Lightweight integrated battery box

Abstract

The utility model discloses a lightweight integrated battery box, which relates to the field of new energy vehicle parts and power battery energy storage, and comprises a battery frame, a battery shell is arranged in the battery frame, an upper cover is arranged at the top end of the battery shell, and a thermal insulation layer matched with the battery frame is arranged on the outer side of the battery shell; the adjacent battery frames are connected through a plurality of fasteners; and a sealing strip is adhered to the joint of the battery shell and the upper cover. The integrated battery box can be used for commercial vehicles such as engineering vehicles, heavy trucks and light trucks, can also be used for an energy storage box, is wide in application and has very good market prospects, and a single layer or multiple layers can be arranged according to the electric quantity requirements of different vehicles; the device can also be adapted to battery cells with different specifications and different structural forms; according to the product requirements of different vehicle types, the battery box bodies with different lengths, widths and heights can be realized by adjusting the lengths of the longitudinal beams, the cross beams and the upright posts.

Description

Technical Field

[0001] The utility model relates to the field of new energy vehicle parts and power battery energy storage, and more specifically, to a lightweight integrated battery box body. Background Technique

[0002] With the increasing emphasis on environmental protection and carbon reduction, the electrification process of commercial vehicles such as construction machinery and heavy trucks has gradually accelerated. To obtain a longer operation time and reduce the charging frequency, these models are equipped with a large amount of electricity and require the use of multiple battery box bodies. The multiple battery box bodies occupy a large space and are relatively heavy. In order to improve the space utilization rate of the whole vehicle, stacked battery packs have emerged in the prior art to save installation space.

[0003] However, the battery box bodies of the prior art have disadvantages such as high cost, large weight, and poor versatility, and cannot better meet the market demands of commercial vehicles such as construction machinery and heavy trucks. For example, the box body made of aluminum profiles has a relatively high cost; the cast box body has a relatively large weight.

[0004] In response to the problems in the related art, no effective solution has been proposed yet. Content of the Utility Model

[0005] In response to the problems in the related art, the utility model proposes a lightweight integrated battery box body to overcome the above technical problems existing in the prior related art.

[0006] To this end, the specific technical solution adopted by the utility model is as follows:

[0007] A lightweight integrated battery box body includes a battery frame. A battery housing is arranged inside the battery frame. An upper cover is arranged at the top of the battery housing. A heat insulation layer matching the battery frame is arranged outside the battery housing. Adjacent battery frames are all connected by a plurality of fasteners. A sealing strip is pasted at the connection between the battery housing and the upper cover.

[0008] Further, in order to be formed by roll pressing and laser welding, the roll pressing cross-sectional shape can be selected as a Japanese character shape, a mesh character shape, etc. A complex cross-sectional shape can improve the rigidity and strength of the battery frame. The battery frame includes two groups of longitudinal beams horizontally arranged outside the battery housing. Cross beams are arranged on both sides of the longitudinal beams. Between the two groups of longitudinal beams and the two groups of cross beams are all connected by columns and brackets; A plurality of mounting holes are arranged on the surfaces of the longitudinal beams and the cross beams, and a spacer sleeve is arranged for the mounting holes. Connecting plates are arranged at the junctions of the longitudinal beams and the cross beams. A plurality of backing plates are evenly arranged at the tops of the longitudinal beams and the cross beams.

[0009] Further, in order to make full use of strain strengthening and improve the rigidity and strength of the bottom plate, longitudinal and transverse reinforcing beams are provided at the bottom, which play the role of fixing the battery cells and increasing the stiffness and strength. The battery housing includes a body disposed inside the longitudinal and transverse beams, and a reinforcing beam is provided at the inner bottom end of the body; a mounting plate is provided on one side of the body; a rivet nut for cooperating with the upper cover is provided at the top of the body. The reinforcing beam is composed of a longitudinal reinforcing beam and a transverse reinforcing beam provided at the inner bottom end of the body, and the longitudinal reinforcing beam and the transverse reinforcing beam are arranged alternately.

[0010] The beneficial effects of the present utility model are as follows: The integrated battery box in the present utility model can be used for commercial vehicles such as engineering vehicles, heavy trucks, and light trucks, and can also be used for energy storage boxes, with a wide range of uses and a very good market prospect. It can be set in a single layer or multiple layers according to the power requirements of different vehicles; it can also be adapted to battery cells of different specifications and different structural forms, reducing the types and quantities of parts; greatly reducing the weight of the assembly, improving the vehicle economy, and reducing the manufacturing cost. Using a rolled part as the main load-bearing part, according to the product requirements of different vehicle models, different lengths, widths, and heights of the battery box can be achieved by adjusting the lengths of the longitudinal beam, transverse beam, and column, with high product specification flexibility and versatility. Using rolled profiles as the main load-bearing part, making full use of the process characteristics of rolling, different cross-sectional shapes can be designed, maximizing the goal of lightweight while meeting the product strength and stiffness requirements; it can also achieve in-line welding and punching, reducing the subsequent processing procedures, and reducing the manufacturing cost and manufacturing process difficulty. The battery housing is processed by cold bending forming + laser welding, with a simple processing process and can ensure the sealing performance of the housing. Utilizing the structural form of the battery box, heat-insulating layers are provided at the bottom and side of the housing, improving the product aesthetics while meeting the heat-insulating performance requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present utility model. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0012] Figure 1 is a schematic structural diagram of a lightweight integrated battery box according to an embodiment of the present utility model;

[0013] Figure 2 is one of the schematic structural diagrams of the battery box in a lightweight integrated battery box according to an embodiment of the present utility model;

[0014] Figure 3 is another schematic structural diagram of the battery box in a lightweight integrated battery box according to an embodiment of the present utility model;

[0015] Figure 4 is a schematic structural view of a battery frame in a lightweight integrated battery box according to an embodiment of the present invention;

[0016] Figure 5 is one of the schematic structural views of a battery housing in a lightweight integrated battery box according to an embodiment of the present invention;

[0017] Figure 6 is another schematic structural view of a battery housing in a lightweight integrated battery box according to an embodiment of the present invention;

[0018] Figure 7 is a schematic structural view of a reinforcing beam in a lightweight integrated battery box according to an embodiment of the present invention;

[0019] Figure 8 is a schematic structural view of a longitudinal and transverse beam in a lightweight integrated battery box according to an embodiment of the present invention;

[0020] Figure 9 is a schematic view of the connection of columns in a lightweight integrated battery box according to an embodiment of the present invention.

[0021] In the figure:

[0022] 1. Battery frame; 101. Longitudinal beam; 102. Cross beam; 103. Column; 104. Bracket; 105. Mounting hole; 106. Spacer; 107. Connecting plate; 2. Battery housing; 201. Body; 202. Reinforcing beam; 108. Pad; 2021. Longitudinal reinforcing beam; 2022. Transverse reinforcing beam; 203. Mounting plate; 204. Rivet nut; 3. Upper cover; 4. Thermal insulation layer; 5. Fastener; 6. Sealing strip. Detailed implementation manners

[0023] To further illustrate each embodiment, the present invention provides accompanying drawings, which are part of the disclosure of the present invention. They are mainly used to illustrate the embodiments and can be used to explain the operating principle of the embodiments in conjunction with the relevant descriptions in the specification. With reference to these contents, those of ordinary skill in the art should be able to understand other possible implementation manners and the advantages of the present invention. The components in the figures are not drawn to scale, and similar component symbols are usually used to represent similar components.

[0024] According to an embodiment of the present invention, a lightweight integrated battery box is provided.

[0025] Now, the present invention will be further described in conjunction with the accompanying drawings and specific implementation manners. As Figures 1-9As shown in the figure, the lightweight integrated battery box according to the embodiment of the present invention includes a battery frame 1. A battery housing 2 is arranged inside the battery frame 1. An upper cover 3 is arranged at the top of the battery housing 2. A heat preservation layer 4 that cooperates with the battery frame 1 is arranged outside the battery housing 2. Adjacent battery frames 1 are all connected by a plurality of fasteners 5. A sealing strip 6 is pasted at the connection between the battery housing 2 and the upper cover 3.

[0026] With the above technical solution, the integrated battery box in the present invention can be used for commercial vehicles such as engineering vehicles, heavy trucks, and light trucks, and can also be used for energy storage boxes, with a wide range of uses and very good market prospects. It can be set in a single layer or multiple layers according to the power requirements of different vehicles. It can also be adapted to different specifications and different structural forms of battery cells, such as: adapting to blade battery cells or square shell battery cells, simplifying the original structure of the frame + module combination, reducing the types and quantities of parts; greatly reducing the weight of the assembly, improving the vehicle economy, and reducing the manufacturing cost. Using a rolled part as the main load-bearing part, according to the product requirements of different vehicle models, different lengths, widths, and heights of the battery box can be achieved by adjusting the lengths of the longitudinal beam, cross beam, and column, with high product specification flexibility and versatility. Using rolled profiles as the main load-bearing part, taking full advantage of the process characteristics of rolling, different cross-sectional shapes can be designed to maximize the lightweight goal on the premise of meeting the product strength and stiffness; online welding and punching can be achieved, reducing the subsequent processing procedures, and reducing the manufacturing cost and manufacturing process difficulty. The battery housing is processed by cold bending forming + laser welding, with a simple processing process and can ensure the sealing performance of the housing. Utilizing the structural form of the battery box, heat preservation layers are arranged at the bottom and side of the housing, improving the product aesthetics on the premise of meeting the heat preservation performance requirements.

[0027] It should also be supplemented that the integrated battery box body in the present utility model can be used alone or stacked in multiple layers. When stacked in multiple layers, it is mostly used for 2 to 5 layers to expand the battery power of the whole vehicle. The battery box bodies of the upper and lower layers are connected by a plurality of bolts. A circle of mounting spacers is provided on the upper part of the battery box body for connecting the upper battery box; a circle of mounting spacers is provided on the lower part for connecting to the vehicle body or the lower battery box body. According to the force characteristics and performance requirements of the battery box body, different materials and structural features are applied at different positions of the integrated battery box body to give full play to the advantages of their respective materials and structures. The overall structure of the battery box body is in a frame shape, which is a basin shape with an open upper part and a closed lower part. It is used to install batteries, electrical components, thermal management and other parts inside, and has the advantages of simple structure and good rigidity. Each part is connected by welding or other means, and the surface is treated by cathodic electrophoresis to improve corrosion resistance. The longitudinal beams, cross beams and columns of the battery frame 1 are made of ultra-high strength steel (such as DP&QP980, DP&QP1180, HS1500, 22MnB5, etc.) and formed by roll forming plus laser welding. The roll forming cross-sectional shape can be selected from Japanese character type, eye character type, etc. The thickness of the parts is 1.0 to 3.0 mm. The complex cross-sectional shape can improve the rigidity and strength of the battery frame. The battery shell 2 is integrally cold-formed by high-strength plates, making full use of strain hardening to improve the rigidity and strength of the bottom plate. Longitudinal and transverse reinforcing beams are provided at the bottom, which play the role of fixing the battery cells and increasing the rigidity and strength. Mounting plates are provided on the side for mounting electrical connectors, water pipe joints, etc. The heat insulation layer 4 is provided at the bottom and side of the battery shell, which plays a heat insulation role and is beneficial to improving the performance of the battery.

[0028] In one embodiment, for the above-mentioned battery frame 1, the battery frame 1 includes two groups of longitudinal beams 101 horizontally arranged outside the battery shell 2. Cross beams 102 are provided on both sides of the longitudinal beams 101. Between the two groups of longitudinal beams 101 and the two groups of cross beams 102, they are all connected by columns 103 and brackets 104. A number of mounting holes 105 are provided on the surfaces of the longitudinal beams 101 and the cross beams 102, and spacers 106 are provided for the mounting holes 105. Connecting plates 107 are provided at the junctions of the longitudinal beams 101 and the cross beams 102. A number of backing plates 108 are evenly provided at the tops of the longitudinal beams 101 and the cross beams 102. Thus, it is formed by roll forming plus laser welding. The roll forming cross-sectional shape can be selected from Japanese character type, eye character type, etc. The thickness of the parts is 1.0 to 3.0 mm. The complex cross-sectional shape can improve the rigidity and strength of the battery frame.

[0029] In one embodiment, for the above-mentioned battery shell 2, the battery shell 2 includes a main body 201 arranged on the inner side of the longitudinal beam 101 and the cross beam 102, and a reinforcing beam 202 is arranged at the inner bottom end of the main body 201; a mounting plate 203 is arranged on one side of the main body 201; a rivet nut 204 matching with the upper cover 3 is arranged at the top end of the main body 201, and the reinforcing beam 202 is composed of a longitudinal reinforcing beam 2021 and a transverse reinforcing beam 2022 arranged at the inner bottom end of the main body 201, and the longitudinal reinforcing beam 2021 and the transverse reinforcing beam 2022 are staggered, so as to make full use of deformation strengthening and improve the rigidity and strength of the bottom plate. The bottom is provided with longitudinal and transverse reinforcing beams, which play the role of fixing the battery cell and increasing the rigidity and strength.

[0030] The specific implementation cases are as follows:

[0031] The integrated battery box is stacked, with the upper and lower layers connected by fasteners; it is based on a 4-layer battery box.

[0032] The structure of the battery box includes a battery frame and a battery shell, which are mainly connected by welding technology, and the welding technology is not limited to laser welding, CMT, argon arc welding, shielded welding, etc.; the upper cover and the battery shell are mainly connected by bolts, and the brackets of the two are provided with sealing strips, which are pasted on the battery shell.

[0033] The structure of the battery frame is a frame structure as a whole, with two layers of longitudinal beams and transverse beams. The wide sides of the longitudinal and transverse beams are designed to be perpendicular to the side surfaces of the shell, so that the installation holes and the sealing strip bonding surfaces can be designed on the wide sides of the longitudinal and transverse beams; the two columns at the four corners are usually designed to be L-shaped, so as to facilitate the flushness with the ends of the longitudinal and transverse beams and the aesthetics of the overall outline of the frame; multiple columns and brackets are arranged around; connecting plates are arranged at the four corners, which play the role of connecting the longitudinal and transverse and strengthening the columns.

[0034] There are multiple mounting holes on the longitudinal and transverse beams on the battery frame for installing spacers; the spacers on the longitudinal and transverse beams mainly connect and fix the battery box through fasteners, and can also disperse the compressive stress of the fasteners on the longitudinal and transverse beams; the upper longitudinal and transverse welded pads play the role of supporting the upper battery box.

[0035] The longitudinal beams, cross beams and columns of the battery box are made of ultra-high-strength steel (DP&QP780, DP&QP980, DP&QP1180, HS1500, 22MnB5, etc.) through roll pressing + laser welding. The shapes can be selected from the Japanese-shaped, mesh-shaped, B-shaped and other cross-sections, and the part thickness is 1.0~3.0mm; this solution uses the Japanese-shaped, with an asymmetric cross-section, a thickness of 1.5mm, and a material of DP980, with 2 welds.

[0036] The battery housing is formed by integral stamping, or can also be manufactured by bending + welding. The material is high-strength steel with a thickness of 1-3 mm. It is welded to the longitudinal reinforcement beam and the transverse reinforcement beam to play the role of carrying the battery cells and related parts, and also plays a sealing role.

[0037] The thermal insulation layer mainly includes thermal insulation cotton and thermal insulation coating. The thickness and material of the thermal insulation cotton are optional. It is mainly pasted around the box body and on the upper side of the bottom, making full use of the concave surfaces of the battery box body; the thermal insulation coating is mainly sprayed on the bottom of the box body with an optional thickness.

[0038] In summary, by means of the above technical solutions of the present invention, the integrated battery box body of the present invention can be used for commercial vehicles such as engineering vehicles, heavy trucks, and light trucks, and can also be used for energy storage box bodies. It has a wide range of uses and has a very good market prospect. It can be set in single layer or multiple layers according to the power requirements of different vehicles; it can also be adapted to battery cells of different specifications and different structural forms, such as: adapting to blade battery cells or square shell battery cells, simplifying the original structure of the frame + module combination, reducing the types and quantities of parts; greatly reducing the weight of the assembly, improving the vehicle economy, reducing the manufacturing cost. Using roll-formed parts as the main load-bearing parts, according to the product requirements of different vehicle models, different lengths, widths, and heights of the battery box body can be realized by adjusting the lengths of the longitudinal beams, cross beams, and columns, with high product specification flexibility and versatility. Using roll-formed profiles as the main load-bearing parts, making full use of the process characteristics of roll-forming, different cross-sectional shapes can be designed to maximize the goal of lightweight under the premise of meeting the product strength and stiffness; at the same time, online welding and punching can be realized, reducing the subsequent processing procedures, and reducing the manufacturing cost and manufacturing process difficulty. The battery housing is processed by cold bending + laser welding, with a simple processing technology and can ensure the sealing of the housing. Using the structural form of the battery box body, thermal insulation layers are provided at the bottom and side of the housing, improving the product aesthetics under the premise of meeting the thermal insulation performance requirements.

[0039] In the present invention, unless otherwise clearly specified and limited, terms such as "installation", "setting", "connection", "fixation", "swivel connection", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium. It can be the internal communication of two components or the interaction relationship between two components. Unless otherwise clearly limited, for those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0040] The above are only the preferred embodiments of the present utility model, and are not intended to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A lightweight integrated battery box body, comprising a plurality of battery frames (1), characterized in that, Inside the battery frame (1), there is a battery housing (2). At the top of the battery housing (2), there is an upper cover (3). Outside the battery housing (2), there is a heat insulation layer (4) that matches the battery frame (1). Between adjacent battery frames (1), they are all connected by a number of fasteners (5).

2. The lightweight integrated battery box according to claim 1, wherein, At the connection between the battery housing (2) and the upper cover (3), there is a sealing strip (6) pasted.

3. The lightweight integrated battery box according to claim 2, wherein The battery frame (1) includes two sets of longitudinal beams (101) horizontally arranged outside the battery housing (2). On both sides of the longitudinal beams (101), there are cross beams (102). Between the two sets of longitudinal beams (101) and the two sets of cross beams (102), there are columns (103) and brackets (104). On the surfaces of the longitudinal beams (101) and the cross beams (102), there are a number of mounting holes (105), and there are spacer sleeves (106) provided in the mounting holes (105).

4. The lightweight integrated battery box according to claim 3, wherein, At the junctions of the longitudinal beams (101) and the cross beams (102), there are connecting plates (107). At the tops of the longitudinal beams (101) and the cross beams (102), there are a number of backing plates (108) evenly arranged.

5. The lightweight integrated battery box according to claim 4, wherein The battery housing (2) includes a body (201) arranged inside the longitudinal beams (101) and the cross beams (102). At the inner bottom end of the body (201), there is a reinforcing beam (202). On one side of the body (201), there is a mounting plate (203). At the top of the body (201), there is a rivet nut (204) that matches the upper cover (3).

6. The lightweight integrated battery box according to claim 5, characterized in that, The reinforcing beam (202) is composed of a longitudinal reinforcing beam (2021) and a transverse reinforcing beam (2022) arranged at the inner bottom end of the body (201), and the longitudinal reinforcing beam (2021) and the transverse reinforcing beam (2022) are arranged alternately.

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