An aluminum alloy battery box

Abstract

This utility model discloses an aluminum alloy battery box, including a cover plate and a box body. The box body is formed by two profiles I, two profiles II, and a liquid-cooled base plate. The liquid-cooled base plate is formed by welding multiple plate units side by side. Each plate unit is a hollow plate, and internal stiffeners divide it into two spaces. Each plate unit has an insertion port at both ends corresponding to the stiffeners, and adjacent plate units have corresponding channel openings. Both profiles I have protrusions that fit the insertion ports, and a gap is left between the protrusion of one profile I and the corresponding stiffener, while the protrusion of the other profile I is in sealed contact with the corresponding stiffener. This utility model meets the requirements for lightweight design. The liquid-cooled base plate is simple to process and has high cooling efficiency, effectively ensuring the thermal management performance of the battery system, greatly reducing processing difficulty, improving manufacturing efficiency, and reducing manufacturing costs, while ensuring that the battery box has excellent airtightness.

Description

Technical Field

[0001] This utility model relates to the field of battery box technology, specifically to an aluminum alloy battery box. Background Technology

[0002] With the rapid development of the new energy electric vehicle and energy storage industry, the safety performance of new energy battery systems has become of paramount importance. In accordance with the specific requirements of national standards for power and energy storage battery boxes, it is necessary to develop battery box structures that are high in structural strength, low in cost, lightweight, and simple in processing technology to meet the ever-evolving market demands.

[0003] Sheet metal battery enclosures hold a significant share of the power battery and energy storage system battery enclosure market due to their good cost-effectiveness. However, most sheet metal enclosures on the market currently have complex and bulky designs, resulting in lower energy density of the battery enclosure, which affects the energy density of the battery system and also leads to relatively high manufacturing costs.

[0004] As the core energy supply component of electric vehicles, the battery pack's capacity and energy density significantly impact the driving range. Minimizing battery pack weight is crucial, making the development of lightweight battery housings paramount. Especially in liquid cooling systems, existing liquid cooling base plates typically employ integral casting or complex stamping processes. These processes are complex, inefficient, and limited in terms of airtightness and structural strength, resulting in high manufacturing costs and long lead times, making them unsuitable for large-scale production. For the heavily used heavy-duty trucks and mining trucks currently being widely deployed, operating in extremely harsh environments, battery housings require not only high structural strength but also significant lightweighting. Steel sheet metal battery housings are insufficient, necessitating specially designed aluminum alloy profile battery housings. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the existing defects and provide an aluminum alloy battery box that meets the requirements of lightweighting. The liquid-cooled base plate is simple to process and has high cooling efficiency, which effectively ensures the thermal management performance of the battery system, greatly reduces the processing difficulty, improves the manufacturing efficiency, and reduces the manufacturing cost. At the same time, it ensures that the battery box has very good airtightness, which can effectively solve the problems in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an aluminum alloy battery box, including a cover plate and a box body, wherein the box body is formed by two profiles I, two profiles II, and a liquid-cooled bottom plate; the liquid-cooled bottom plate is formed by welding multiple plate units in parallel, the plate units are hollow plates, and the internal stiffeners of the plate units divide them into two spaces, each plate unit has an insertion port at both ends corresponding to the stiffeners, and each two adjacent plate units have a corresponding channel opening; both of the two profiles I have protrusions adapted to the insertion ports, and a gap is left between the protrusion of one profile I and the corresponding stiffener, while the protrusion of the other profile I is in sealed contact with the corresponding stiffener, and the liquid-cooled bottom plate and the two profiles I form a folded cooling channel.

[0007] Preferably, one of the profiles I has a coolant inlet and outlet port on its side wall, and the profile I has through holes corresponding to the coolant inlet and outlet ports respectively, and the coolant inlet and outlet ports are connected to the folded cooling channel.

[0008] Preferably, the two profiles I are inserted into the liquid-cooled base plate and then welded by friction stir welding, and the two profiles II are aligned with the liquid-cooled base plate and then welded by friction stir welding. Profiles I and II are made of aluminum alloy MIG welding.

[0009] Preferably, both profile I and profile II are provided with a water-retaining edge at their upper ends, a sealing gasket is provided between the cover plate and the box body, the cover plate and the box body are connected by fastening bolts, and the height of the water-retaining edge and the thickness of the sealing gasket after compression are the same.

[0010] Preferably, both profile I and profile II have multiple partitioned cavities inside.

[0011] Preferably, the lower side of the profile II is provided with a mounting beam, which extends to the inner side through the cross section of the profile II and protrudes to form an inner cantilever beam.

[0012] Preferably, the profile I, profile II, and plate unit are all aluminum profiles.

[0013] Compared with existing technologies, the advantages of this utility model are: the liquid-cooled base plate has an innovative structure, is easy to process, and has high cooling efficiency. The liquid-cooled base plate is spliced ​​from multiple hollow plate units, with internal stiffeners forming a double-channel structure. After being inserted into profile I, it is welded by friction stir welding to form a folded cooling channel. This not only makes it easy to process, but also provides a long and efficient cooling path, effectively ensuring the thermal management performance of the battery system, greatly reducing processing difficulty, improving manufacturing efficiency, and ensuring that the battery box has excellent airtightness. The lightweight design and improved profile structure enhance the safety performance of the battery box frame, meet lightweight requirements, and reduce manufacturing costs. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this utility model;

[0015] Figure 2 This is a schematic diagram of the structure of each part of the box body of this utility model;

[0016] Figure 3 This is a cross-sectional view of profile I of this utility model;

[0017] Figure 4 This is a cross-sectional view of profile II of this utility model;

[0018] Figure 5 This is a schematic diagram showing the fit between profile I, profile II, and liquid-cooled base plate of this utility model;

[0019] Figure 6 This is a cross-sectional view of the sheet metal unit of this utility model.

[0020] In the diagram: 1. Cover plate, 2. Box body, 2.1 Profile I, 2.11 Protrusion, 2.2 Profile II, 2.21 Mounting beam, 2.3 Liquid cooling base plate, 2.31 Plate unit, 2.32 Rib plate, 2.33 Channel opening. Detailed Implementation

[0021] The present invention can be explained in detail through the following embodiments. The purpose of disclosing the present invention is to protect all technical improvements within the scope of the present invention. In the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "front", "rear", "left", "right" indicating the orientation or positional relationship, they are only corresponding to the drawings of this application for the convenience of describing the present invention, and do not indicate or imply that the device or element referred to must have a specific orientation.

[0022] Please see Figure 1-6 The present invention provides the following technical solution:

[0023] Example 1: An aluminum alloy battery box includes a cover plate 1 and a box body 2. The box body 2 is formed by two profiles I 2.1, two profiles II 2.2, and a liquid-cooled bottom plate 2.3. The liquid-cooled bottom plate 2.3 is formed by welding multiple plate units 2.31 in parallel. The plate unit 2.31 is a hollow plate. The internal stiffeners 2.32 of the plate unit 2.31 divide it into two spaces. Both ends of the plate unit 2.31 corresponding to the stiffeners 2.32 are provided with sockets. Each of two adjacent plate units 2.31 is provided with a channel opening 2.33. Both profiles I 2.1 are provided with protrusions 2.11 that are adapted to the sockets. A gap is left between the protrusion 2.11 of one profile I 2.1 and the corresponding stiffener 2.32. The protrusion 2.11 of the other profile I 2.1 is in sealed contact with the corresponding stiffener 2.32. The liquid-cooled bottom plate 2.3 and the two profiles I 2.1 form a folded cooling channel.

[0024] The liquid cooling base plate 2.3 is improved to make it easier to process and form. The two profiles I 2.1 are inserted into the liquid cooling base plate 2.3 and then welded by friction stir welding. The two profiles II 2.2 are aligned with the liquid cooling base plate 2.3 and then welded by friction stir welding. Profiles I 2.1 and II 2.2 are made of aluminum alloy MIG welding. The traditional structure of the liquid cooling base plate 2.3 is changed. The liquid cooling plate 2.3 and profile I 2.1 are directly welded and sealed to form a folded cooling channel, which greatly reduces the processing difficulty, improves the manufacturing efficiency, and ensures that the battery box has very good airtightness.

[0025] One of the profiles I2.1 has a coolant inlet and outlet port on its side wall. The profile I2.1 has through holes corresponding to the coolant inlet and outlet ports respectively. The coolant inlet and outlet ports are connected to the folded cooling channel. That is, the coolant inlet port passes through the profile I2.1 and is connected to the inlet end of the folded cooling channel, and the coolant outlet port passes through the profile I2.1 and is connected to the outlet end of the folded cooling channel.

[0026] Example 2: Unlike Example 1, both profiles I 2.1 and II 2.2 have water-blocking edges at their upper ends, and a sealing gasket is provided between the cover plate 1 and the box body 2. The cover plate 1 and the box body 2 are connected by fastening bolts. The height of the water-blocking edges and the thickness of the sealing gasket after compression are the same, which further improves the sealing performance of the battery box body.

[0027] Example 3: Unlike Example 1, profile I 2.1, profile II 2.2, and plate unit 2.31 are all aluminum profiles with a lightweight design. Profile I 2.1 and profile II 2.2 have multiple partitioned cavities inside, which improves the torsional and bending resistance of the profiles, enhances the safety performance of the battery box frame, ensures that the internal modules of the battery box are not mechanically damaged, meets the lightweight requirements, and reduces manufacturing costs.

[0028] In addition, a mounting beam 2.21 is provided on the lower side of profile II 2.2. The mounting beam 2.21 extends to the inner side through the cross section of profile II 2.2 and protrudes to form an inner cantilever beam, ensuring that the side frame has very high structural strength. The mounting beam 2.21 fixes the battery box, and the inner cantilever beam fixes the battery module inside the box.

[0029] The parts of this utility model not described in detail are prior art. It is obvious to those skilled in the art that this utility model is not limited to the details of the above exemplary embodiments, and that this utility model can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and are intended to include all changes that fall within the meaning and scope of equivalents in the content of this utility model.

Claims

1. An aluminum alloy battery box comprising a cover plate (1) and a box body (2), characterized in that: The housing (2) is formed by two profiles I (2.1), two profiles II (2.2), and a liquid-cooled base plate (2.3); the liquid-cooled base plate (2.3) is formed by welding multiple plate units (2.31) side by side. Each plate unit (2.31) is a hollow plate, and the internal stiffeners (2.32) of each plate unit (2.31) divide it into two spaces. Each plate unit (2.31) has slots at both ends corresponding to the stiffeners (2.32). Two adjacent plate units (2.31) 2.31) Both are provided with a channel opening (2.33); both profiles I (2.1) are provided with a protrusion (2.11) that is adapted to the insertion port, and there is a gap between the protrusion (2.11) of one profile I (2.1) and the corresponding stiffener (2.32), and the protrusion (2.11) of the other profile I (2.1) is in sealed contact with the corresponding stiffener (2.32). The liquid cooling base plate (2.3) and the two profiles I (2.1) form a folded cooling channel.

2. The aluminum alloy battery box of claim 1, wherein: One of the profiles I (2.1) has a coolant inlet and outlet port on its side wall. The profile I (2.1) has through holes corresponding to the coolant inlet and outlet ports respectively. The coolant inlet and outlet ports are connected to the folded cooling channel.

3. The aluminum alloy battery box of claim 1, wherein: The two profiles I (2.1) are inserted into the liquid-cooled base plate (2.3) and then welded by friction stir welding. The two profiles II (2.2) are aligned with the liquid-cooled base plate (2.3) and then welded by friction stir welding. The profiles I (2.1) and II (2.2) are made of aluminum alloy MIG welding.

4. The aluminum alloy battery box of claim 1, wherein: Both profiles I (2.1) and II (2.2) are provided with a water-blocking edge at their upper ends. A sealing gasket is provided between the cover plate (1) and the box body (2). The cover plate (1) and the box body (2) are connected by fastening bolts. The height of the water-blocking edge and the thickness of the sealing gasket after compression are the same.

5. The aluminum alloy battery box of claim 1, wherein: Both profile I (2.1) and profile II (2.2) have multiple partitioned cavities inside.

6. The aluminum alloy battery box of claim 1, wherein: The profile II (2.2) is provided with a mounting beam (2.21) on the lower side. The mounting beam (2.21) extends to the inner side through the cross section of the profile II (2.2) and protrudes to form an inner cantilever beam.

7. The aluminum alloy battery box of claim 1, wherein: The profile I (2.1), profile II (2.2), and plate unit (2.31) are all aluminum profiles.

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