Sheet metal box body structure and battery pack

Abstract

The utility model discloses a sheet metal box body structure and battery pack, including tray, in-box girder, in-box plate, reinforcer and lifting lug, in-box liner plate is added in at least one position of lifting lug of tray, in-box liner plate is bending structure, can realize the three-layer connection of in-box liner plate bottom surface / side surface, tray, lifting lug spot welding, and can realize the in-box liner plate in-box liner plate bottom surface / side surface, tray, lifting lug spot welding. And the bottom surface of the Y-direction beam, the tray and the lifting lug are in three-layer spot welding connection. According to the structure, the tray inner beams and the tray outer lifting lugs can be effectively connected while the tray is locally added, the problem that the tray loses efficacy and cracks due to low yield strength of materials is avoided, safety performance is improved, the problem that local stress at the connecting positions of the tray and the lifting lugs is high is solved, the thickness of the tray materials can be further reduced, and weight and cost are reduced.

Description

Technical Field

[0001] This utility model relates to a sheet metal box structure and a battery pack, belonging to the field of battery pack sheet metal technology. Background Technology

[0002] As the heart of new energy vehicles, the overall structural safety and reliability of the battery pack are of paramount importance.

[0003] Currently, some electric vehicles use sheet metal for their battery pack enclosures, which are assembled by forming and welding parts. The sheet metal enclosure typically includes multiple mounting lugs, trays, internal beams, and other components. The mounting lugs transfer the battery pack load to the vehicle frame and are generally made of high-yield-strength steel. The trays are typically deep-drawn, possessing excellent ductility, deep-drawing properties, and drawability, but with relatively low yield strength. The internal beams, as the main load-bearing components within the enclosure, support the loads of the modules and other connecting parts, and are generally made of high-yield-strength steel.

[0004] Due to the shape of the lifting lugs, some areas of the battery pack housing cannot be directly connected to the lifting lugs via a three-layer resistance spot welding process. The lifting lugs, pallet, and internal beams cannot directly transfer the load to the lifting lugs. A pallet is needed as a transfer element, and while the pallet also needs to bear the load, its material has a lower yield strength due to its molding requirements. The internal beam structure is generally designed with a "U"-shaped cross-section, and as the main load-bearing structure, the beams need to ensure both strength and stiffness.

[0005] How to further solve and optimize existing problems, and how to improve the overall mechanical performance of the battery pack structure, are the key points and difficulties in the design, because they affect the safety and reliability of the battery pack and even the whole vehicle. Utility Model Content

[0006] The purpose of this utility model is to provide a sheet metal box structure and battery pack. The internal beam structure is stamped and then welded with sheet metal to improve strength and rigidity while reducing the thickness of the sheet metal.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] This utility model provides a sheet metal box structure, including a pallet, an inner beam, an inner panel, reinforcing members, and lifting lugs. The inner beam includes a Y-direction beam and an X-direction beam. An inner lining plate is welded to at least one lifting lug position on the pallet. The inner lining plate, the pallet, and the lifting lugs are connected in three layers by spot welding. The Y-direction beam and the X-direction beam at the lifting lug position are both welded to the inner lining plate.

[0009] Preferably, the pallet is formed by deep stamping of sheet metal, and multiple horizontal and vertical ribs are provided at the bottom.

[0010] Preferably, the inner lining of the box has a bent structure, and the bottom surface of the inner lining is connected to the pallet and the lifting lugs in three layers by spot welding, and the side surface of the inner lining is connected to the pallet and the lifting lugs in three layers by spot welding.

[0011] Preferably, the Y-direction beam includes a Y-direction front beam, a Y-direction rear beam, and a Y-direction middle beam, which are respectively welded to the two sides and the middle position of the tray;

[0012] The Y-direction central beam is formed by deep drawing. The inclined areas at both ends of the Y-direction central beam are broken during the blanking stage, and the hollow area in the middle of the Y-direction central beam stamping component is welded with reinforcing sheet metal.

[0013] The Y-shaped forward beam is formed by stamping and is composed of two layers of steel plate structures welded together. The bottom area between the two layers of steel plate structures is reinforced with sheet metal welded together. The sheet metal walls of the two ends of the Y-shaped forward beam extend to both sides and are welded to the tray surface.

[0014] The Y-direction rear beam is formed by stamping, with both ends bent downwards, and the bent extension area is connected to the side beam and the pallet surface; the bottom of the Y-direction rear beam is welded to the pallet with reinforcing sheet metal.

[0015] Preferably, the bottom regions of the Y-direction forward beam, Y-direction rear beam, and Y-direction middle beam are all semi-circular.

[0016] Preferably, the X-direction beam includes an X-direction side beam, an X-direction center beam, and an X-direction corner beam, which are welded to the two sides and the middle position of the pallet, respectively;

[0017] The X-direction side beam is formed by stamping, and a protrusion is formed on the X-direction side beam by stamping; several holes are opened on the X-direction side beam for fixing the wire harness;

[0018] The X-direction angle beam is welded to the corner of the pallet;

[0019] The top area of ​​the X-direction beam has an opening for fixing the wire harness, and the side has a ramp structure for wire exit.

[0020] Preferably, the lifting lug is made of three layers of sheet metal welded together, from bottom to top: bottom sheet metal one, bottom sheet metal two, and side connecting sheet metal. The bottom sheet metal two is stepped, with one end of the step connecting to the bottom of the tray and the other end welded to the bottom sheet metal one. The side connecting sheet metal is trapezoidal, with its bottom welded to the bottom sheet metal two and its side welded to the side surface of the tray.

[0021] Preferably, a through hole is provided between the second support sheet metal and the first support sheet metal, and a bushing is provided at the through hole. The battery pack and the vehicle end are installed and connected by bolts passing through the through hole and the inner hole of the bushing of the second support sheet metal and the first support sheet metal.

[0022] Preferably, the sheet metal box body structure further includes an X-direction strengthening beam, which connects the Y-direction front beam and the front lifting lug. The X-direction strengthening beam is used for installing electrical components and transferring the module load to the front lifting lug through the Y-direction front beam and the X-direction strengthening beam.

[0023] The present utility model also provides a battery pack, which adopts the above sheet metal box body structure.

[0024] The beneficial effects of the present utility model are as follows:

[0025] (1) The present utility model provides a sheet metal box body structure, in which the beam structure is stamped with specific rib positions, which is beneficial to forming and effectively preventing springback after stamping, and at the same time enhances the structure.

[0026] (2) In the sheet metal box body structure of the present utility model, after the beam structure is stamped, at least one place is added with sheet metal welding, which is equivalent to adding rib positions and enhancing the stiffness. Compared with the "U" beam structure, after adding sheet metal welding, under the same material thickness, the moment of inertia of this section is increased greatly, improving the strength and stiffness while also providing a way to reduce the sheet material thickness. Through structural increase and material thickness reduction, lightweight is achieved.

[0027] (3) In the sheet metal box body structure of the present utility model, at least one lifting lug position of the tray has an inner box lining plate added inside. Through resistance spot welding, it not only increases the tray locally but also effectively connects the inner beam of the tray with the outer lifting lug of the tray, avoiding the problem of failure cracking of the tray caused by the low yield strength of the material, improving the safety performance, solving the situation of high local stress at the connection between the tray and the lifting lug, and further reducing the tray material thickness, reducing weight and cost.

[0028] (4) The sheet metal box body structure provided by the present utility model can achieve complex shapes and structures through mature processes such as stamping and bending to improve space utilization rate. Through structural design, multi-directional weight reduction is achieved, enabling the steel sheet metal box body structure to have the lightweight advantage that general steel sheet metal box bodies do not have to a certain extent. The process maturity of the present utility model is high, with the lightweight structure advantage under the same material, further effectively controlling costs and improving product competitiveness. Brief Description of the Drawings

[0029] Figure 1 It is a schematic diagram of the sheet metal box body structure provided by the present utility model;

[0030] Figure 2 It is an exploded view of the sheet metal box body structure provided by the present utility model;

[0031] Figure 3 It is a schematic diagram of the inner box lining plate in the sheet metal box body structure provided by the present utility model;

[0032] Figure 4The diagram shows the Y-direction beam in the sheet metal box structure provided by this utility model. (a) is the middle beam in the Y direction, (b) is the front beam in the Y direction, and (c) is the rear beam in the Y direction.

[0033] Figure 5 The following is a schematic diagram of the X-direction beam in the sheet metal box structure provided by this utility model: (a) is the X-direction side beam, (b) is a schematic diagram of the welding of the X-direction side beam, (c) is the X-direction corner beam, and (d) is the X-direction center beam.

[0034] Figure 6 A schematic diagram showing the connection of the lifting lugs, tray, inner lining plate, and inner beam in the sheet metal box structure provided by this utility model;

[0035] Figure 7 The following are schematic diagrams of the welding of the lifting lugs in the sheet metal box structure provided by this utility model: (a) is a schematic diagram of the welding of the lifting lugs and the pallet, and (b) is a schematic diagram of the welding of the three-layer sheet metal parts of the lifting lugs.

[0036] Figure 8 A schematic diagram of the installation of the X-direction reinforcing beam structure in the sheet metal box structure provided by this utility model. Detailed Implementation

[0037] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The embodiments described below with reference to the accompanying drawings are illustrative and intended to explain this utility model, and should not be construed as limiting this utility model.

[0038] In the description of this utility model, it should be noted that the terms "upper", "lower", "front", "rear", "end", "bottom", "side", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0039] In this utility model, unless otherwise explicitly specified and limited, the terms "connection," "installation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a direct connection, or a connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0040] Secondly, the term "an embodiment" or "embodiment" as used in this utility model refers to a specific feature, structure, or characteristic that can be included in at least one implementation of this utility model. The phrase "in an embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0041] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0042] This utility model provides a sheet metal box structure, see [link / reference] Figure 1 and Figure 2 The sheet metal box structure mainly includes a pallet 3, internal beams, internal panels, reinforcing parts, lifting lugs 8, and welded nuts / studs, etc., all of which are assembled by welding. The internal beams include Y-direction beams and X-direction beams. The Y-direction beams include a front Y-direction beam 4, a rear Y-direction beam 6, and a middle Y-direction beam 5. The X-direction beams include an edge X-direction beam 2, a middle X-direction beam 7, and a corner X-direction beam 1. The edge X-direction beams and the middle X-direction beams are perpendicular to the Y-direction beams.

[0043] In this invention, the pallet is formed by deep stamping of sheet metal, and multiple horizontal and vertical ribs are provided at the bottom to enhance the structure and effectively transfer the load.

[0044] Furthermore, an inner lining plate 13 is welded to at least one lifting lug location on the pallet, see [reference]. Figure 3 The inner lining plate 13 of the pallet features a bent structure, which can be easily formed through stamping or bending processes. The inner lining plate is resistance-spot welded, enhancing the local strength of the pallet while effectively connecting the inner beams to the outer lifting lugs. This prevents the pallet from failing and cracking due to the low yield strength of the material, improving safety performance and resolving the issue of excessive local stress at the connection point between the pallet and the lifting lugs. This design further reduces the pallet material thickness and weight, providing a new approach to lightweight design.

[0045] See Figure 2 and Figure 4 The Y-direction beam includes a Y-direction front beam, a Y-direction rear beam, and a Y-direction middle beam, which are welded to the two sides and the middle of the pallet, respectively.

[0046] See Figure 4 In (a), the Y-direction central beam is deep-stamped. Considering the difficulty of the forming process, the inclined areas at both ends are broken during the blanking stage to facilitate forming, and then the structure is reinforced by welding. At the same time, the hollow area in the middle of the Y-direction central beam-stamped component 51 is reinforced by welding and sheet metal, that is, the Y-direction central beam-reinforcing component 52 in (a) is conducive to strengthening the structure and can appropriately reduce the material thickness, which is beneficial to cost control and weight reduction.

[0047] See Figure 4 In (b), the Y-beam is stamped and formed, consisting of two layers of steel plates welded together (i.e., Y-beam-stamped component 41 in the figure). Simultaneously, reinforced sheet metal is welded to the bottom area between the Y-beam-stamped component 41, i.e., Y-beam-reinforcement component 42 in (b), which enhances the structure and increases its strength. The sheet metal walls extending to both ends are welded to the tray surface, increasing the welding area and helping to reduce and control stress at the connection points.

[0048] Furthermore, at least one additional reinforcing sheet metal is added to the bottom of the Y-beam-reinforcing member 42, namely... Figure 2 Central Y-beam forward-facing beam - reinforcement component 243.

[0049] See Figure 4 (c) The Y-direction rear beam, through a stamping structure, avoids the high-pressure insert functional area while simultaneously fulfilling the module installation function. Its downward bends at both ends enhance the structural rigidity at the two corners of the pallet and other connecting edges. The extended bend area facilitates connection with the side beams and the pallet surface, improving collision resistance. Simultaneously, the welded joint between the bottom of the Y-direction rear beam and the pallet is reinforced with sheet metal. Figure 2 The Y-direction rear beam - reinforcement member 62 is beneficial for strengthening the structure.

[0050] Furthermore, the bottom areas of the Y-direction front beam, Y-direction rear beam, and Y-direction middle beam are all made with semi-circular features, which facilitates the placement and positioning of the heating system or insulation system and improves efficiency.

[0051] See Figure 2 and Figure 5 The X-direction beam includes an X-direction side beam, an X-direction center beam, and an X-direction corner beam. The X-direction side beam and the X-direction center beam are perpendicular to the Y-direction beam and are welded to the sides and the middle of the tray, respectively.

[0052] See Figure 5 In (a) and (b), the X-direction side beam is stamped and formed, and the height difference of the profiles at both ends enables the construction of the plate surface. It can be effectively connected by welding. The stamped convex area on the X-direction side beam strengthens the box body. Several holes are opened on the X-direction side beam to fix the wire harness and facilitate the quality of electrophoresis.

[0053] See Figure 5 In section (c), the X-direction corner beam is used for welding to the corner of the pallet to protect the corner position of the pallet and strengthen the beam connection structure.

[0054] See Figure 5 In section (d), the X-direction beam enhances the connection structure. An opening in the top area allows for wire harness installation and fixation. A ramp structure (see arrow) is incorporated on the side to accommodate the wire harness, meeting the requirements for bottom heating and wire exit while also reinforcing the structure and preventing issues such as springback during mass production. This invention utilizes the X-direction beam for wire exit and wiring harness routing to improve space utilization.

[0055] In this utility model, the connection method of the lifting lugs, pallet, inner lining plate, and inner beam is described in [reference needed]. Figure 6Inside the pallet 3, an inner liner 13 is welded to the position opposite to the lifting lug 8. The inner liner 13 has a bent structure. Both the X-direction side beam 2 and the Y-direction center beam 5 are welded to the inner liner 13, with the Y-direction center beam 5 positioned between the two X-direction side beams 2. Furthermore, the bottom surface of the inner liner 13, the pallet, and the lifting lug are connected by spot welding in three layers, as are the sides of the inner liner 13, the pallet, and the lifting lug; the bottom surface of the Y-direction center beam 5, the pallet, and the lifting lug are also connected by spot welding in three layers. This connection structure facilitates the effective connection between the lifting lug and the Y-direction center beam. The use of high-strength steel in the inner liner locally reinforces the pallet with its lower yield strength, reducing the risk of cracking of the lower yield strength pallet during vehicle operation and improving safety performance.

[0056] Further, see Figure 7 In (a), the lifting lug is made of three layers of sheet metal welded together; see details below. Figure 7 In section (b), from bottom to top, there are three sheet metal components: a base support sheet metal one, a base support sheet metal two, and a side connecting sheet metal. Base support sheet metal two is stepped, with one end connecting to the bottom of the tray and the other end welded to base support sheet metal one. The side connecting sheet metal is trapezoidal, welded to base support sheet metal two at the bottom and to the side of the tray at the side. Additionally, a through hole is provided between base support sheet metal two and base support sheet metal one, with a bushing added for reinforcement. The battery pack is installed and connected to the vehicle end by bolts passing through the through hole in base support sheet metal two and base support sheet metal one, as well as the inner hole of the bushing. This structure facilitates reinforcement of the connection structure with the vehicle.

[0057] Furthermore, this utility model also includes an X-direction reinforcing beam structure, see [link / reference]. Figure 8 The X-direction reinforcing beam 10 connects to the Y-direction forward beam 4 and the front lifting lug, and is pre-installed. Electrical component sheet metal brackets 11 and 12 have mounting nuts at the bottom; their stamped structure facilitates connection to the housing pallet and the X-direction reinforcing beam 10. The BMS mounting plate 9 is pre-connected to welding studs and then welded to the housing pallet, achieving a simple and efficient BMS connection structure.

[0058] This X-direction reinforcing beam structure can not only install electrical components, but also transfer the module load to the front hanger lug through the Y-direction front beam and the X-direction reinforcing beam via reinforced connections. Furthermore, in complex conditions such as side impacts, the front hanger lug can reduce intrusion into the box body and mitigate risks and asset losses through the internal beam connection structure.

[0059] Through the above structural design, this utility model achieves multi-faceted weight reduction, giving the steel sheet metal box structure a lightweight advantage that general steel sheet metal boxes do not possess, thereby further effectively controlling costs and improving product competitiveness.

[0060] Based on the above sheet metal housing structure, this utility model provides a battery pack that adopts the above sheet metal housing structure.

[0061] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of this utility model. Any modifications or equivalent substitutions that do not depart from the spirit and scope of this utility model should be covered within the protection scope of the claims of this utility model.

Claims

1. A sheet metal box structure, characterized in that, The system includes a pallet, internal beams, internal panels, reinforcing members, and lifting lugs. The internal beams include Y-direction beams and X-direction beams. An internal liner is welded to the pallet at at least one lifting lug location. The internal liner is connected to the pallet and the lifting lugs in a three-layer configuration by spot welding. The Y-direction beams and X-direction beams at the lifting lug locations are both welded to the internal liner. The Y-direction beam includes a Y-direction front beam, a Y-direction rear beam, and a Y-direction middle beam, which are welded to the two sides and the middle position of the tray, respectively. The Y-direction central beam is formed by deep drawing. The inclined areas at both ends of the Y-direction central beam are broken during the blanking stage, and the hollow area in the middle of the Y-direction central beam stamping component is welded with reinforcing sheet metal. The Y-shaped forward beam is formed by stamping and is composed of two layers of steel plate structures welded together. The bottom area between the two layers of steel plate structures is reinforced with sheet metal welded together. The sheet metal walls of the two ends of the Y-shaped forward beam extend to both sides and are welded to the tray surface. The Y-direction rear beam is formed by stamping, with both ends bent downwards, and the bent extension area is connected to the side beam and the pallet surface; the bottom of the Y-direction rear beam is welded to the pallet with reinforcing sheet metal; The X-direction beam includes an X-direction side beam, an X-direction center beam, and an X-direction corner beam, which are welded to the two sides and the middle position of the pallet, respectively. The X-direction side beam is formed by stamping, and a protrusion is formed on the X-direction side beam by stamping; several holes are opened on the X-direction side beam for fixing the wire harness; The X-direction angle beam is welded to the corner of the pallet; The top area of ​​the X-direction beam has an opening for fixing the wire harness, and the side has a ramp structure for wire exit.

2. The sheet metal box structure according to claim 1, characterized in that, The tray is formed by deep stamping of sheet metal, and multiple horizontal and vertical ribs are provided on the bottom.

3. The sheet metal box structure according to claim 1, characterized in that, The inner lining of the box has a bent structure. The bottom surface of the inner lining is connected to the pallet and the lifting lugs in three layers by spot welding. The side surface of the inner lining is also connected to the pallet and the lifting lugs in three layers by spot welding.

4. The sheet metal box structure according to claim 1, characterized in that, The bottom areas of the Y-shaped front beam, Y-shaped rear beam, and Y-shaped middle beam are all semi-circular.

5. A sheet metal box structure according to claim 1, characterized in that, The lifting lug is made of three layers of sheet metal welded together. From bottom to top, they are bottom sheet metal one, bottom sheet metal two, and side connecting sheet metal. The bottom sheet metal two is stepped. One end of the bottom sheet metal two is connected to the bottom of the tray, and the other end is welded to the bottom sheet metal one. The side connecting sheet metal is trapezoidal. The bottom is welded to the bottom sheet metal two, and the side is welded to the side surface of the tray.

6. A sheet metal box structure according to claim 5, characterized in that, A through hole is provided between the second support sheet metal and the first support sheet metal, and a bushing is provided at the through hole. The battery pack and the vehicle end are installed and connected by bolts passing through the through hole and the inner hole of the bushing of the second support sheet metal and the first support sheet metal.

7. A sheet metal box structure according to claim 1, characterized in that, The sheet metal box structure also includes an X-direction reinforcing beam, which connects the Y-direction forward beam and the front lifting lug. The X-direction reinforcing beam is used to install electrical components and to transfer the module load to the front lifting lug through the Y-direction forward beam and the X-direction reinforcing beam.

8. A battery pack, characterized in that, The sheet metal box structure described in any one of claims 1 to 7 is adopted.

Images