Rolling battery case boundary beam

Abstract

The utility model relates to a rolling battery shell edge beam, which is formed by rolling and forming a steel belt, the section of the rolling battery shell edge beam is an integrated section shaped like a Chinese character'mu ', the rolling battery shell edge beam comprises a first closed cavity, a second closed cavity and a third closed cavity which are arranged in sequence, and the first closed cavity and the second closed cavity are separated by a first reinforcing vertical rib; the second closed cavity and the third closed cavity are separated through a second reinforcing vertical rib, the first closed cavity and the third closed cavity share one upper end face, and the first closed cavity and the second closed cavity share one first lower end face. The section structure of the edge beam is formed by the steel belt through roll bending, the forming mode is simple, the number of working procedures is small, the technology is simple, the section shaped like the Chinese character'mu 'can be achieved without the working procedures such as section tailor welding and repair welding, the structure is novel, strength is high, and practicability is high.

Description

Technical Field

[0001] The utility model relates to a roll - pressed battery case side beam, belonging to the technical field of automotive battery profiles. Background Art

[0002] As a core component of new - energy vehicles, the battery pack is of particular importance in terms of safety. The battery pack mainly includes a battery case, an electronic control unit, a water - cooled plate, and battery modules. The battery case is mainly composed of a battery case side beam, a middle beam, a cover plate, and a support plate. At present, the battery cases are mainly made of aluminum products. When a vehicle has a side collision, due to the low strength of aluminum profiles, they are prone to deformation. The side beam has low bending resistance and is likely to damage the battery modules, causing the battery to catch fire or explode, seriously endangering the safety of passengers. Moreover, the cost of aluminum extrusion profiles is high, and there are many processes when processing them into battery case side beams, resulting in a high cost for aluminum - made battery case side beams. In addition, the cross - sections of common profiles generally adopt multi - roll - pressed profiles for welding. There are many weld seams, it is difficult to control welding deformation, the overall accuracy of parts is poor, and the process of the welded roll - pressed beam is complex and costly. Therefore, for the battery case side beam of new - energy vehicles, how to improve the rigidity and anti - deformation performance of the battery case side beam, enhance safety, and reduce processing costs has become the research direction of researchers. Content of the Utility Model

[0003] In order to overcome the drawbacks of the prior art, the utility model provides a roll - pressed battery case side beam, which is formed by roll - bending a single steel strip. The forming method is simple, with fewer processes and a simple technology. It can achieve a rectangular - shaped cross - section without processes such as cross - section welding and repair welding. It has a novel structure, high strength, and strong practicability.

[0004] The technical solution adopted by the utility model to solve its technical problems is as follows:

[0005] A roll - pressed battery case side beam, the battery case side beam is formed by roll - bending a single steel strip, and its cross - section is an integral rectangular - shaped cross - section, including a first closed cavity, a second closed cavity, and a third closed cavity arranged in sequence. The first closed cavity and the second closed cavity are separated by a first strengthening vertical rib, the second closed cavity and the third closed cavity are separated by a second strengthening vertical rib, the first closed cavity and the third closed cavity share an upper end surface, and the first closed cavity and the second closed cavity share a first lower end surface.

[0006] For the above - mentioned roll - pressed battery case side beam, the second closed cavity is enclosed by the first strengthening vertical rib, an upper inner rib, the second strengthening vertical rib, and the first lower end surface. The second contact point of the upper inner rib and the upper end surface is welded and fixed. The end of the first strengthening vertical rib is roll - bent and extended to form a first flanging rib, and the first contact point of the first flanging rib and the first lower end surface is welded by laser penetration welding. The end of the first lower end surface is roll - bent and extended to form a second flanging rib, and the third contact point of the second flanging rib and the second strengthening vertical rib is welded by laser penetration welding.

[0007] For the above-mentioned roll-formed battery case side beam, the lengths of the first flanging rib and the second flanging rib are both greater than or equal to 4 mm.

[0008] For the above-mentioned roll-formed battery case side beam, the first closed cavity is enclosed by an upper end face, a first side face, a first lower end face and a first strengthening vertical rib.

[0009] For the above-mentioned roll-formed battery case side beam, the third closed cavity is enclosed by an upper end face, a second side face, a second lower end face and a second strengthening vertical rib.

[0010] For the above-mentioned roll-formed battery case side beam, a first step is provided at the upper end face located at the upper end of the third closed cavity, and the height difference D of the first step matches the thickness of the battery case cover plate; there is a second step between the second lower end face and the first lower end face, and the height difference S of the second step is consistent with the thickness of the battery case support plate.

[0011] For the above-mentioned roll-formed battery case side beam, the first flanging rib and the first strengthening vertical rib are roll-bent and formed, and the included angle α at the roll-bent part is 45° - 150°; the first strengthening rib and the upper inner rib are roll-bent and formed, and the included angle β at the roll-bent part is 45° - 150°; the upper inner rib and the second strengthening vertical rib are roll-bent and formed, and the included angle γ at the roll-bent part is 30 - 150°.

[0012] For the above-mentioned roll-formed battery case side beam, the upper inner rib and the upper end face are welded by laser penetration welding or roll spot welding.

[0013] Advantages of the present utility model:

[0014] 1. The cross-section of the battery case side beam of the present utility model is an integral box-shaped cross-section. This cross-section is a brand-new cross-section, which is formed by roll-bending a steel strip. The forming method is simple, with few processes and simple technology. The box-shaped cross-section can be achieved without processes such as cross-section splicing and welding repair. It has a novel structure, high strength and strong practicability.

[0015] 2. Adopting a brand-new complex winding method, by this winding method, a vehicle coordinate Z-direction strengthening rib is added, which is beneficial to improving the Z-direction anti-deformation ability of the battery case. At the same time, the number of Y-direction chambers is increased, effectively reducing the deformation of the cross beam during collision, and achieving the strengthening of the strength in both Y and Z directions with one cross-section.

[0016] 3. Two strengthening vertical ribs are arranged in the middle of this cross-section, effectively guiding the Y-direction radial crushing sequence and stability of the product. At the same time, the three-chamber structure increases the Z-direction supporting force.

[0017] 4. The lap joint of the second flanging rib and the second strengthening vertical rib is welded by laser penetration welding, effectively increasing the axial static pressure reaction force and Z-direction supporting force of the product; the establishment of the first strengthening vertical rib, the second flanging rib and the second strengthening vertical rib can effectively improve the seat support and the axial reaction force of the cross beam.

[0018] 5. The installation of the first flange can improve the compliance of vehicle side impact regulations.

[0019] 5. The upper end face and the upper inner rib are laser-penetrating welded or roller spot welded, which effectively solves the problem of connecting the two ribs in the closed cavity.

[0020] 6. A first step is provided on the upper end surface, and the height difference D of the first step matches the thickness of the battery case cover plate; there is a second step between the second lower end surface and the first lower end surface, and the height difference S of the second step is consistent with the thickness of the battery case support plate. The two steps can fit tightly with the upper and lower plates of the battery case to ensure the airtightness of the product.

[0021] 7. This cross-section is made of steel, which has the advantages of high strength, small thickness, high melting point and high safety compared with aluminum profiles under the same performance conditions. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings.

[0023] Figure 1 This is a schematic diagram of the battery casing side beam structure of this utility model;

[0024] Figure 2 A schematic diagram of a cross-sectional structure for the side beam of a battery casing;

[0025] Figure 3 This is a schematic diagram of another type of roller-punched edge beam structure;

[0026] Figure 4 This is a schematic diagram of the overlapping structure between the battery casing side beam and the upper and lower cover plates of the battery casing.

[0027] Figure 5 This is a schematic diagram of the assembled battery pack frame structure.

[0028] In the diagram: 1. Top end face; 2. Upper inner rib; 3. Second side face; 4. Second lower end face; 5. Second reinforcing vertical rib; 6. Second flange rib; 7. First reinforcing vertical rib; 8. First flange rib; 9. First lower end face; 10. First side face; 11. Mounting hole; 201. First enclosed cavity; 202. Second enclosed cavity; 203. Third enclosed cavity; 101. First contact point; 102. Second contact point; 103. Third contact point. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings.

[0030] See Figure 1 and Figure 2, the utility model relates to a rolled battery case side beam, which is formed by rolling a steel strip. Its cross-section is an integral eye-shaped cross-section, including a first closed cavity 201, a second closed cavity 202 and a third closed cavity 203 arranged in sequence. The first closed cavity 201 and the second closed cavity 202 are separated by a first reinforcing vertical rib 7, and the second closed cavity 202 and the third closed cavity 203 are separated by a second reinforcing vertical rib 5. The first closed cavity 201 and the third closed cavity 203 share an upper end face 1, and the first closed cavity 201 and the second closed cavity 202 share a first lower end face 9. According to actual needs, the shapes of the first closed cavity 201, the second closed cavity 202 and the third closed cavity 203 can be triangular, rectangular or trapezoidal. The structure has various changes, can adapt to various boundaries, and at the same time increases the strength and improves the structural strength and stability. The first closed cavity 201 is surrounded by the upper end face 1, the first side face 10, the first lower end face 9 and the first reinforcing vertical rib 7. The second closed cavity 202 is surrounded by the first reinforcing vertical rib 7, the upper inner rib 2, the second reinforcing vertical rib 5 and the first lower end face 9. The third closed cavity 203 is surrounded by the upper end face 1, the second side face 3, the second lower end face 4 and the second reinforcing vertical rib 5.

[0031] The second contact point 102 between the upper inner rib 2 of the second closed cavity and the upper end face 1 is welded and fixed by laser penetration welding or roller spot welding; the end of the first reinforcing vertical rib 7 is rolled and extended to form a first flanging rib 8, and the first contact point 101 between the first flanging rib 8 and the first lower end face 9 is welded by laser penetration welding. The end of the first lower end face 9 is rolled and extended to form a second flanging rib 6, and the third contact point 103 between the second flanging rib 6 and the second reinforcing vertical rib 5 is welded by laser penetration welding.

[0032] See Figures 3 to 5 , another cross-section of the utility model, a first step is provided at the upper end face 1 located at the upper end of the third closed cavity 203, and the height difference D of the first step matches the thickness of the battery case cover plate; there is a second step between the second lower end face 4 and the first lower end face 9, and the height difference S of the second step is consistent with the thickness of the battery case support plate. The two steps can be closely fitted with the upper and lower plates of the battery case to ensure the airtightness of the product.

[0033] The battery casing side beam of this utility model is formed by one-piece roll forming. The roll forming sequence is as follows: the first flange rib 8 and the first reinforcing vertical rib 7 are roll formed, with the included angle α at the roll bend being 45°~150°; the first reinforcing rib 7 and the upper inner rib 2 are roll formed, with the included angle β at the roll bend being 45°~150°; the upper inner rib 2 and the second reinforcing vertical rib 5 are roll formed, with the included angle γ at the roll bend being 30°~150°; the second reinforcing vertical rib 5 and the second lower end face 4 are roll formed; the second lower end face 4 and the second side face 3 are roll formed; the second side face 3 and the upper end face 1 are roll formed; the upper end face 1 and the first side face 10 are roll formed; the first side face 10 and the first lower end face 9 are roll formed; the first lower end face 9 and the second flange rib 6 are roll formed. The lengths of the first flange rib 8 and the second flange rib 6 are both greater than or equal to 4mm. A first step can also be roll formed on the upper end face.

[0034] During the roll forming process, mounting holes 11 for the battery case side beam are formed on the side beam, avoiding the need to machine the mounting holes on the battery case side beam under the roll forming line, thus improving processing efficiency. After roll forming, other accessories for the battery case can be installed at the mounting hole positions.

[0035] The side beam of the battery casing of this utility model is made of high-strength steel or ultra-high-strength steel. The strength of the rolled material is 1180MPa or below, and the minimum radius of curvature (R) of the cross section is required to be greater than or equal to 3 times the material thickness. When the strength of the rolled material is greater than 1180MPa, the minimum radius of curvature (R) of the cross section is required to be greater than or equal to 4 times the material thickness.

Claims

1. A roll-formed battery casing side beam, characterized in that: The side beam of the battery case is formed by roll bending a steel strip, and its cross-section is an integral box-shaped cross-section, including a first closed cavity (201), a second closed cavity (202), and a third closed cavity (203) arranged in sequence. The first closed cavity (201) and the second closed cavity (202) are separated by a first reinforcing vertical rib (7), and the second closed cavity (202) and the third closed cavity (203) are separated by a second reinforcing vertical rib (5). The first closed cavity (201) and the third closed cavity (203) share an upper end face (1), and the first closed cavity (201) and the second closed cavity (202) share a first lower end face (9).

2. The roll-formed battery casing side beam according to claim 1, characterized in that: The second closed cavity (202) is enclosed by the first reinforcing vertical rib (7), an upper inner rib (2), the second reinforcing vertical rib (5), and the first lower end face (9). The second contact point (102) of the upper inner rib (2) and the upper end face (1) is fixed by laser penetration welding. The end of the first reinforcing vertical rib (7) is roll-bent and extended to form a first flanging rib (8), and the first contact point (101) of the first flanging rib (8) and the first lower end face (9) is welded by laser penetration welding. The end of the first lower end face (9) is roll-bent and extended to form a second flanging rib (6), and the third contact point (103) of the second flanging rib (6) and the second reinforcing vertical rib (5) is welded by laser penetration welding.

3. The roll-formed battery casing side beam according to claim 2, characterized in that: The lengths of the first flanging rib (8) and the second flanging rib (6) are both greater than or equal to 4 mm.

4. The roll-formed battery casing side beam according to claim 3, characterized in that: The first closed cavity (201) is enclosed by the upper end face (1), a first side face (10), the first lower end face (9), and the first reinforcing vertical rib (7).

5. The roll-formed battery casing side beam according to claim 4, characterized in that: The third closed cavity (203) is enclosed by the upper end face (1), a second side face (3), a second lower end face (4), and the second reinforcing vertical rib (5).

6. The roll-formed battery casing side beam according to claim 5, characterized in that: A first step is provided at the upper end face (1) located at the upper end of the third closed cavity (203), and the height difference D of the first step matches the thickness of the battery case cover plate; there is a second step between the second lower end face (4) and the first lower end face (9), and the height difference S of the second step is consistent with the thickness of the battery case support plate.

7. The roll-formed battery casing side beam according to claim 6, characterized in that: The first flanging rib (8) and the first reinforcing vertical rib (7) are roll-bent, and the included angle α at the roll-bending position is 45° - 150°. The first reinforcing vertical rib (7) and the upper inner rib (2) are roll-bent, and the included angle β at the roll-bending position is 45° - 150°. The upper inner rib (2) and the second reinforcing vertical rib (5) are roll-bent, and the included angle γ at the roll-bending position is 30 - 150°.

8. The roll-formed battery casing side beam according to claim 7, characterized in that: The upper inner rib (2) and the upper end face (1) are welded by laser penetration welding or roll spot welding.

9. The roll-formed battery casing side beam according to claim 8, characterized in that: A plurality of mounting holes (11) are provided on the upper end face (1).

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