Rolled liquid steel cooling integrated battery box body

Abstract

The utility model discloses a rolling liquid steel cooling integrated type battery box, which relates to the technical field of battery boxes, and comprises a bottom protective plate, a liquid cooling plate and an assembly frame which are integrally arranged, the liquid cooling plate is embedded in the assembly frame, a water cooling channel is arranged on the liquid cooling plate, and the bottom protective plate is arranged at the bottom of the assembly frame; the assembly frame comprises frame beams located on the periphery, a middle beam and a cold plate supporting beam are arranged in the frame beams, the middle beam is located at the top of the liquid cooling plate, and the cold plate supporting beam is located at the bottom of the liquid cooling plate. And the overall structure supporting strength is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of battery boxes, in particular to a rolled steel water-cooled integrated battery box. Background Art

[0002] Against the backdrop of continuous innovation in battery case technology, the design of battery box cases is developing towards a more efficient, more compact and more economical direction. Traditionally, battery box cases are divided into two main types according to the cooling method: water-cooled rear-mounted type and water-cooled integrated type. Although the water-cooled rear-mounted type solves the heat dissipation problem of the battery pack to a certain extent, its design is complex, which increases the difficulty and cost of the production process in the vehicle factory. In contrast, the water-cooled integrated solution, with its highly integrated characteristics, not only effectively meets the thermal management requirements of the battery system, but also significantly saves space, improves the energy density of the entire pack, and is expected to further reduce production costs, becoming the preferred solution in the industry.

[0003] However, when implementing a water-cooled integrated solution, the selection of materials and innovation in connection technology have become key challenges. Currently on the market, the main material of the battery box is mostly 6061-T6 aluminum alloy, which is popular for its good mechanical properties and processing properties. For aluminum alloy materials, the FDS (Flow Drill Screw, self-tapping screw) cold connection method is widely used in water-cooled integrated solutions due to its efficient and reliable connection effect. However, when considering the use of rolled steel as the box material, the situation becomes complicated. Rolled steel has gradually attracted attention due to its high strength, light weight and cost-effectiveness, but its thinner wall thickness (usually ≤1.2mm) makes FDS connection technology no longer applicable, which directly limits the application of rolled steel in water-cooled integrated solutions. Utility Model Content

[0004] The purpose of the present invention is to overcome the problems in the background technology and propose a rolled steel water-cooled integrated battery box. The battery support and the liquid cooling plate support are independent of each other by utilizing the water-cooling integrated design, thereby improving the overall structural support strength.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a rolled steel water-cooled integrated battery box, comprising an integrated bottom guard plate, a liquid cooling plate, and an assembly frame, wherein the liquid cooling plate is embedded in the assembly frame, a water cooling channel is provided on the liquid cooling plate, and the bottom guard plate is arranged at the bottom of the assembly frame; the assembly frame includes frame beams located on all sides, an intermediate beam and a cold plate support beam are arranged in the frame beam, the intermediate beam is located at the top of the liquid cooling plate, and the cold plate support beam is located at the bottom of the liquid cooling plate.

[0006] In order to further optimize the present invention, the following technical solutions may be preferably used:

[0007] Preferably, the bottom guard plate is a steel bottom guard plate, and reinforcement ribs are provided on the steel bottom guard plate protruding upward.

[0008] Preferably, there are multiple intermediate beams distributed in a cross shape, and the middle part of the intermediate beam located in the middle of the assembly frame is connected to the cold plate support beam by bolts.

[0009] Preferably, the frame beams and the bottom of the middle beam of the assembly frame are connected to the bottom guard plate by glue and rivets; and the liquid cooling plate and the cold plate support beam of the assembly frame are riveted to each other.

[0010] Preferably, mounting brackets are symmetrically provided on the outer side of the assembly frame.

[0011] Preferably, the middle beam is a high-strength steel stamping part, and the frame beams and the middle beam are welded to each other to form a battery support frame.

[0012] Preferably, the liquid cooling plate is a 3003 brazed liquid cooling plate.

[0013] The beneficial effects of the present invention are mainly reflected in the following aspects:

[0014] 1) Good side impact test performance: Because the rolled steel case is made of high-strength or ultra-high-strength steel, the overall strength of the battery case structure is improved. During the experiment, it was found that the steel case with the same structure has a collision and extrusion capacity twice that of the aluminum case. Through an integrated design, the bottom guard plate, liquid cooling plate and assembly frame are tightly combined to form an integral structure. The frame beams, middle beams and cold plate support beams in the assembly frame each perform their respective functions, ensuring both stable support for the battery pack and effective fixation of the liquid cooling plate. This design makes the battery support and liquid cooling plate support independent of each other, avoiding mutual interference, thereby significantly improving the overall structural support strength and enhancing the vibration and impact resistance of the battery case.

[0015] 2) Integrated Liquid Cooling System: This solution integrates a 3003 brazed water-cooling plate with the riveted assembly of the battery box to cool the module. Optimizing thermal management: The liquid-cooling plate is embedded directly within the assembly frame and features efficient water-cooling channels, enabling rapid heat transfer and dissipation from the battery pack. This integrated water-cooling design not only improves cooling efficiency but also simplifies the cooling system layout, reduces thermal resistance, and ensures the battery pack operates within the optimal temperature range, extending battery life and enhancing vehicle safety and reliability.

[0016] 3) Lower production cost: The rolled steel box body is made of high-strength steel, which is far superior to aluminum alloy in terms of material availability and cost. In addition, the application experience of steel in the automotive industry is rich and mature, making it more advantageous for body parts.

[0017] 4) Possess higher temperature resistance: The main material of the aluminum box is aluminum alloy. When the temperature of aluminum alloy is too high, the mechanical properties will change significantly. When the temperature exceeds 150℃, the strength will become unstable, and when it exceeds 200℃, the strength will drop too obviously. The high temperature resistance of steel can reach 1000℃. In terms of thermal runaway of the battery box, rolled steel has better high temperature resistance than aluminum alloy and is safer.

[0018] 5) High degree of industrialization: Rolled steel profiles have high production efficiency, and the production speed is 3-5 times that of aluminum alloy extrusion. Due to the difference in steel and aluminum properties, steel deformation is smaller than welding thermal deformation. Some structures can reduce assembly CNC, thereby saving production area. Aluminum alloy does not undergo surface treatment, which makes it more prone to bumps and scratches during the production process. Since the rolled steel box needs to be electrophoretically treated in the later process, there is no such problem, and the overall appearance consistency of the box is better.

[0019] 6) Suitable for platform design: Due to the further simplification of the structure, rolled profiles such as the side beams can be used universally, requiring only the mounting bracket and length to be changed. This means that the size of the battery housing made of rolled steel can be flexibly changed to accommodate platform vehicles of different sizes.

[0020] 7) Space Saving and Energy Density Improvement: Thanks to its integrated design, the battery case is more compact, effectively saving space. This allows for more cells to be accommodated within the same volume, thereby increasing the overall energy density and extending the vehicle's range. Furthermore, the compact design helps reduce vehicle weight and improve energy efficiency.

[0021] 8) The battery case is primarily constructed of rolled steel, offering cost advantages over traditional aluminum alloys. Furthermore, the integrated design reduces the number of components and assembly steps, lowering production costs and cycle time. Furthermore, the excellent processability of rolled steel facilitates automated production, improving efficiency.

[0022] 9) The roll-formed steel tank's mounting points are welded using separate lifting lugs, making it more versatile and compatible across different vehicle models and platforms. This allows for easier adaptation and installation when the battery system needs to be replaced or upgraded, reducing the complexity of vehicle design and manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the three-dimensional structure of the integrated battery box;

[0024] Figure 2 The figure is a schematic diagram of the connection between the bottom guard plate and the assembly frame;

[0025] Figure 3 Schematic diagram of the three-dimensional structure of the bottom guard plate;

[0026] Figure 4 It is a top view of the structure of the finished battery box;

[0027] Figure 5 This is the cross-sectional view at AA;

[0028] Figure 6 This is the cross-sectional view at BB.

[0029] In the figure: 1. Assembly frame; 2. Liquid cooling plate; 3. Bottom guard plate; 4. Frame beam; 5. Middle beam; 6. Cold plate support beam; 7. Reinforcement rib; 8. Mounting bracket. DETAILED DESCRIPTION

[0030] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0031] See also Figures 1-6 A rolled steel water-cooled integrated battery box includes an integrated bottom guard plate 3, a liquid cooling plate 2, and an assembly frame 1. The liquid cooling plate 2 is embedded in the assembly frame 3, a water cooling channel is provided on the liquid cooling plate, and the bottom guard plate is provided at the bottom of the assembly frame; the assembly frame includes frame beams 4 located on all sides, an intermediate beam 5 and a cold plate support beam 6 are provided in the frame beams, the intermediate beam is located at the top of the liquid cooling plate, and the cold plate support beam is located at the bottom of the liquid cooling plate; this solution uses an integrated design to tightly combine the bottom guard plate, the liquid cooling plate and the assembly frame to form an integral structure. The frame beams, intermediate beams and cold plate support beams in the assembly frame each perform their respective functions, ensuring both the stable support of the battery pack and the effective fixation of the liquid cooling plate. This design makes the battery support and the liquid cooling plate support independent of each other, avoiding mutual interference, thereby significantly improving the overall structural support strength and enhancing the vibration and impact resistance of the battery box.

[0032] In a preferred embodiment, the bottom guard plate 3 is made of steel and has upwardly projecting reinforcement ribs 7. This design not only provides solid bottom protection, preventing direct damage to the battery case from external impacts, but also further enhances its rigidity and deformation resistance. This design helps improve the structural strength of the entire battery case, ensuring stability and safety under various complex operating conditions.

[0033] As a preferred embodiment, multiple intermediate beams 5 are arranged in a cross pattern. The middle portion of the intermediate beam located in the center of the assembly frame is bolted to the cold plate support beam. This cross-shaped arrangement of the intermediate beams, bolted to the cold plate support beam, not only improves the support provided by the intermediate beams to the liquid cold plate but also ensures more uniform stress distribution across the entire assembly frame. The bolted connection enhances reliability and maintainability, facilitating removal and replacement when necessary.

[0034] As a preferred embodiment, the bottoms of the frame's frame beams 4 and center beams 5 are connected to the bottom guard plate 3 using glue and rivets. The liquid cooling plate and the frame's cold plate support beam are riveted together, ensuring a secure connection while avoiding thermal deformation that might occur with welding. Furthermore, the riveted connection between the cold plate and the cold plate support beam ensures the stability and sealing of the cooling system.

[0035] As a preferred embodiment, mounting brackets 8 are symmetrically arranged on the outside of the assembly frame, facilitating the installation and securing of the battery box. This design allows the battery box to be easily adapted to different vehicle models and platforms, improving the product's versatility and market competitiveness.

[0036] In a preferred embodiment, the center beam 5 is a high-strength steel stamping. The frame beams and center beams are welded together to form the battery support frame. This material selection and process design not only ensure the overall strength of the battery box but also achieve lightweighting. The use of high-strength steel reduces material usage, reduces weight, and improves energy efficiency.

[0037] As a preferred embodiment, the liquid cooling plate 2 utilizes a 3003 brazed liquid cooling plate. Selecting this 3003 brazed liquid cooling plate as a cooling element ensures the efficiency and reliability of the cooling system. 3003 aluminum alloy has excellent thermal conductivity and processability. Through brazing, it is integrated with the housing to achieve precise cooling of the battery modules, improving the efficiency and safety of the battery pack.

[0038] In summary, this battery case has brought significant beneficial effects in terms of enhancing structural strength, optimizing connection process, improving installation convenience, achieving lightweight and improving cooling efficiency, further improving the overall performance of the rolled steel water-cooled integrated battery case.

[0039] The assembly process of this battery box is as follows:

[0040] 1) The battery case is primarily constructed from roll-formed steel. The side beams, center beam, mounting bracket, and cold plate support beam all utilize a roll-formed structure to enhance extrusion resistance. The rolled section can be laser-welded or high-frequency-welded to create a closed cross-section. The cold plate support beam is a high-strength steel stamping. The roll-formed length can be customized by laser cutting based on the product structure. The mounting bracket is welded and adjustable to suit the product configuration, facilitating the platform of the battery case.

[0041] 2) CMT welds side beams and cold plate support beams together to form the battery frame. The side beams and cold plate support beams are used to support the battery module and resist vibration and extrusion.

[0042] 3) At the bottom of the assembly frame, the bottom of the side beam and the cold plate support beam are connected with glue and rivets to ensure airtightness requirements and make the box meet the IP68 sealing standard;

[0043] 4) Connect the liquid cooling plate to the battery frame using blind rivets. Since the liquid cooling plate is mounted on the support beam of the assembly frame, the plate has a certain load-bearing capacity.

[0044] 5) After the liquid cold plate is assembled, the horizontal and vertical beams in the middle beam are assembled and connected. The horizontal and vertical beams are connected to the assembly frame through L-shaped angle connectors and CMT welding to improve the overall rigidity of the box and meet the mechanical performance requirements of the product.

[0045] 6): The middle parts of the cross beam and longitudinal beam in the middle beam are connected to the cold plate support beam with bolts.

[0046] It should be noted that in the description of the present invention, terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings. These are merely for ease of description and are not intended to indicate or imply that the device or component described must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] Furthermore, it should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0048] The term "comprise" or any other similar term is intended to cover non-exclusive inclusion, such that a process, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed or inherent to such process, article, or apparatus / device.

[0049] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

Claims

1. A rolled steel water-cooled integrated battery box, characterized by: It includes an integrated bottom guard plate, a liquid cooling plate, and an assembly frame. The liquid cooling plate is embedded in the assembly frame. A water cooling channel is provided on the liquid cooling plate. The bottom guard plate is arranged at the bottom of the assembly frame. The assembly frame includes frame beams located on all sides. An intermediate beam and a cold plate support beam are arranged in the frame beams. The intermediate beam is located at the top of the liquid cooling plate, and the cold plate support beam is located at the bottom of the liquid cooling plate.

2. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: The bottom guard plate is a steel bottom guard plate, and reinforcement ribs are provided on the steel bottom guard plate so as to protrude upward.

3. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: There are multiple intermediate beams distributed in a "cross" shape, and the middle part of the intermediate beam located in the middle of the assembly frame is connected to the cold plate support beam through bolts.

4. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: The frame beams and bottoms of the middle beams of the assembly frame are connected to the bottom guard plate by glue and rivets; the liquid cooling plate and the cold plate support beam of the assembly frame are riveted to each other.

5. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: Mounting brackets are symmetrically arranged on the outer side of the assembly frame.

6. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: The middle beam is a high-strength steel stamping part, and the frame beams and the middle beam are welded to each other to form a battery support frame.

7. The rolled steel water-cooled integrated battery box according to claim 1, characterized in that: The liquid cooling plate adopts 3003 brazed liquid cooling plate.

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