Multi-layer steel-aluminum hybrid battery box body

Abstract

The utility model discloses a multi-layer steel-aluminum hybrid battery box. The multi-layer steel-aluminum hybrid battery box comprises an aluminum alloy frame, a plurality of high-strength steel laminates, a plurality of battery modules, an aluminum alloy sealing plate and a door cover, a cavity and a dismounting opening communicated with the cavity are defined by the aluminum alloy frame. The high-strength steel laminates divide the cavity into a plurality of module cavities, and the high-strength steel laminates are detachably connected to the aluminum alloy frame through fasteners. And each battery module is arranged in the corresponding module cavity. The aluminum alloy sealing plate is connected to the aluminum alloy frame. According to the multi-layer steel-aluminum hybrid battery box disclosed by the invention, a plurality of battery modules are arranged in the box instead of battery packs, so that the height of the whole box can be effectively reduced, and more space is saved. And the box body is made of the combination of the aluminum alloy frame and the high-strength steel laminates, so that the box body is low in production cost compared with an all-aluminum material, is light in weight compared with an all-steel material, is convenient to transport and can stably support the battery module, and on the premise of ensuring the structural strength, the cost is reduced, and the cruising ability of the electric vehicle using the box body is improved.

Description

A multi-layer steel-aluminum hybrid battery box Technical Field

[0001] This utility model relates to the field of energy storage technology, and in particular to a multi-layer steel-aluminum hybrid battery box. Background Technology

[0002] In existing technologies, battery boxes mostly adopt a multi-layer frame structure to house the battery pack, resulting in a high overall height, large space occupation, and large battery cavity design dimensions. The boxes in existing technologies are mostly made of all-aluminum alloy. While aluminum alloy is lightweight, it has poor hardness. To ensure the structural strength of the box, thicker layers are required in the frame, further increasing the height of the battery box. Furthermore, the high cost of aluminum alloy leads to a high overall production cost for energy storage.

[0003] Existing technologies also use all-steel enclosures. Steel is stronger and cheaper than aluminum alloy, but it is also heavier. This makes the entire energy storage system very heavy, which makes it inconvenient to transport and indirectly reduces the range of electric vehicles using the system.

[0004] In view of the above, this utility model is hereby proposed. Summary of the Invention

[0005] To solve one of the above-mentioned technical problems, this utility model provides a multi-layer steel-aluminum hybrid battery box.

[0006] The present invention adopts the following technical solution:

[0007] A multi-layer steel-aluminum hybrid battery casing, comprising:

[0008] An aluminum alloy frame, wherein the aluminum alloy frame encloses a cavity and a disassembly port communicating with the cavity;

[0009] Multiple high-strength steel shelves are provided, each of which is located within the cavity and is arranged sequentially along the height of the aluminum alloy frame. The high-strength steel shelves divide the cavity into multiple modular cavities. The high-strength steel shelves are detachably connected to the aluminum alloy frame by fasteners.

[0010] Multiple battery modules, each of which is disposed in a corresponding module cavity;

[0011] An aluminum alloy sealing plate, which is connected to the aluminum alloy frame;

[0012] A door cover, which is detachably connected to the aluminum alloy frame to close the disassembly port, and the door cover and the aluminum alloy sealing plate cooperate to close the cavity.

[0013] Optionally, the aluminum alloy frame includes a bottom frame, a rear frame, a top frame, and two side frames;

[0014] The rear frame and the two side frames are all connected to the bottom frame. The two side frames are located on both sides of the bottom frame. The rear frame is located between the two side frames and is connected to the two side frames respectively. The top frame is connected to the rear frame and the two side frames respectively.

[0015] The bottom frame, rear frame, top frame, and two side frames enclose and form the cavity and disassembly / assembly port;

[0016] A module cavity is formed between adjacent pairs of the bottom frame, the top frame, and each of the high-strength steel layers;

[0017] Each of the high-strength steel shelves is located between the two side frames, and the high-strength steel shelves are respectively connected to the side frames on both sides by fasteners.

[0018] Optionally, the side frame has multiple crossbeams;

[0019] Each of the aforementioned crossbeams is arranged at intervals along the height direction of the aluminum alloy frame;

[0020] The high-strength steel plate is supported on corresponding crossbeams on both sides;

[0021] Fasteners pass through the high-strength steel plate and are connected to the crossbeam.

[0022] Optionally, rivet nuts are provided on the crossbeam;

[0023] The fastener includes a stud and a nut connecting the stud, the stud passing through the high-strength steel plate and connected to the rivet nut, and the nut being confined to the high-strength steel plate.

[0024] Optionally, the side frame has multiple uprights, and each of the crossbeams is connected to the uprights;

[0025] The high-strength steel plate has multiple extended sections along its edge, and a clearance gap is formed between adjacent extended sections. The column passes through the clearance gap.

[0026] The extension piece is supported on the crossbeam and is connected to the crossbeam by fasteners.

[0027] Optionally, the aluminum alloy sealing plate includes an aluminum alloy skin and an aluminum alloy layer plate;

[0028] The aluminum alloy skin covers the top frame, side frames, and rear frame;

[0029] The aluminum alloy shelf covers the side of the bottom frame near the top frame.

[0030] Optionally, the aluminum alloy shelf extends beyond the rear frame and the side frame;

[0031] The aluminum alloy layer and the aluminum alloy skin are in contact and sealed by welding.

[0032] Optionally, the surface of the high-strength steel plate is provided with multiple hollowed-out grooves.

[0033] Optionally, a through hole is provided on the side of the high-strength steel plate near the disassembly port.

[0034] Optionally, the multi-layer steel-aluminum hybrid battery housing includes a sealing gasket;

[0035] The sealing gasket is located between the door cover and the aluminum alloy frame;

[0036] The sealing gasket seals the gap between the door cover and the aluminum alloy frame.

[0037] By adopting the above technical solution, this application has the following beneficial effects:

[0038] This application discloses a multi-layered steel-aluminum hybrid battery box that houses multiple battery modules instead of a battery pack, effectively reducing the overall height of the box and saving considerable space. Furthermore, the combination of an aluminum alloy frame and high-strength steel shelves results in lower production costs compared to all-aluminum construction, and is lighter and easier to transport than all-steel construction, while providing stable support for the battery modules. This design reduces costs and improves the range of electric vehicles using the box while ensuring structural strength.

[0039] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings. Attached Figure Description

[0040] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments and descriptions of the present invention are used to explain the present invention, but do not constitute an undue limitation of the present invention. Obviously, the drawings described below are merely some embodiments; those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings:

[0041] Figure 1 is a schematic diagram of the multi-layer steel-aluminum hybrid battery box without the connecting door cover and aluminum alloy skin provided in the embodiment of this application;

[0042] Figure 2 is a schematic diagram of the aluminum alloy frame and fasteners of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0043] Figure 3 is a schematic diagram of the high-strength steel layer of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0044] Figure 4 is a schematic diagram of the aluminum alloy skin of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0045] Figure 5 is a structural schematic diagram of the door cover and sealing gasket of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0046] Figure 6 is an enlarged view of a portion of the aluminum alloy frame of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0047] Figure 7 is a cross-sectional view of the fastener connection between the high-strength steel layer plate and the crossbeam of the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application;

[0048] Figure 8 is a partial enlarged view of the high-strength steel layer plate near the disassembly port in the multi-layer steel-aluminum hybrid battery box provided in the embodiment of this application.

[0049] In the diagram: Aluminum alloy frame 1, bottom frame 11, rear frame 12, top frame 13, side frame 14, crossbeam 141, rivet nut 1411, column 142, high-strength steel shelf 2, extension piece 21, connecting hole 211, clearance notch 22, hollowed-out groove 23, through hole 24, aluminum alloy skin 31, aluminum alloy shelf 32, door cover 4, fastener 5, stud 51, nut 52, sealing gasket 6.

[0050] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the present invention in any way, but rather to illustrate the concept of the present invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0052] In the description of this utility model, it should be noted that the terms "upper", "lower", "inner", "outer", 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, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0053] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0054] Referring to Figures 1 to 8, this application provides a multi-layer steel-aluminum hybrid battery box, including: an aluminum alloy frame 1, multiple high-strength steel shelves 2, multiple battery modules (not shown), an aluminum alloy sealing plate, and a door cover 4. The aluminum alloy frame 1 encloses a cavity and a disassembly / assembly port communicating with the cavity. Each of the high-strength steel shelves 2 is located within the cavity, and each of the high-strength steel shelves 2 is arranged sequentially along the height direction of the aluminum alloy frame 1. Each of the high-strength steel shelves 2 divides the cavity into multiple module cavities, and the high-strength steel shelves 2 are detachably connected to the aluminum alloy frame 1 by fasteners 5. The high-strength steel shelves 2 refer to shelves made of high-strength steel plates. High-strength steel plates have high strength, especially in the normalized or normalized and tempered state, exhibiting high comprehensive mechanical properties. The high-strength steel shelves 2 have significantly enhanced tensile strength compared to aluminum alloy shelves, can withstand greater pressure, and can maintain good shape stability and deformation capacity, increasing load-bearing capacity and service life. Each battery module is respectively housed within its corresponding module cavity. The aluminum alloy sealing plate is connected to the aluminum alloy frame 1. The door cover 4 is detachably connected to the aluminum alloy frame 1 to close the disassembly port, and the door cover 4 and the aluminum alloy sealing plate cooperate to close the cavity. The multi-layer steel-aluminum hybrid battery box of this application houses multiple battery modules instead of a battery pack, effectively reducing the overall height of the box and saving considerable space. Furthermore, the combination of an aluminum alloy frame and high-strength steel shelves results in lower production costs compared to all-aluminum materials, and is lighter and easier to transport than all-steel materials, while providing stable support for the battery modules. This reduces costs and improves the range of electric vehicles using the box while ensuring structural strength.

[0055] As shown in Figures 1 and 2, the aluminum alloy frame 1 includes a bottom frame 11, a rear frame 12, a top frame 13, and two side frames 14. The rear frame 12 and the two side frames 14 are all connected to the bottom frame 11. The two side frames 14 are located on both sides of the bottom frame 11, and the rear frame 12 is located between the two side frames 14 and connected to each of them. The top frame 13 is connected to both the rear frame 12 and the two side frames 14. The bottom frame 11, rear frame 12, top frame 13, and two side frames 14 enclose and form the cavity and disassembly / assembly port. The bottom frame 11, top frame 13, and adjacent high-strength steel plates 2 form module cavities, and each battery module is disposed within its corresponding module cavity. Each high-strength steel plate 2 is located between two side frames 14, and each high-strength steel plate 2 is connected to the side frames 14 on both sides by fasteners 5. In existing technologies, all-aluminum alloy and all-steel battery cases are typically connected using welding. Welding can cause deformation of the shelves, resulting in poor flatness of the battery module mounting surface and a significant reduction in the battery module's energy density. The multi-layer steel-aluminum hybrid battery case of this application connects the high-strength steel shelves 2 to the side frames 14 on both sides via fasteners 5, reducing deformation issues caused by welding and ensuring high flatness of the battery module mounting surface. This is crucial for improving the overall energy density of the battery pack. The high-strength steel shelves 2 are high-strength and low-cost, maintaining necessary structural strength while remaining relatively inexpensive, thus achieving economic optimization without sacrificing performance.

[0056] As shown in Figures 1 and 2, the side frame 14 has multiple crossbeams 141, which are spaced apart sequentially along the height direction of the aluminum alloy frame 1. The high-strength steel layer 2 is supported on the corresponding crossbeams 141 on both sides, and fasteners 5 pass through the high-strength steel layer 2 and are connected to the crossbeams 141. The multiple crossbeams 141 increase the structural strength of the side frame 14. The cold connection method of fastening reduces the deformation problem caused by welding, ensures the high flatness of the battery module mounting surface, and not only avoids the degradation of material properties caused by the heat-affected zone, but also simplifies the production process, improves assembly accuracy and consistency, and is conducive to improving the quality and reliability of the multi-layer steel-aluminum hybrid battery box of this application, and is also convenient to disassemble and assemble.

[0057] In one possible implementation, as shown in Figures 6 and 7, a rivet nut 1411 is provided on the crossbeam 141. The fastener 5 includes a stud 51 and a nut 52 connecting the stud 51. The stud 51 passes through the high-strength steel plate 2 and is connected to the rivet nut 1411, and the nut 52 is confined on the high-strength steel plate 2. The fastener 5 can be a bolt, and the rivet nut 1411 has a threaded groove. The stud 51 passes through the high-strength steel plate 2 and is threadedly connected to the threaded groove, and the nut 52 is confined to the side of the high-strength steel plate 2 opposite to the high-strength steel plate 2.

[0058] As shown in Figures 1, 2, and 3, the side frame 14 has multiple columns 142, and each of the crossbeams 141 is connected to the column 142. The column 142 is vertically connected to the crossbeam 141, and the staggered connection of the crossbeam 141 and the column 142 results in a high-strength structure. The high-strength steel plate 2 has multiple extension pieces 21 along its edge, with clearance notches 22 formed between adjacent extension pieces 21. The column 142 passes through the clearance notches 22. The extension pieces 21 are supported by the crossbeams 141 and are connected to the crossbeams 141 by fasteners 5. The extension pieces 21 have connecting holes 211, and the studs 51 of the fasteners 5 pass through the connecting holes 211 and are threaded into the threaded groove of the rivet nut 1411. The nut 52 is located on the side of the high-strength steel plate 2 away from the high-strength steel plate 2.

[0059] In one possible implementation, as shown in Figures 1 and 4, the aluminum alloy cover plate includes an aluminum alloy skin 31 and an aluminum alloy shelf 32. The aluminum alloy skin 31 covers the top frame 13, the side frame 14, and the rear frame 12, and the aluminum alloy shelf 32 covers the bottom frame 11 on the side closest to the top frame 13. The battery module on the module cavity closest to the bottom frame 11 is supported by the aluminum alloy shelf 32. The bottom frame 11 has high structural strength and can bear the weight of the battery module, thus increasing the load-bearing capacity of the aluminum alloy shelf 32 and making it less prone to deformation.

[0060] As shown in Figure 1, the aluminum alloy shelf 32 extends beyond the rear frame 12 and the side frame 14, facilitating contact with the aluminum alloy skin 31. The aluminum alloy shelf 32 and the aluminum alloy skin 31 are in contact and sealed by welding. The welded connection has good sealing performance, and the side frame 14 can at least be supported by the aluminum alloy shelf 32.

[0061] In one possible implementation, as shown in Figure 3, the surface of the high-strength steel plate 2 is provided with multiple perforated grooves 23. These perforated grooves 23 have a weight-reducing effect, maintaining the necessary structural strength of the high-strength steel plate 2 while also making it lighter.

[0062] As shown in Figures 3 and 8, a through hole 24 is provided on the side of the high-strength steel plate 2 near the disassembly port. The through hole 24 can be used to install a cable tie, which is used to fix the cable. The cable tie may include a cable loop through which the cable passes. The cable tie is connected to the through hole 24. The cable tie may be a cable tie.

[0063] In one possible implementation, as shown in FIG5, the multi-layer steel-aluminum hybrid battery case includes a sealing gasket 6. The sealing gasket 6 is located between the door cover 4 and the aluminum alloy frame 1. The sealing gasket 6 seals the gap between the door cover 4 and the aluminum alloy frame 1. The sealing gasket 6 has the function of sealing the gap between the door cover 4 and the aluminum alloy frame 1, ensuring the airtightness of the multi-layer steel-aluminum hybrid battery case of this application.

[0064] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A multi-layered steel-aluminum hybrid battery box, characterized in that, include: An aluminum alloy frame, wherein the aluminum alloy frame encloses a cavity and a disassembly port communicating with the cavity; Multiple high-strength steel shelves are provided, each of which is located within the cavity and is arranged sequentially along the height of the aluminum alloy frame. The high-strength steel shelves divide the cavity into multiple modular cavities. The high-strength steel shelves are detachably connected to the aluminum alloy frame by fasteners. Multiple battery modules, each of which is disposed in a corresponding module cavity; An aluminum alloy sealing plate is connected to the aluminum alloy frame; a door cover is detachably connected to the aluminum alloy frame to close the disassembly port, and the door cover and the aluminum alloy sealing plate cooperate to close the cavity.

2. The multi-layer steel-aluminum hybrid battery box according to claim 1, characterized in that, The aluminum alloy frame includes a bottom frame, a rear frame, a top frame, and two side frames. The rear frame and the two side frames are connected to the bottom frame. The two side frames are located on both sides of the bottom frame. The rear frame is located between the two side frames and is connected to both side frames. The top frame is connected to the rear frame and the two side frames. The bottom frame, rear frame, top frame, and two side frames enclose and form the cavity and disassembly / assembly port. A module cavity is formed between adjacent pairs of the bottom frame, top frame, and each of the high-strength steel shelves. Each of the high-strength steel shelves is located between the two side frames, and the high-strength steel shelves are respectively connected to the side frames on both sides by fasteners.

3. The multi-layer steel-aluminum hybrid battery box according to claim 2, characterized in that, The side frame has multiple crossbeams; each crossbeam is arranged at intervals along the height direction of the aluminum alloy frame; the high-strength steel shelf is supported on the corresponding crossbeams on both sides; fasteners pass through the high-strength steel shelf and are connected to the crossbeams.

4. The multi-layer steel-aluminum hybrid battery box according to claim 3, characterized in that, A rivet nut is provided on the crossbeam; the fastener includes a stud and a nut connecting the stud, the stud passes through the high-strength steel plate and is connected to the rivet nut, and the nut is confined to the high-strength steel plate.

5. The multi-layer steel-aluminum hybrid battery box according to claim 3, characterized in that, The side frame has multiple uprights, and each of the crossbeams is connected to the uprights; the high-strength steel shelf has multiple extension pieces along its edge, and a clearance gap is formed between adjacent extension pieces, through which the uprights pass; the extension pieces are supported by the crossbeams, and the extension pieces are connected to the crossbeams by fasteners.

6. The multi-layer steel-aluminum hybrid battery box according to claim 2, characterized in that, The aluminum alloy cover plate includes an aluminum alloy skin and an aluminum alloy shelf; the aluminum alloy skin covers the top frame, side frame and rear frame; the aluminum alloy shelf covers the bottom frame on the side near the top frame.

7. The multi-layer steel-aluminum hybrid battery box according to claim 6, characterized in that, The aluminum alloy shelf extends out of the rear frame and the side frame; the aluminum alloy shelf and the aluminum alloy skin are in contact and sealed by welding.

8. The multi-layer steel-aluminum hybrid battery box according to any one of claims 1-7, characterized in that, The surface of the high-strength steel plate has multiple hollowed-out grooves.

9. The multi-layer steel-aluminum hybrid battery case according to any one of claims 1-7, characterized in that, The high-strength steel plate has a through hole on the side near the disassembly port.

10. The multi-layer steel-aluminum hybrid battery case according to any one of claims 1-7, characterized in that, Includes a sealing gasket; the sealing gasket is located between the door cover and the aluminum alloy frame; the sealing gasket seals the gap between the door cover and the aluminum alloy frame.

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