A battery tray frame structure

Abstract

The utility model discloses a kind of battery tray frame structures, it is related to battery tray technical field;Including boundary beam and the hanger assembly connected in the outer side of boundary beam, the outer side wall of the boundary beam is welded with first stud through resistance, the hanger assembly includes connecting plate and hanger plate, the hanger plate is fixedly connected on connecting plate, mounting hole is set up on the connecting plate, first stud passes through mounting hole and is locked in the outer wall of boundary beam by screw thread connection first nut.Connecting hanger assembly by resistance welding stud and nut, reduce the overall welding deformation, reduce product size correction work in later period, improve production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of battery tray structure technology, specifically to a battery tray frame structure. Background Technology

[0002] The battery tray is the core load-bearing and protective structure of the power battery system of new energy vehicles. Its main functions include supporting the battery module, ensuring safety and sealing, realizing lightweight design and optimizing heat dissipation management. As the "skeleton" of the battery system, it forms a cavity with a frame and a base plate to fix the battery module and resist external impact, vibration and gravel puncture.

[0003] Existing battery trays have lifting lugs on their side walls, which are bolted to rigidly connect the battery tray to the vehicle body, bearing axial shear forces and vibration loads under conditions such as vehicle bumps and sharp turns. In the existing battery tray structure, the lifting lugs are welded to the perimeter of the battery tray frame using arc welding. The arc welding process between the lifting lugs and the battery tray frame generates a large amount of heat, causing defects such as bending deformation, torsional deformation, and dimensional reduction in the tray frame, affecting battery installation. The existing battery tray frame is made of steel sections welded together into a rectangular structure, with arc welding connections at the corners. This results in numerous weld seams, making it prone to cracking, causing the internal cavities of the frame steel to fail to meet sealing requirements, and also complicating the manufacturing process. Utility Model Content

[0004] The purpose of this utility model is to solve the above-mentioned technical problems and provide a battery tray frame structure, which aims to reduce tray frame deformation and improve production efficiency.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A battery tray frame structure includes a side beam and a lifting lug assembly connected to the outer side of the side beam. A first stud is resistance-welded to the outer wall of the side beam. The lifting lug assembly includes a connecting plate and a lifting lug plate. The lifting lug plate is fixedly connected to the connecting plate, which has mounting holes. The first stud passes through the mounting holes and is threadedly connected to a first nut to lock the connecting plate to the outer wall of the side beam. The first stud is a cylindrical structure with external threads.

[0007] Using the above technical solution, the first stud is resistance welded to the side beam, and the lifting lug assembly is connected through the first stud. The welding area is small, the welding heat is small, and the warping deformation of the side beam is reduced, thereby improving product quality. Moreover, the stud has no hexagonal head, and there is no step formed by the hexagonal head at the weld after welding. This allows the connecting plate on the lifting lug assembly to fit against the surface of the side wall of the side beam, increasing the contact area between the connecting plate and the side beam. After being locked by the first nut, the connection strength and reliability are improved.

[0008] Furthermore, the first stud is connected to the side wall of the side beam by projection welding. Projection welding, where the weld points are formed by the contact of the projection points, increases the pressure and current density per unit area. This helps to break through the oxide film on the workpiece surface, concentrates heat, reduces current shunting, and minimizes warping deformation during workpiece welding.

[0009] Furthermore, the connecting plate has two rows of mounting holes, with multiple mounting holes in each row; the outer side of the side beam is provided with first studs corresponding to the positions of the mounting holes. By setting multiple first studs to form a combination, the connection strength is improved, ensuring the reliability of the connection between the lifting lug assembly and the side beam.

[0010] Furthermore, the side beam is a ring-shaped frame structure, with an inner beam connected inside. A second stud is resistance-welded to the inner wall of the side beam, and a fixing plate is fixedly connected to the end of the inner beam. The fixing plate has a U-shaped groove, through which the second stud passes and is threaded with a second nut to lock the inner beam onto the side beam. The inner beam is connected by the second stud, reducing welding seams and structural deformation.

[0011] Furthermore, the side beam is a ring-shaped frame structure formed by bending rectangular profile tubes end to end. The two ends of the rectangular profile tube are a first end and a second end. The first end is processed using a tube-reduction technique to create a reduced-diameter joint with an outer wall dimension smaller than the inner cavity dimension of the second end. This reduced-diameter joint is inserted into the second end, and the second end is welded to the first end at the joint. The side beam, formed by bending and connecting rectangular profiles into a ring structure, has only one welded joint at the end, reducing the number of welded joints found in traditional frame structures composed of multiple profiles, thus reducing welding deformation. The reduced-diameter joint, formed by the tube-reduction process and inserted into the second end, improves the joint lap strength.

[0012] Furthermore, a sealing ring is provided between the outer wall of the reduced-diameter joint and the inner wall of the second end, forming a sealed fit. By setting the sealing ring in the radial gap between the reduced-diameter joint and the second end, a sealed fit is achieved between the two. The sealing ring is made of soft material, which prevents the seal from failing due to vibration or deformation under stress, thus improving the sealing effect and preventing leakage of the protective air circuit inside the frame, ensuring the safe operation of the air circuit inside the frame. The sealing ring can be a molded sealing ring or formed by applying sealant around the periphery of the reduced-diameter joint and then curing it.

[0013] The battery tray frame structure provided by this utility model has the following advantages: the lifting lug assembly is connected by projection welding studs and nuts, which reduces the overall welding deformation caused by arc welding of the lifting lugs in the prior art, reduces the dimensional correction work in the later stage of the product, and improves production efficiency; the side beam joints are connected by tube shrinking and then plugging, and then only the joint is welded, which increases the overall structural strength of the frame, simplifies the process, and reduces production costs; the joints are sealed by sealing rings, which improves the sealing effect and sealing reliability. Attached Figure Description

[0014] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings:

[0015] Figure 1 A schematic diagram of a battery tray frame structure with the first nut removed, provided by this utility model;

[0016] Figure 2 A schematic diagram of the ear plate assembly in a battery tray frame structure provided by this utility model;

[0017] Figure 3 A partial cross-sectional structural diagram of the connection between the ear plate assembly and the side beam in a battery tray frame structure provided by this utility model;

[0018] Figure 4 for Figure 3 A schematic diagram of the local structure of part A in the middle;

[0019] Figure 5 A partial structural diagram of a battery tray frame structure provided by this utility model, showing the removal of the second nut at the connection between the inner beam and the side beam;

[0020] Figure 6 A cross-sectional structural diagram of the connection between the inner beam and the side beam in a battery tray frame structure provided by this utility model;

[0021] Figure 7 This utility model provides a schematic diagram of the side beam structure in a battery tray frame structure.

[0022] Figure 8 This is a partial cross-sectional structural diagram of the side beam joint in a battery tray frame structure provided by this utility model.

[0023] The following are the labels in the diagram: 1. Side beam; 10. Rectangular profile tube; 11. First end; 12. Second end; 13. Reduction joint; 14. Sealing ring; 2. Lifting lug assembly; 21. Connecting plate; 22. Lifting lug plate; 23. Mounting hole; 3. First stud; 31. Projection weld; 4. First nut; 5. Inner beam; 51. Fixing plate; 52. U-shaped groove; 6. Second stud; 7. Second nut. Detailed Implementation

[0024] It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0025] The technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this utility model.

[0026] It should be noted that all directional indications (such as up-down-left-right-forward-backward...) in the embodiments of this utility model are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly. The connection can be a direct connection or an indirect connection.

[0027] like Figures 1-4 As shown, a battery tray frame structure includes a side beam 1 and a lifting lug assembly 2 connected to the outside of the side beam 1. A first stud 3 is resistance-welded to the outer wall of the side beam 1. The lifting lug assembly 2 includes a connecting plate 21 and a lifting lug plate 22. The lifting lug plate 22 is fixedly connected to the connecting plate 21. The connecting plate 21 has a mounting hole 23. The first stud 3 passes through the mounting hole 23 and is threadedly connected to a first nut 4 to lock the connecting plate 21 to the outer wall of the side beam 1. The first stud 3 is a cylindrical structure with external threads.

[0028] Using the above technical solution, the first stud 3 is resistance welded on the side beam 1, and the lifting lug assembly 2 is connected through the first stud 3. The welding area is small and the welding heat is small, which reduces the warping deformation of the side beam 1 and thus improves the product quality. Moreover, the stud has no hexagonal head, and there is no step formed by the hexagonal head at the weld after welding. This allows the connecting plate 21 on the lifting lug assembly 2 to fit against the surface of the side wall of the side beam 1, increasing the contact area between the connecting plate 21 and the side beam 1. After being locked by the first nut 4, the connection strength and connection reliability are improved.

[0029] Specifically, the first stud 3 is connected to the side wall of the side beam 1 by projection welding. Projection welding is a new resistance welding process. During welding, the projection point contacts to form a projection weld point 31, which increases the pressure and current density per unit area. This helps to break through the oxide film on the surface of the workpiece, concentrate heat, reduce current shunting, and reduce warping deformation of the workpiece during welding.

[0030] Specifically, the connecting plate 21 has two rows of mounting holes 23, with multiple mounting holes 23 in each row; the outer side of the side beam 1 is provided with first studs 3 corresponding to the positions of the mounting holes 23. By setting multiple first studs 3 to form a combination, the connection strength is improved, ensuring the reliability of the connection between the lifting lug assembly 2 and the side beam 1.

[0031] In some embodiments, such as Figure 5 , Figure 6 As shown, the side beam 1 is a ring-shaped frame structure. An inner beam 5 is connected inside the side beam 1. A second stud 6 is resistance-welded to the inner wall of the side beam 1. A fixing plate 51 is fixedly connected to the end of the inner beam 5. A U-shaped groove 52 is formed on the fixing plate 51. The second stud 6 passes through the U-shaped groove 52 and is threadedly connected to a second nut 7. The second nut 7 locks the inner beam 5 onto the side beam 1. The inner beam 5 is connected by the second stud 6, reducing welding seams and structural deformation. The second stud 6 is a cylindrical structure with external threads and no hexagonal head at its end.

[0032] In some embodiments, such as Figure 7 , Figure 8 As shown, the side beam 1 is a ring-shaped frame structure formed by bending rectangular profile tubes 10 and connecting them end to end. The two ends of the rectangular profile tubes 10 are a first end 11 and a second end 12, respectively. The first end 11 is processed using a tube reduction process to form a reduced-diameter joint 13 with an outer wall dimension smaller than the inner cavity dimension of the second end 12. The reduced-diameter joint 13 is inserted into the second end 12, and the second end 12 and the first end 11 are welded together at the joint. The side beam 1 is formed into a ring structure by bending and connecting rectangular profiles, with only one welded joint at the end, reducing the number of welded joints that exist in the traditional method of splicing multiple profiles into a frame shape, and reducing welding deformation. The reduced-diameter joint 13 is formed by the tube reduction process and inserted into the second end 12, thereby improving the joint lap strength.

[0033] Based on the aforementioned inventive concept, the accessories on the side beam are connected using welded studs and nuts, including the connection between the upper and lower ends of the side beam and the top and bottom covers of the battery pack. Traditional pallet frames connect accessories using welded bolts or rivets. Bolt connections require welded hexagonal heads, which are large, while rivets have a large pan head. This necessitates wider rectangular profiles to accommodate the welding or rivet installation space requirements. The side beam profile width needs to be 35mm-40mm, and using a bending process requires a 100mm bending radius, resulting in low space utilization. Furthermore, welding and splicing profiles can easily cause structural deformation. However, the welded studs used in this application have a smaller diameter than the bolt hexagonal head, allowing for a narrower rectangular profile tube width of up to 20mm. A narrower rectangular profile tube results in a smaller bending radius during bending (60mm is sufficient), leading to higher space utilization and providing more space for battery pack installation.

[0034] Specifically, a sealing ring 14 is provided between the outer wall of the reduced diameter joint 13 and the inner wall of the second end 12, forming a sealed fit. By providing the sealing ring 14 in the radial gap between the reduced diameter joint 13 and the second end 12, a sealed fit is achieved between the two. The sealing ring 14 is made of soft material, which prevents the seal from failing due to vibration or deformation under force, improves the sealing effect, prevents leakage of the protective air circuit inside the frame, and ensures the safe operation of the air circuit inside the frame. The sealing ring 14 can be a molded sealing ring 14, or it can be formed by applying sealant around the reduced diameter joint 13 and then curing it.

[0035] The studs on the side beam 1 of this invention are welded using projection welding. The studs and nuts are then used to fix the attached lifting lug assembly 2 and the inner beam 5 onto the side beam 1. This reduces the overall welding deformation caused by arc welding of the lifting lugs in existing technologies, reduces the need for subsequent dimensional correction, and improves production efficiency. The side beam 1 is constructed by bending rectangular profiles end to end, reducing product deformation caused by welding, increasing the overall structural strength of the frame, simplifying the process, and lowering production costs. The sealing ring 14 seals the joints at both ends of the side beam 1, preventing seal failure due to joint deformation under stress and improving the sealing effect. The joints at both ends of the side beam 1 are welded to ensure connection strength, and the sealing ring 14 ensures sealing performance. Since welds are prone to leakage under stress, the elastic sealing of the sealing ring 14 improves the reliability of the seal.

[0036] It should be noted that, with adaptive modifications based on the above structure, it can be applied to products with other frame structures.

[0037] The parts not covered in this technical solution can be implemented using existing technologies.

[0038] The foregoing has shown and described the basic principles, main features, and characteristics of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model includes the appended claims and their equivalents.

Claims

1. A battery tray frame structure, characterized in that: The device includes a side beam (1) and a lug assembly (2) connected to the outside of the side beam (1). A first stud (3) is resistance welded to the outer wall of the side beam (1). The lug assembly (2) includes a connecting plate (21) and a lug plate (22). The lug plate (22) is fixedly connected to the connecting plate (21). The connecting plate (21) has a mounting hole (23). The first stud (3) passes through the mounting hole (23) and is threaded to a first nut (4) to lock the connecting plate (21) to the outer wall of the side beam (1).

2. The battery tray frame structure according to claim 1, characterized in that: The first stud (3) is connected to the side wall of the side beam (1) by projection welding.

3. The battery tray frame structure according to claim 1, characterized in that: The connecting plate (21) has two rows of mounting holes (23) on its upper and lower sides, and each row has multiple mounting holes (23); the outer side of the side beam (1) is provided with a first stud (3) corresponding to the position of the mounting hole (23).

4. The battery tray frame structure according to claim 1, characterized in that: The side beam (1) is a ring frame structure. An inner beam (5) is connected inside the side beam (1). A second stud (6) is welded to the inner wall of the side beam (1) by resistance welding. A fixing plate (51) is fixedly connected to the end of the inner beam (5). A U-shaped groove (52) is opened on the fixing plate (51). The second stud (6) passes through the U-shaped groove (52) and is threaded with a second nut (7) to lock the inner beam (5) onto the side beam (1).

5. A battery tray frame structure according to any one of claims 1-4, characterized in that: The side beam (1) is a ring frame structure formed by bending rectangular profile tubes (10) end to end. The two ends of the rectangular profile tube (10) are a first end (11) and a second end (12). The first end (11) is processed into a reduced diameter joint (13) with an outer wall size smaller than the inner cavity size of the second end (12) using a tube reduction process. The reduced diameter joint (13) is inserted into the second end (12), and the second end (12) and the first end (11) are welded together at the joint.

6. A battery tray frame structure according to claim 5, characterized in that: A sealing ring (14) is provided between the outer wall of the reduced diameter joint (13) and the inner wall of the second end (12), and a sealing fit is formed through the sealing ring (14).

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