum alloy. The three-layer structure of the energy absorption layer 4, the structural layer 5 and the contact layer 6 of the upper box body 1 and the lower box body 2 is integrally formed using hot molding technology, and then a plurality of connecting components 3 are arranged at intervals on the outer walls of the upper box body 1 and the lower box body 2, the connecting components 3 on the outer side of the upper box body 1 are hot molded with the energy absorption layer 4 on the outer side of the upper box body 1, and the connecting components 3 on the outer side of the lower box body 2 are hot molded with the energy absorption layer 4 on the outer side of the lower box body 2, finally, the battery pack is placed, the upper box body 1 is installed on the upper side of the lower box body 2, so that the end of the upper box body 1 in the opening direction contacts the top of the lower box body 2, and the bolts are passed through the connecting components 3 at the corresponding positions of the upper box body 1 and the lower box body 2 to fasten the upper box body 1 and the lower box body 2. The utility model can reduce the weight of the battery box and improve the impact resistance of the battery box by setting the carbon fiber reinforced composite material, foam aluminum and aluminum alloy to a corresponding thickness ratio.

[0047] The above is only a preferred embodiment of the present invention and does not constitute any limitation to the present invention. Any simple modification, change and equivalent structural transformation made to the above embodiments according to the technical essence of the present invention shall still fall within the protection scope of the technical solution of the present invention.

Claims

1. A lightweight battery box for a new energy electric vehicle, characterized in that: The invention comprises an upper box body (1), a lower box body (2) and a connecting component (3), wherein the upper box body (1) and the lower box body (2) are both hollow square structures and have the same size, and the contacting sides of the upper box body (1) and the lower box body (2) are both open, and the number of the connecting components (3) is plural, and the plural connecting components (3) are arranged at intervals on the outer side walls of the upper box body (1) and the lower box body (2), and the upper box body (1) and the lower box body (2) are connected by the connecting component (3), and the upper box body (1) and the lower box body (2) are respectively an energy absorption layer (4), a structural layer (5) and a contact layer (6) from the outside to the inside, and the thickness ratio of the structural layer (5) to the contact layer (6) is 2, and the thickness ratio of the energy absorption layer (4) to the contact layer (6) is 1.

5.

2. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The number of connecting components (3) provided on each outer side wall of the upper box body (1) and the lower box body (2) along the length direction is the same, and the number of connecting components (3) provided on each outer side wall of the upper box body (1) and the lower box body (2) along the width direction is the same.

3. A lightweight battery box for a new energy electric vehicle according to claim 2, characterized in that: The positions of the multiple connecting parts (3) of the upper box body (1) correspond one-to-one with the positions of the multiple connecting parts (3) of the lower box body (2), so as to facilitate the fastening connection between the upper box body (1) and the lower box body (2).

4. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The cross section of each connecting component (3) is trapezoidal.

5. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The energy absorbing layer (4) has a density of 1750 kg / m 3 And the thickness of the carbon fiber reinforced composite material is 1.5mm.

6. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The structural layer (5) has a density of 510 kg / m 3 And the thickness of the foamed aluminum is 2.5mm.

7. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The contact layer (6) has a density of 2698 kg / m 3 And the thickness of aluminum alloy is 1mm.

8. A lightweight battery box for a new energy electric vehicle according to claim 1, characterized in that: The energy absorbing layer (4), the structural layer (5) and the contact layer (6) are integrally formed using hot film pressing technology.

9. A lightweight battery box for a new energy electric vehicle according to claim 7, characterized in that: The contact layer (6) is made of 4032 aluminum alloy.

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