Aluminum die cast blank shell for battery pack water cooling plate based on surface low porosity
By designing cross-grid protrusions on the blank shell of aluminum die-cast water-cooled plate, the problems of pinhole defects and high porosity on the surface of aluminum die-cast water-cooled plate are solved, achieving a high efficiency improvement in surface quality and insulation performance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- IKD CO LTD
- Filing Date
- 2025-05-26
- Publication Date
- 2026-06-09
AI Technical Summary
In existing technologies, aluminum die-cast water-cooled plates are prone to pinhole defects after surface treatment, which affects the insulation qualification rate. In addition, traditional processing technology has problems such as high porosity and low production efficiency.
The aluminum die-cast blank shell with a cross-grid protrusion design uses cross grooves on the mold to make the molten aluminum vortex, which carries away impurities and gas, reduces the internal defect rate, and provides additional gas venting channels to improve surface quality.
It significantly reduces the porosity of die-cast parts, improves surface quality, avoids pinhole defects, enhances structural strength, and improves production efficiency and insulation qualification rate.
Smart Images
Figure CN224333408U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of water-cooled plates for battery packs of new energy vehicles, and in particular to aluminum die-cast blank shells for battery pack water-cooled plates that are directly formed by aluminum die casting without machining. Background Technology
[0002] With the rapid development of the new energy vehicle industry, the performance and safety of battery packs, as their core power components, have received widespread attention. Battery packs generate a large amount of heat during operation; if this heat cannot be effectively dissipated, it can lead to decreased battery performance, shortened lifespan, and even safety issues such as thermal runaway. Therefore, an efficient thermal management system has become one of the indispensable key technologies for new energy vehicle battery packs, and the design and manufacturing process of water-cooled plates, as a core component of the thermal management system, is particularly important. Traditional new energy vehicle battery pack cooling plates are mostly formed using aluminum alloy machining or extrusion molding processes.
[0003] Patent CN221613985U discloses a cooling device and a battery pack. The cooling device includes a liquid cooling plate and two connecting parts. The liquid cooling plate has a first cooling channel and a second cooling channel extending along a first direction. The two connecting parts are respectively assembled with both ends of the liquid cooling plate, so that the through liquid cooling plate is encapsulated, forming a complete flow channel structure.
[0004] Aluminum die casting is a precision casting process in which molten metal is rapidly filled into a mold cavity under high pressure and then solidified under pressure. In recent years, with the increasing demand for lightweight and high-performance components in new energy vehicles, aluminum die casting technology has been increasingly widely used in automotive parts manufacturing. Aluminum die-cast water-cooled plates have also become a key technology for the evolution of new energy vehicle batteries towards higher efficiency, integration, and lower cost, and will continue to develop towards ultra-large integrated die casting in the future.
[0005] Battery pack water cooling plates include functional surfaces for placing battery cells. These functional surfaces have strict insulation requirements, so aluminum die-cast water cooling plates need to be insulated on the surface, generally using processes such as electrophoresis and powder coating.
[0006] The forming of aluminum die-cast water-cooled plates is generally based on customer drawings, with a uniform machining allowance of 0.5-1mm added to the machined surface. Subsequent CNC machining is then used to remove these defects to ensure dimensional compliance. The main problem is that after removing the dense layer from the blank surface, internal defects such as pores are exposed. These defects can easily form pinholes during powder coating, significantly impacting the insulation pass rate of the finished product. Utility Model Content
[0007] The technical problem to be solved by this utility model is to provide an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity.
[0008] The technical solution of this utility model is as follows: an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity, comprising a cooling plate body in the middle and structural bodies at both ends; the cooling plate body and the structural bodies are integrally formed by aluminum die casting;
[0009] The first side of the thickness of the cooling plate body has a concave and open flow channel groove, and the flow channel groove has a flow channel partition wall; the outer side of the structure is provided with an inlet and an outlet that connect to the flow channel groove; the second side of the thickness of the cooling plate body is provided with a functional surface; the functional surface is covered with a cross-grid protrusion composed of multiple grid units; the bottom surface of the grid unit of the cross-grid protrusion is a plane.
[0010] The preferred technical solution of this utility model is: the outer edge of the second side of the thickness of the cooling plate body is provided with an annular protrusion surrounding the functional surface.
[0011] The preferred technical solution of this utility model is that the cross-grid protrusions are uniform rhomboid or square grids.
[0012] The preferred technical solution of this utility model is: the width of the cross-grid protrusions gradually decreases from the root to the end face, and the end face is a plane.
[0013] The preferred technical solution of this utility model is that the height of the cross-grid protrusions is 0.3mm-0.5mm.
[0014] The preferred technical solution of this utility model is: the distribution density of the grid cells with cross-grid protrusions is 9-12 cells / cm².
[0015] The preferred technical solution of this utility model is that the edges of the grid-like protrusions form an angle of 15°-25° with the bottom surface of the grid unit.
[0016] The technical solution of this utility model is as follows: an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity, including a cooling plate body formed by aluminum die casting, wherein a water-cooling channel is provided inside the cooling plate body; the outer surface of the cooling plate body includes at least one functional surface; the entire functional surface is provided with cross-grid protrusions.
[0017] The preferred technical solution of this utility model is: a structure located at both ends of the cooling plate body and integrally die-cast with the cooling plate body;
[0018] The first side of the thickness of the cooling plate body has a concave and open flow channel groove, and the flow channel groove has a flow channel partition wall; the outer side of the structure is provided with an inlet and an outlet that communicate with the flow channel groove; the second side of the thickness of the cooling plate body is provided with the functional surface.
[0019] The preferred technical solution of this utility model is as follows: the width of the ridge of the cross-grid protrusion gradually decreases from the root to the end face and the end face is flat; the height of the ridge of the cross-grid protrusion is 0.3mm-0.5mm.
[0020] Compared with the prior art, the advantages of this utility model are: when the molten aluminum fills into the product cavity and passes through the intersecting grooves on the mold, the molten aluminum undergoes a vortex phenomenon in the grooves, thereby trapping impurities on the surface of the molten aluminum and some gas in the cavity within the groove structure. This reduces the rate of hole defects and impurities in the body part that needs to be retained later. Not only is the surface quality of the functional surfaces significantly improved, but also the porosity of the entire die-casting part is reduced because the gas in the die casting has an additional venting channel. Therefore, after CNC machining removes these structures, the surface quality of each surface, especially the second side of the bottom shell, is greatly improved, thereby avoiding pinhole defects in the subsequent insulation treatment that would affect the insulation qualification rate. Attached Figure Description
[0021] The present invention will be further described in detail below with reference to the accompanying drawings and preferred embodiments. However, those skilled in the art will understand that these drawings are drawn only for the purpose of explaining the preferred embodiments and therefore should not be construed as limiting the scope of the present invention. Furthermore, unless specifically indicated, the drawings are only schematic representations of the composition or structure of the described objects and may contain exaggerated depictions, and the drawings are not necessarily drawn to scale.
[0022] Figure 1 This is a schematic diagram of the structure of an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity. Figure 1 ;
[0023] Figure 2 This is a schematic diagram of the structure of an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity. Figure 2 ;
[0024] Figure 3 A schematic diagram of the cross-grid-like raised ridges of the aluminum die-cast blank shell used for the water-cooling plate of the base battery pack;
[0025] Figure 4 A schematic diagram of the die casting of an aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity;
[0026] Figure 5 This is a schematic diagram of the water-cooled plate of the battery pack.
[0027] Reference numerals: blank shell 100; aluminum alloy cover plate 200; cooling plate body 1; structure 2; flow channel 3; water inlet 4; water outlet 5; functional surface 6; cross grid-like protrusion 7; annular protrusion 8; product cavity 11; groove 12; edge 71; grid unit bottom surface 72. Detailed Implementation
[0028] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Those skilled in the art will appreciate that these descriptions are merely descriptive and exemplary and should not be construed as limiting the scope of protection of the present invention.
[0029] It should be noted that similar labels in the following figures indicate similar items; therefore, once an item is defined in one figure, it will not be further defined and explained in subsequent figures.
[0030] like Figure 1-2 As shown, the aluminum die-cast blank shell 100 for battery pack water cooling plate based on low surface porosity is a die-cast part directly formed by aluminum die casting. It is an intermediate process object in the preparation of battery pack water cooling plate, and its size and surface morphology are finally changed by machining.
[0031] like Figure 1 As shown, the aluminum die-cast blank shell 100 for a battery pack water-cooling plate based on low surface porosity includes a cooling plate body 1 located in the middle and structures 2 at both ends. The cooling plate body 1 and the structures 2 are integrally formed by aluminum die casting. The first side of the thickness of the cooling plate body 1 has a concave and open flow channel groove 3, and the flow channel groove 3 has a flow channel partition wall. The outer side of the structure 2 is provided with an inlet 4 and an outlet 5 that communicate with the flow channel groove 3.
[0032] like Figure 2 As shown, the second side of the thickness of the cooling plate body 1 has a functional surface 6. This functional surface 6 needs to be coated with an insulating layer after subsequent machining, therefore, it has relatively strict requirements regarding surface flatness and porosity. Aluminum die-cast parts are prone to porosity defects during the die-casting process. These pores are usually located inside the solid where venting is poor. Therefore, after dimensional adjustments and deburring to remove the dense layer from the blank surface during machining, internal porosity and other defects in the aluminum die-cast part are easily exposed on the surface, thus affecting the surface performance of the product.
[0033] like Figure 2-3 As shown, in this embodiment, the functional surface 6 of the blank shell 100 is specially designed so that it can meet the surface performance requirements of subsequent processes after machining. Specifically, by setting intersecting grooves on the die-casting mold of the blank shell 100, a cross-grid protrusion 7 composed of multiple grid units is formed on the functional surface 6 of the blank shell 100, and the bottom surface 72 of the grid unit of the cross-grid protrusion 7 is a plane.
[0034] like Figure 4As shown, when molten aluminum fills into the product cavity 11 and passes through the groove 12 on the mold, the molten aluminum undergoes a vortex phenomenon within the groove, thereby trapping impurities on the surface of the molten aluminum and some gas from within the cavity within the groove structure. This reduces the rate of hole defects and impurities in the body portion that needs to be retained subsequently, thus improving the internal quality of the product.
[0035] For aluminum die-cast products, machining is a common technique for adjusting the size and deburring the blank shell 100 to form the final product. In this embodiment, the additional cross-grid protrusions 7 are removed while adjusting the size and deburring the blank through machining, which avoids the addition of extra processes and thus ensures production efficiency.
[0036] The design of the cross-grid protrusions 7 not only significantly improves the surface quality of the functional surface 6, but also reduces the porosity of the entire die casting by providing additional channels for the gas to escape. Therefore, after CNC machining removes these structures, the surface quality of each surface, especially the second side of the bottom shell, is greatly improved, thus avoiding pinhole defects in subsequent insulation treatment that could affect the insulation pass rate.
[0037] The design of this cross-grid protrusion 7 has another advantage: since the aluminum pressing components will face stress during demolding and subsequent processing, the cross-grid protrusion design can reduce the amount of demolding deformation by enhancing the structural strength of the blank, and avoid product damage and deformation during subsequent processing, thus providing many conveniences for subsequent processes.
[0038] Preferably, the intersecting grid-like protrusions 7 are uniform rhomboid or square grids. The width of the edges 71 of the intersecting grid-like protrusions 7 gradually decreases from the root to the end face, and the end face is flat. This design detail plays a crucial role in the smoothness of the die-casting process and the uniformity of the product. The design of the gradually decreasing width of the edges of the intersecting grid-like protrusions 7 from the root to the end face creates a certain inclination angle between the outer surface of the edges and the bottom surface of the grid unit. This inclination design corresponds to the design of the mold groove, which can greatly promote the smoother entry of gas into the mold groove during the die-casting process.
[0039] like Figure 4 As shown, when molten aluminum fills the product cavity, it is injected laterally, with its main filling direction aligned with the reference plane. The inclined, transitional grid-like protrusions effectively guide gas and impurities into the internal structure, thus creating more gas venting channels within the die-cast part. This design feature not only significantly reduces the porosity of the die-cast part but also greatly improves the internal quality of the product.
[0040] At the same time, such as Figure 3As shown, the inclined shape of the edges 71 of the cross-grid protrusions 7 can also avoid the influence of the cross-grid protrusions 7 on the internal stress of the blank shell 100. Preferably, the edge height of the cross-grid protrusions 7 is 0.3mm-0.5mm. The grid cell distribution density of the cross-grid protrusions 7 is 9-12 cells / cm². The edges 71 of the cross-grid protrusions form an angle of 15°-25° with the bottom surface 72 of the grid cells. The design of these parameters can achieve a balance between surface properties, mechanical strength, and ease of processing.
[0041] It should be noted that in other embodiments, the surface of the blank shell 100 with water cooling channels may not only include one functional surface 6. According to the concept of this embodiment, cross-grid protrusions 7 can be arranged on each functional surface 6 to meet the performance requirements of the surface after subsequent machining.
[0042] In this embodiment: as Figure 5 As shown, the aluminum die-cast blank shell 100 of the battery pack water-cooling plate is welded and encapsulated with an aluminum alloy cover plate 200 by friction welding to form an assembly. The assembly is then machined, with dimensions adjusted by cutting off allowances and removing intersecting grid-like protrusions, resulting in a component with the required surface properties.
[0043] In this embodiment, as Figure 2 As shown, the outer edge of the second side of the thickness of the cooling plate body 1 is provided with an annular protrusion 8 surrounding the functional surface 6. This annular protrusion surrounds the functional area to achieve stable placement of the battery cells.
[0044] This paper introduces the aluminum die-cast blank shell for battery pack water cooling plate based on low surface porosity provided by this utility model. Specific examples are used to illustrate the principle and implementation of this utility model. The above description of the embodiments is only for the purpose of helping to understand this utility model and its core ideas.
Claims
1. An aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity, characterized in that: It includes a cooling plate body in the middle and structures at both ends; the cooling plate body and the structures are integrally formed by aluminum die casting; The first side of the thickness of the cooling plate body has a concave and open flow channel groove, and the flow channel groove has a flow channel partition wall; the outer side of the structure is provided with an inlet and an outlet that connect to the flow channel groove; the second side of the thickness of the cooling plate body is provided with a functional surface; the functional surface is covered with a cross-grid protrusion composed of multiple grid units; the bottom surface of the grid unit of the cross-grid protrusion is flat; the battery pack water cooling plate is made of aluminum die-cast blank shell and aluminum alloy cover plate and is welded and encapsulated by friction welding to form an assembly; the assembly is then machined, and the dimensions are adjusted by cutting the allowance and the cross-grid protrusion is removed.
2. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The outer edge of the second side of the thickness of the cooling plate body is provided with an annular protrusion surrounding the functional surface.
3. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The intersecting grid-like protrusions are uniform rhomboid or square grids.
4. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The width of the ridges of the intersecting grid-like protrusions gradually decreases from the root to the end face, and the end face is flat.
5. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The height of the cross-grid protrusions is 0.3mm-0.5mm.
6. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The grid cell distribution density of the intersecting mesh-like protrusions is 9-12 cells / cm². 2 .
7. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 1, characterized in that: The edges of the grid-like protrusions form an angle of 15°-25° with the bottom surface of the grid unit.
8. An aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity, characterized in that: The cooling plate body is formed by aluminum die casting, and a water cooling channel is provided inside the cooling plate body; the outer surface of the cooling plate body includes at least one functional surface; the functional surface is covered with cross-grid protrusions.
9. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity as described in claim 8, characterized in that: Includes structural bodies located at both ends of the cooling plate body and integrally die-cast with the cooling plate body; The first side of the thickness of the cooling plate body has a concave and open flow channel groove, and the flow channel groove has a flow channel partition wall; the outer side of the structure is provided with an inlet and an outlet that communicate with the flow channel groove; the second side of the thickness of the cooling plate body is provided with the functional surface.
10. The aluminum die-cast blank shell for a battery pack water-cooling plate based on low surface porosity according to claim 9, characterized in that: The width of the ridges of the intersecting grid-like protrusions gradually decreases from the root to the end face, and the end face is flat; the height of the ridges of the intersecting grid-like protrusions is 0.3mm-0.5mm.