A battery tray structure, chassis and vehicle
By optimizing the battery tray structure using aluminum alloy extruded profiles and ring-shaped composite beam pulsed laser welding technology, the problems of insufficient strength, heavy weight, and poor thermal management of traditional battery trays have been solved, resulting in higher safety, longer battery life, and better economy.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- LIAONING ZHONGWANG GROUP CO LTD
- Filing Date
- 2025-03-24
- Publication Date
- 2026-06-16
AI Technical Summary
Traditional battery tray structures lack sufficient strength and rigidity, are heavy, and have inadequate thermal management capabilities, which affect the safety performance of the battery pack, driving range, and the fuel economy of the vehicle.
The battery pack's front, left, rear, right, and middle beams are designed using extruded aluminum alloy profiles, combined with a reinforcing rib structure and an optimized battery tray connection mechanism. Annular composite beam pulsed laser welding technology is employed to improve structural strength and rigidity, and simplify assembly and maintenance.
The structure strength and rigidity of the battery tray have been improved, the weight has been reduced, the thermal management capability has been optimized, the safety performance and driving range of the whole vehicle have been improved, the production and maintenance costs have been reduced, and the environmental performance and economy have been improved.
Smart Images
Figure CN224360976U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of automotive technology, and specifically discloses a battery tray structure, chassis and vehicle. Background Technology
[0002] In the field of new energy vehicles, the battery tray, as a key structural component supporting the battery pack, directly impacts the vehicle's safety, driving range, and manufacturing costs. With the rapid development of electric vehicles, market demands for battery trays are constantly increasing, including higher structural strength, better thermal management capabilities, lighter weight, and easier assembly and maintenance. Traditional battery tray structures typically employ simple frame designs. While this design can meet basic usage requirements to some extent, it has several shortcomings in practical applications. First, traditional battery trays lack sufficient strength and rigidity, making it difficult to withstand the various dynamic loads experienced by the battery pack during vehicle operation. Especially during high-speed or aggressive driving, this structure is prone to deformation, affecting the safety and performance of the battery pack. Second, traditional battery trays are relatively heavy, increasing the overall weight of the vehicle and impacting its driving range. Furthermore, traditional battery trays have inadequate thermal management capabilities; if the heat generated during charging and discharging cannot be effectively dissipated, it can lead to decreased battery performance or even damage. Moreover, with advancements in battery technology and the expansion of the new energy vehicle market, the performance requirements for battery trays are continuously increasing. Consumers are not only concerned with vehicle safety and driving range but also increasingly value the vehicle's environmental performance and economic efficiency.
[0003] Based on this, this utility model proposes a novel battery tray structure, which aims to improve the structural strength and rigidity of the battery tray, reduce weight, optimize thermal management capabilities, and simplify assembly and maintenance through innovative design, thereby improving the overall vehicle performance while taking into account the vehicle's environmental performance and economy. Utility Model Content
[0004] This utility model addresses the problem of insufficient strength and rigidity of the battery tray structure, which leads to ineffective heat dissipation and consequently low safety and performance of the battery pack. It proposes a battery tray structure, chassis, and vehicle.
[0005] This utility model provides a battery tray structure, including a front beam, a left beam, a rear beam, a right beam, a middle beam assembly, a bottom plate assembly, and a battery tray connecting mechanism. The front beam, left beam, rear beam, and right beam are sequentially connected to form a battery pack frame. The middle beam assembly is disposed inside the battery pack frame and connected to the left and right beams. The bottom plate assembly is disposed below the battery pack frame, and the battery tray connecting mechanism is disposed outside the battery pack frame.
[0006] According to some embodiments of this application, a battery tray structure includes a battery pack beam assembly comprising a first battery pack beam and a second battery pack beam. The left and right ends of the first battery pack beam are respectively connected to the left and right beams of the battery pack, and the left and right ends of the second battery pack beam are respectively connected to the left and right beams of the battery pack. The first and second battery pack beams are evenly disposed between the front and rear beams of the battery pack.
[0007] According to some embodiments of this application, in a battery tray structure, the first battery pack beam and the second battery pack beam are both square tube structures with internal reinforcing ribs. The first battery pack beam and the second battery pack beam are both aluminum alloy extruded profiles, which are both produced by extrusion. The first battery pack beam and the second battery pack beam are connected to the left beam and the right beam of the battery pack by welding.
[0008] According to some embodiments of this application, a battery tray structure is provided, wherein the battery pack bottom plate assembly includes a first battery pack bottom plate, a second battery pack bottom plate, and a third battery pack bottom plate. The first battery pack bottom plate is disposed between the front beam and the middle beam of the battery pack, the second battery pack bottom plate is disposed between the middle beam of the first battery pack and the middle beam of the second battery pack, and the third battery pack bottom plate is disposed between the middle beam of the second battery pack and the rear beam of the battery pack.
[0009] According to some embodiments of this application, a battery tray structure includes a battery pack front mounting beam, a battery pack left mounting beam, a battery pack rear mounting beam, and a battery pack right mounting beam. The battery pack front mounting beam is disposed at the front end of the battery pack front beam, the battery pack left mounting beam is disposed at the left end of the battery pack left beam, the battery pack rear mounting beam is disposed at the rear end of the battery pack rear beam, and the battery pack right mounting beam is disposed at the right end of the battery pack right beam.
[0010] According to some embodiments of this application, a battery tray structure is provided with a plurality of lateral opening grooves along the longitudinal direction of the left mounting beam of the battery pack, and a plurality of lateral opening grooves along the longitudinal direction of the right mounting beam of the battery pack.
[0011] According to some embodiments of this application, in a battery tray structure, the front mounting beam of the battery pack is a hollow profile and is provided with reinforcing ribs inside. The front mounting beam of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The front mounting beam of the battery pack is connected to the front beam of the battery pack by welding.
[0012] The left mounting beam of the battery pack is a hollow profile with internal reinforcing ribs. The left mounting beam of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The left mounting beam of the battery pack is connected to the left beam of the battery pack by welding.
[0013] The rear mounting beam of the battery pack is a hollow profile with internal reinforcing ribs. The rear mounting beam of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The rear mounting beam of the battery pack is connected to the rear beam of the battery pack by welding.
[0014] The right mounting beam of the battery pack is a hollow profile with internal reinforcing ribs. The right mounting beam of the battery pack is an aluminum alloy extruded profile, which is produced by extrusion. The right mounting beam of the battery pack is connected to the right beam of the battery pack by welding.
[0015] According to some embodiments of this application, in a battery tray structure, the front beam, left beam, rear beam, and right beam of the battery pack are all square tube structures with internal reinforcing ribs. The front beam, left beam, rear beam, and right beam of the battery pack are all aluminum alloy extruded profiles, all manufactured by extrusion.
[0016] This utility model provides a chassis, which includes the battery tray structure described above.
[0017] This utility model provides a vehicle, which includes the chassis described above.
[0018] The battery tray structure proposed in this invention optimizes the design of the tray frame and base plate, enabling it to withstand greater loads while maintaining sufficient strength and rigidity, thus improving the overall vehicle safety performance. The design employs lightweight materials and structural design, effectively reducing the weight of the battery tray and thereby increasing the vehicle's driving range. Furthermore, the battery tray mechanism design of this invention optimizes the connection structure, simplifies assembly and maintenance methods, reduces production and maintenance costs, improves production efficiency, reduces energy consumption, and enhances environmental performance and economic efficiency. This battery tray structure improves the performance of electric vehicles while also considering cost-effectiveness and ease of maintenance, providing a new technical solution for new energy vehicles. Attached Figure Description
[0019] Figure 1 This is a three-dimensional structural diagram of a battery tray structure according to an embodiment of the present invention;
[0020] Figure 2 This is a left-side view of a battery tray structure according to an embodiment of the present invention.
[0021] In the diagram, 1 is the front beam of the battery pack, 2 is the left beam of the battery pack, 3 is the rear beam of the battery pack, 4 is the right beam of the battery pack, 5 is the middle beam of the first battery pack, 6 is the middle beam of the second battery pack, 7 is the bottom plate of the first battery pack, 8 is the bottom plate of the second battery pack, 9 is the bottom plate of the third battery pack, 10 is the front mounting beam of the battery pack, 11 is the left mounting beam of the battery pack, 12 is the rear mounting beam of the battery pack, and 13 is the right mounting beam of the battery pack. Detailed Implementation
[0022] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model.
[0023] In the description of this utility model, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this utility model, it should be noted that unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances. Furthermore, in the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0024] This embodiment provides a battery tray structure, such as Figure 1 As shown, the battery pack includes a front beam 1, a left beam 2, a rear beam 3, a right beam 4, a middle beam assembly, a bottom plate assembly, and a battery tray connecting mechanism. The front beam 1, left beam 2, rear beam 3, and right beam 4 are sequentially connected to form the battery pack frame. The middle beam assembly is located inside the battery pack frame and connected to the left beam 2 and right beam 4. The bottom plate assembly is located below the battery pack frame, and the battery tray connecting mechanism is located outside the battery pack frame.
[0025] In a preferred embodiment, the battery pack beam assembly includes a first battery pack beam 5 and a second battery pack beam 6. The left and right ends of the first battery pack beam 5 are connected to the left battery pack beam 2 and the right battery pack beam 4, respectively. Similarly, the left and right ends of the second battery pack beam 6 are connected to the left battery pack beam 2 and the right battery pack beam 4, respectively. The first and second battery pack beams 5 and 6 are evenly distributed between the front battery pack beam 1 and the rear battery pack beam 3. More specifically, both the first and second battery pack beams 5 and 6 are square tubular structures with internal reinforcing ribs. Both are made of extruded aluminum alloy profiles and are manufactured through extrusion. The first and second battery pack beams 5 and 6 are connected to the left battery pack beam 2 and the right battery pack beam 4 by welding.
[0026] As a preferred embodiment, the battery pack base plate assembly specifically includes a first battery pack base plate 7, a second battery pack base plate 8, and a third battery pack base plate 9. The first battery pack base plate 7 is disposed between the front beam 1 and the middle beam 5 of the battery pack, the second battery pack base plate 8 is disposed between the middle beam 5 and the middle beam 6 of the first battery pack, and the third battery pack base plate 9 is disposed between the middle beam 6 and the rear beam 3 of the battery pack.
[0027] As a preferred embodiment, the battery tray connecting mechanism specifically includes a front mounting beam 10 for the battery pack, a left mounting beam 11 for the battery pack, a rear mounting beam 12 for the battery pack, and a right mounting beam 13 for the battery pack. Figure 2 As shown, the front mounting beam 10 of the battery pack is located at the front end of the front beam 1 of the battery pack, the left mounting beam 11 of the battery pack is located at the left end of the left beam 2 of the battery pack, the rear mounting beam 12 of the battery pack is located at the rear end of the rear beam 3 of the battery pack, and the right mounting beam 13 of the battery pack is located at the right end of the right beam 4 of the battery pack. Preferably, the left mounting beam 11 of the battery pack has a plurality of grooves with lateral openings along the longitudinal direction, and the right mounting beam 13 of the battery pack has a plurality of grooves with lateral openings along the longitudinal direction.
[0028] In a preferred embodiment, specifically, the front mounting beam 10 of the battery pack is a hollow profile with internal reinforcing ribs, and is made of extruded aluminum alloy. The front mounting beam 10 is welded to the front beam 1 of the battery pack. The left mounting beam 11 of the battery pack is a hollow profile with internal reinforcing ribs, and is made of extruded aluminum alloy. The left mounting beam 11 is welded to the left beam 2 of the battery pack. The rear mounting beam 12 of the battery pack is a hollow profile with internal reinforcing ribs, and is made of extruded aluminum alloy. The rear mounting beam 12 is welded to the rear beam 3 of the battery pack. The right mounting beam 13 of the battery pack is a hollow profile with internal reinforcing ribs, and is made of extruded aluminum alloy. The right mounting beam 13 is welded to the right beam 4 of the battery pack.
[0029] As a preferred embodiment, specifically, the front beam 1, left beam 2, rear beam 3, and right beam 4 of the battery pack are all square tube structures with internal reinforcing ribs. The front beam 1, left beam 2, rear beam 3, and right beam 4 of the battery pack are all aluminum alloy extruded profiles, all of which are produced by extrusion.
[0030] This embodiment also provides a chassis, which includes the aforementioned battery tray structure, lower body structure, front subframe structure and rear subframe structure.
[0031] This embodiment also provides a vehicle, which includes the chassis described above.
[0032] As a preferred embodiment, the battery tray structure also includes a battery pack cover, which is disposed at the upper end of the battery pack frame and can also serve as the undercarriage floor.
[0033] Furthermore, as a preferred embodiment, the front beam 1, left beam 2, rear beam 3, right beam 4, front mounting beam 10, left mounting beam 11, rear mounting beam 12, right mounting beam 13, first battery pack middle beam 5, and second battery pack middle beam 6 of the battery pack are all made of Al-Si alloys. More specifically, all of the above components are made of 6082 aluminum alloy. The yield strength of 6082 aluminum alloy extrusion can reach over 250 MPa, which is far higher than the yield strength of ordinary castings.
[0034] In this embodiment, all components are made of high-strength multi-cavity extruded profiles, which can further improve product performance. First, the multiple cavities inside the component are composed of multiple single tubes. In mechanics, there is a saying that a pillar can support a thousand pounds. At the same time, the mechanical properties are increased geometrically when these single tubes are stacked together. Second, the multiple diagonal reinforcing ribs inside form multiple triangles. The triangular spatial structure is the most stable and can provide good support and transmission of force, ensuring the overall rigidity and strength of the beam.
[0035] The battery tray structure implemented in this embodiment shows a significant improvement in rigidity and structural strength compared to existing steel-aluminum hybrid battery tray structures and all-steel battery tray structures. This battery tray structure also offers greater flexibility in material selection, ensuring that the right material is used for the right part of the vehicle body. Furthermore, while existing integrated die-cast lower chassis simplifies the original rear floor plate's more than 70 welded parts into a single component, it still suffers from disadvantages in practical applications, including equipment cost, precision control, maintenance difficulty, casting defects, manufacturing limitations, and environmental impact. Moreover, adopting this technology requires mass production as a prerequisite; otherwise, the high equipment investment and mold costs cannot be amortized. From an economic perspective, the battery tray structure implemented in this embodiment is more cost-effective.
[0036] This embodiment utilizes a ring-shaped composite beam pulsed laser welding technology for the core components of the battery tray structure, employing high-strength aluminum alloy multi-cavity structural profiles. Based on factors such as component materials, welding structure, and welding technology, and focusing on improving the joint performance of welded parts, this innovative welding technology replaces traditional cast aluminum alloys with a complex multi-cavity extruded profile. The ring-shaped composite beam pulsed laser welding technology features a ring-shaped composite beam, forming a larger and more stable keyhole, facilitating the escape of metal vapor. It minimizes molten metal contamination, increases welding speed while reducing spatter by 90% or more, stabilizes the molten pool, and controls cooling to overcome shrinkage stress, achieving crack-free welding. By adjusting welding process parameters and analyzing the weld quality and post-weld mechanical properties, the influence of different welding process parameters on weld formation was investigated. This addresses the challenge of complex casting processes and numerous material defects affecting chassis manufacturing performance.
[0037] The embodiments of this utility model are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the utility model to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical applications of this utility model, and to enable those skilled in the art to understand this utility model and design various embodiments with various modifications suitable for a particular purpose.
Claims
1. A battery tray structure, characterized in that, The battery pack includes a front beam (1), a left beam (2), a rear beam (3), a right beam (4), a middle beam assembly, a bottom plate assembly, and a battery tray connecting mechanism. The front beam (1), left beam (2), rear beam (3), and right beam (4) are connected sequentially to form a battery pack frame. The middle beam assembly is located inside the battery pack frame and is connected to the left beam (2) and right beam (4). The bottom plate assembly is located below the battery pack frame, and the battery tray connecting mechanism is located outside the battery pack frame. The battery tray connecting mechanism includes a front mounting beam (10), a left mounting beam (11), a rear mounting beam (12), and a right mounting beam (13). The front mounting beam (10) is located at the front end of the front beam (1), the left mounting beam (11) is located at the left end of the left beam (2), the rear mounting beam (12) is located at the rear end of the rear beam (3), and the right mounting beam (13) is located at the right end of the right beam (4). The left mounting beam (11) of the battery pack is provided with a plurality of grooves with lateral openings along the longitudinal direction, and the right mounting beam (13) of the battery pack is provided with a plurality of grooves with lateral openings along the longitudinal direction. The front mounting beam (10) of the battery pack is a hollow profile and is provided with reinforcing ribs inside. The front mounting beam (10) of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The front mounting beam (10) of the battery pack is connected to the front beam (1) of the battery pack by welding. The left mounting beam (11) of the battery pack is a hollow profile and is provided with reinforcing ribs inside. The left mounting beam (11) of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The left mounting beam (11) of the battery pack is connected to the left beam (2) of the battery pack by welding. The rear mounting beam (12) of the battery pack is a hollow profile and is provided with reinforcing ribs inside. The rear mounting beam (12) of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The rear mounting beam (12) of the battery pack is connected to the rear beam (3) of the battery pack by welding. The right mounting beam (13) of the battery pack is a hollow profile and is provided with reinforcing ribs inside. The right mounting beam (13) of the battery pack is an aluminum alloy extruded profile, which is made by extrusion. The right mounting beam (13) of the battery pack is connected to the right beam (4) of the battery pack by welding.
2. The battery tray structure according to claim 1, characterized in that, The battery pack beam assembly includes a first battery pack beam (5) and a second battery pack beam (6). The left and right ends of the first battery pack beam (5) are connected to the left battery pack beam (2) and the right battery pack beam (4) respectively. The left and right ends of the second battery pack beam (6) are connected to the left battery pack beam (2) and the right battery pack beam (4) respectively. The first battery pack beam (5) and the second battery pack beam (6) are evenly arranged between the front battery pack beam (1) and the rear battery pack beam (3).
3. The battery tray structure according to claim 2, characterized in that, The first battery pack beam (5) and the second battery pack beam (6) are both square tube structures with internal reinforcing ribs. The first battery pack beam (5) and the second battery pack beam (6) are both aluminum alloy extruded profiles, which are made by extrusion. The first battery pack beam (5) and the second battery pack beam (6) are connected to the left beam (2) and the right beam (4) of the battery pack by welding.
4. The battery tray structure according to claim 2, characterized in that, The battery pack base plate assembly includes a first battery pack base plate (7), a second battery pack base plate (8), and a third battery pack base plate (9). The first battery pack base plate (7) is disposed between the front beam (1) and the middle beam (5) of the battery pack. The second battery pack base plate (8) is disposed between the middle beam (5) of the first battery pack and the middle beam (6) of the second battery pack. The third battery pack base plate (9) is disposed between the middle beam (6) of the second battery pack and the rear beam (3) of the battery pack.
5. A battery tray structure according to claim 1, characterized in that, The front beam (1), left beam (2), rear beam (3) and right beam (4) of the battery pack are all square tube structures with internal reinforcing ribs. The front beam (1), left beam (2), rear beam (3) and right beam (4) of the battery pack are all aluminum alloy extruded profiles, all of which are made by extrusion.
6. A chassis, characterized in that, The chassis includes the battery tray structure as described in any one of claims 1-5.
7. A vehicle, characterized in that, The vehicle includes the chassis as described in claim 6.