Roll-pressing battery frame with water cooling structure

Abstract

The utility model provides a kind of roll forming battery frame with water cooling structure, comprising: bottom plate part, left longitudinal beam part, right longitudinal beam part and water cooling structure;Left longitudinal beam part and right longitudinal beam part are respectively connected with the both ends of bottom plate part, form the mounting rack body for installing battery;Form the mounting space for installing battery on mounting rack body;Water cooling structure is connected with bottom plate part, bottom plate part is between water cooling structure and mounting space;Water cooling structure includes water cooling bottom plate and multiple water cooling cavities spacedly distributed on water cooling bottom plate;First water cooling channel is formed in water cooling cavity, and water cooling groove is formed between adjacent two water cooling cavities;Second water cooling channel is formed between water cooling groove and bottom plate part.The utility model is integrated water cooling structure in roll forming battery frame, utilizes the bottom plate of battery frame to form part water cooling channel, to further reduce the weight of battery frame, saves sheet material.

Description

Technical Field

[0001] This utility model relates to the field of roll forming profile technology, specifically to a roll forming battery frame with a water-cooled structure. Background Technology

[0002] In battery system design, heat dissipation performance is a key factor affecting battery safety, lifespan, and charge / discharge efficiency. During charging and discharging, especially at high rates, batteries generate significant heat. If this heat cannot be dissipated in time, it can lead to overheating, increasing the risk of thermal runaway and accelerating battery aging, thus reducing cycle life. Therefore, to achieve battery thermal management, cooling is necessary after the battery has been heated during operation. Current methods typically employ battery pack frames with water-cooled channel plates for secure battery mounting.

[0003] like Figure 1 As shown, the main structure of the existing battery pack frame consists of left and right longitudinal beams and front and rear crossbeams. The left and right longitudinal beams include a left longitudinal beam 13 and a right longitudinal beam 14, and the front and rear crossbeams include a front crossbeam and a rear crossbeam. Figure 1 The structure conceals a front and rear crossbeam, a left longitudinal beam, a right longitudinal beam, a front crossbeam, and a rear crossbeam—a total of four parts forming a prefabricated frame surrounding the battery. The joints between adjacent parts require welding. The prefabricated frame and the water-cooling channel plate 15 are then connected via friction stir welding to form a battery pack tray. However, because this structure is formed through multi-point welding, the frame's connection and support strength are limited. It cannot effectively protect the battery from external impacts, and the frame's lifespan is relatively short. Furthermore, the structure requires multiple welding operations, making its fabrication process quite complex. Utility Model Content

[0004] In view of the deficiencies in the prior art, the purpose of this utility model is to provide a roll-formed battery frame with a water-cooled structure.

[0005] A roll-formed battery frame with a water-cooled structure provided by the present invention includes: a base plate, a left longitudinal beam, a right longitudinal beam, and a water-cooled structure. The left longitudinal beam and the right longitudinal beam are respectively connected to both ends of the base plate to form a mounting frame for installing batteries; the mounting frame has an installation space for installing batteries. The base plate, the left longitudinal beam, and the right longitudinal beam are an integral roll forming structure; The water-cooling structure is connected to the base plate, and the base plate is located between the water-cooling structure and the installation space; The water-cooling structure includes a water-cooling base plate and a plurality of water-cooling cavities spaced apart on the water-cooling base plate; a first water-cooling channel is formed in the water-cooling cavity, and a water-cooling groove is formed between two adjacent water-cooling cavities; A second water-cooling channel is formed between the water-cooling groove and the base plate.

[0006] Preferably, the base plate, the left longitudinal beam, the right longitudinal beam, and the water-cooling structure are all made of aluminum profiles.

[0007] Preferably, the top wall of each of the water-cooled cavities is welded to the bottom plate.

[0008] Preferably, a connecting structure is provided at each end of the water-cooling structure, and the top wall of the connecting structure is welded to the bottom plate.

[0009] Preferably, the two connecting structures are respectively connected to the water-cooling cavities located at both ends of the water-cooling structure.

[0010] Preferably, a third water-cooling channel is formed within the connecting structure.

[0011] Preferably, the cross-sectional shape of the first water-cooling channel, the second water-cooling channel, and the third water-cooling channel is trapezoidal.

[0012] Preferably, both the base plate and the water-cooled base plate are rectangular plates; The length direction of the base plate is parallel to the length direction of the water-cooled base plate; The length direction of the water-cooled cavity is parallel to the length direction of the water-cooled base plate; Multiple water-cooled cavities are spaced apart along the width direction of the water-cooled base plate.

[0013] Preferably, the left longitudinal beam is any of the following profile structures: first H-shaped structure, second H-shaped structure, eye-shaped structure, L-shaped structure, single-mouth structure, and double-mouth structure.

[0014] Preferably, the right longitudinal beam is any of the following profile structures: first H-shaped structure, second H-shaped structure, eye-shaped structure, L-shaped structure, single-mouth structure, and double-mouth structure.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The bottom plate, left longitudinal beam, and right longitudinal beam of this utility model are integrally formed roll-pressed structures, which improves the connection strength and support strength of the battery frame. At the same time, a water-cooling structure is welded and integrated on the bottom plate, forming a first water-cooling channel on the water-cooling structure. A second water-cooling channel is formed between the water-cooling groove on the water-cooling structure and the bottom plate, thereby ensuring the water-cooling effect on the battery. Description of Drawings

[0016] Other features, objects and advantages of the present utility model will become more apparent upon reading the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 is a schematic perspective view of an existing battery pack frame; Figure 2 is a cross-sectional schematic view of a roll-formed battery frame with a water cooling structure according to the present utility model; Figure 3 is Figure 2 an enlarged view of the structural details in; Figure 4 is a front view of a roll-formed battery frame with a water cooling structure provided with a front cross beam portion and a rear cross beam portion; Figure 5 is Figure 4 an enlarged view of the structural details of; Figure 6 is a cross-sectional schematic view of the water cooling structure; Figure 7 is Figure 6 an enlarged view of the structural details of; Figure 8 is a partial schematic perspective view of the water cooling structure; Figures 9-11 is a schematic diagram of the forming process of the roll-formed battery frame with the water cooling structure; Figure 12 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt a first Japanese-character-shaped structure; Figure 13 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt a second Japanese-character-shaped structure; Figure 14 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt a grid-shaped (Chinese "mu" character-shaped) structure; Figure 15 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt L-shaped structures; Figure 16 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt single-opening structures; Figure 17 is a structural schematic diagram where both the left longitudinal beam portion and the right longitudinal beam portion adopt double-opening structures.

[0017] What is shown in the drawings: 1. Base plate; 2. Left longitudinal beam; 3. Right longitudinal beam; 4. Water-cooled structure; 41. Water-cooled base plate; 42. Water-cooled cavity; 421. First water-cooled channel; 43. Water-cooled groove; 431. Second water-cooled channel; 5. Installation space; 6. First H-shaped structure; 7. Second H-shaped structure; 8. Eye-shaped structure; 9. L-shaped structure; 10. Single-opening structure; 11. Double-opening structure; 12. Connecting structure; 121. Third water-cooled channel; 13. Left longitudinal beam; 14. Right longitudinal beam; 15. Water-cooled channel plate; 16. Front crossbeam. Detailed Implementation

[0018] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0019] Example 1 like Figures 2-11 As shown, this embodiment provides a roll-formed battery frame with a water-cooled structure, including: a base plate 1, a left longitudinal beam 2, a right longitudinal beam 3, and a water-cooling structure 4; the left longitudinal beam 2 and the right longitudinal beam 3 are respectively connected to both ends of the base plate 1 to form a mounting frame for installing batteries; the mounting frame has an installation space 5 for installing batteries; the base plate 1, the left longitudinal beam 2, and the right longitudinal beam 3 are integrally roll-formed structures; the water-cooling structure 4 is connected to the base plate 1, and the base plate 1 is located between the water-cooling structure 4 and the installation space 5; the water-cooling structure 4 includes a water-cooled base plate 41 and a plurality of water-cooled cavities 42 spaced apart on the water-cooled base plate 41; a first water-cooling channel 421 is formed in the water-cooled cavity 42, and a water-cooling groove 43 is formed between two adjacent water-cooled cavities 42; a second water-cooling channel 431 is formed between the water-cooling groove 43 and the base plate 1. Figure 4 The diagram shown is a structural schematic of a roll-formed battery frame with a front crossbeam 16.

[0020] Both the base plate 1 and the water-cooled base plate 41 are rectangular plates; the length direction of the base plate 1 and the length direction of the water-cooled base plate 41 are parallel to each other; the length direction of the water-cooled cavity 42 is parallel to the length direction of the water-cooled base plate 41; multiple water-cooled cavities 42 are spaced apart along the width direction of the water-cooled base plate 41. The base plate 1, the left longitudinal beam 2, the right longitudinal beam 3, and the water-cooled structure 4 are all aluminum profile structures.

[0021] The top wall of each water-cooled cavity 42 is welded to the base plate portion 1, and the welding method is brazing. In this embodiment, a connecting structure 12 is respectively provided at both ends of the water-cooled structure 4, and the top wall of the connecting structure 12 is welded to the base plate portion 1; the two connecting structures 12 are respectively connected to the water-cooled cavities 42 located at both ends of the water-cooled structure 4. A third water-cooling channel 121 is formed in the connecting structure 12. The cross-sectional shapes of the first water-cooling channel 421, the second water-cooling channel 431 and the third water-cooling channel 121 are all trapezoidal.

[0022] The left longitudinal beam portion 2 is any one of the following profile structures: a first Japanese-shaped structure 6, a second Japanese-shaped structure 7, a grid-shaped structure 8, an L-shaped structure 9, a single-opening structure 10, and a double-opening structure 11. The right longitudinal beam portion 3 is any one of the following profile structures: a first Japanese-shaped structure 6, a second Japanese-shaped structure 7, a grid-shaped structure 8, an L-shaped structure 9, a single-opening structure 10, and a double-opening structure 11.

[0023] As Figure 12 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the first Japanese-shaped structure 6; as Figure 13 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the second Japanese-shaped structure 7; as Figure 14 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the grid-shaped structure 8; as Figure 15 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the L-shaped structure 9; as Figure 16 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the single-opening structure 10; as Figure 17 shown, both the left longitudinal beam portion and the right longitudinal beam portion are the double-opening structure 11.

[0024] Example 2 A person skilled in the art can understand the present embodiment as a more specific description of Embodiment 1.

[0025] The present embodiment provides a roll-formed battery frame with a water-cooled structure, which uses a high-strength aluminum strip as a raw material, and both sides are simultaneously designed to have a special-shaped cavity. As Figures 12-17 shown, the special-shaped cavity can be a Japanese-shaped cavity, a grid-shaped cavity, an L-shaped cavity, a single-opening cavity, a double-opening cavity, etc. A supporting bottom plate structure is arranged in the middle of the cavity, the cavities on both sides and the supporting bottom structure are integrally formed, the cavities are laser-welded, and the processing technology is roll forming. For battery thermal management, heat dissipation and cooling are required after operation and heating, so a water-cooled plate structure is additionally arranged on the supporting bottom plate. As Figure 11 shown.

[0026] The water-cooling channel structure of the present embodiment is manufactured by an aluminum extrusion process, the lower layer is in a flat plate state, independent cavity structures are intermittently distributed on the flat plate, and the upper layer is in an open state. After being connected with the supporting bottom plate structure of the integrated roll-formed frame, independent closed cavities are formed, and at this time the water-cooling channel plate is more complete.

[0027] like Figure 2 The image shows a front view of the battery frame structure with the front and rear crossbeams concealed. Figure 3 As shown, Figure 2 Enlarged structural detail diagram, in Figure 2 Based on the integral roll-formed profile, the front and rear aluminum plates are processed by bending to form a predetermined cavity. Then, the connection is welded to finally form an integral molded aluminum frame.

[0028] like Figure 4 The image shown is a front view of the overall frame containing the battery. Figure 5 As shown, Figure 4 Enlarged detail of the structure.

[0029] like Figure 1 As shown, an existing main structure processing method for a battery pack frame consists of left and right longitudinal beams and front and rear cross beams (4 parts). The joints are welded together around the perimeter to form a prefabricated frame. The prefabricated aluminum frame and water-cooling channel plate are then connected by friction stir welding to finally form a battery pack tray. The disadvantages of this structure are: a large variety of materials, a long processing flow, and low production efficiency. The long processing flow specifically involves: frame material extrusion → welding → frame assembly welding → friction stir welding of the water-cooling channel plate and aluminum frame → CNC machining. Quality control and welding are difficult, and due to the large deformation after welding and low dimensional accuracy, subsequent CNC machining is required to ensure the installation accuracy of the riveting holes. Furthermore, the low extrusion strength of aluminum (around 200 MPa) makes it difficult to further reduce weight and achieve lightweighting. In addition, equipment investment, processing, and labor costs are high.

[0030] There is also an existing battery pack frame whose main structure is formed by riveting steel roll-formed profiles with aluminum water-cooling channel plates. Existing steel battery frames use high-strength steel, but the water-cooling channel plates are made of aluminum. Welding dissimilar materials is very difficult, or even impossible, so riveting, a cold-connection method, is required. The water-cooling plate can be placed at the bottom or top. For steel battery packs with a bottom-welded base plate, the water-cooling plate can only be placed at the top. Regardless of the form, only pull riveting and blind riveting connections can be used, which presents a technical challenge.

[0031] In this embodiment, the base plate 1, left longitudinal beam 2, right longitudinal beam 3, and water-cooling structure 4 are all made of high-strength aluminum, specifically 6-series and 7-series aluminum plates with a strength up to 400 MPa. They are manufactured using an advanced roll forming process for integrated online molding, resulting in high product quality, production stability, and efficiency. The application of high-strength aluminum plates further reduces the overall weight of the aluminum profile frame, thereby reducing the overall vehicle weight, increasing the driving range of new energy batteries, reducing welding processes and the amount of welding, achieving higher forming precision, and ensuring the structural integrity and overall strength and rigidity, thus improving the structure's collision resistance.

[0032] In this embodiment, the base plate 1, left longitudinal beam 2, right longitudinal beam 3, and water-cooling structure 4 are made of the same material. Structurally, the use of the same material makes it easy to connect the overall aluminum roll-formed frame and the aluminum water-cooling channel plate, eliminating the use of rivets, reducing material costs, and removing the restriction on the position of the water-cooling plate, which can be set arbitrarily up or down, greatly improving the innovation and feasibility of the battery frame design.

[0033] The structure in this embodiment uses high-strength aluminum plates with a strength of 400MPa or higher, further achieving lightweighting of materials and structure. It can be manufactured in the following two ways: Method 1: After the high-strength aluminum plate is rolled into shape by a roll forming mold, the two sides of the aluminum plate are rolled into multiple cavities. The cavities are connected by aluminum plates to form a whole, serving as the bottom plate of the battery frame. The left and right cavities are longitudinal beams used for frame support and collision prevention. The front and rear aluminum plates are bent to form two single-cavity crossbeams. The frame is welded around its perimeter to form a whole, ensuring the integrity, stability, and performance requirements of the entire frame structure. Then, the prefabricated aluminum water-cooling channel plate (i.e., water-cooling structure 4) of this embodiment is set on the bottom plate. The prefabricated aluminum water-cooling channel plate is processed by aluminum extrusion or aluminum plate stamping + brazing or blow forming. The high-strength aluminum frame bottom plate and the prefabricated aluminum water-cooling channel plate are connected by welding, mainly by brazing. Method 2: High-strength aluminum plates are pre-connected to pre-fabricated aluminum water-cooling channel plates in a flat state, using aluminum extrusion or aluminum plate stamping + brazing or blow forming. This yields a pre-fabricated high-strength aluminum plate with water-cooling channels, such as... Figures 9-12 As shown, the battery pack is then roll-formed using a molding die to form the left and right longitudinal beam structures. The front and rear beam structures are formed by bending, and finally welded together to form an integral battery pack frame with a water-cooled channel plate structure. Figure 9 The structure is made of high-strength aluminum plate with prefabricated water-cooling channel plate. Figure 10 The structure is a semi-finished frame formed by roll forming of left and right longitudinal beams. Figure 11 The structure shown is the finished structure of the battery pack frame.

[0034] This invention integrates a water-cooling structure into a roll-formed battery frame, utilizing the bottom plate of the battery frame to form a partial water-cooling channel, thereby reducing the weight of the battery frame and saving sheet material.

[0035] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and 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. Therefore, they should not be construed as limitations on this application.

[0036] The specific embodiments of this utility model have been described above. It should be understood that this utility model is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the substantive content of this utility model. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A roll-formed battery frame with a water-cooled structure, characterized in that, include: The base plate (1), the left longitudinal beam (2), the right longitudinal beam (3), and the water-cooled structure (4); The left longitudinal beam (2) and the right longitudinal beam (3) are respectively connected to both ends of the base plate (1) to form a mounting frame for installing batteries; the mounting frame has an installation space (5) for installing batteries. The base plate (1), the left longitudinal beam (2), and the right longitudinal beam (3) are integral roll forming structures; The water-cooled structure (4) is connected to the base plate (1), and the base plate (1) is located between the water-cooled structure (4) and the installation space (5); The water-cooled structure (4) includes a water-cooled base plate (41) and a plurality of water-cooled cavities (42) spaced apart on the water-cooled base plate (41); a first water-cooled channel (421) is formed in the water-cooled cavity (42), and a water-cooled groove (43) is formed between two adjacent water-cooled cavities (42). A second water-cooling channel (431) is formed between the water-cooled groove (43) and the bottom plate (1).

2. The roll-formed battery frame with a water-cooled structure according to claim 1, characterized in that, The base plate (1), the left longitudinal beam (2), the right longitudinal beam (3), and the water-cooling structure (4) are all aluminum profile structures.

3. The roll-formed battery frame with a water-cooled structure according to claim 1, characterized in that, The top wall of each of the water-cooled cavities (42) is welded to the bottom plate (1).

4. The roll-formed battery frame with a water-cooled structure according to claim 3, characterized in that, The water-cooled structure (4) has a connecting structure (12) at each end, and the top wall of the connecting structure (12) is welded to the bottom plate (1).

5. The roll-formed battery frame with a water-cooled structure according to claim 4, characterized in that, The two connecting structures (12) are respectively connected to the water-cooling cavities (42) located at both ends of the water-cooling structure (4).

6. The roll-formed battery frame with a water-cooled structure according to claim 5, characterized in that, A third water-cooling channel (121) is formed within the connecting structure (12).

7. The roll-formed battery frame with a water-cooled structure according to claim 6, characterized in that, The cross-sectional shape of the first water-cooling channel (421), the second water-cooling channel (431) and the third water-cooling channel (121) is trapezoidal.

8. The roll-formed battery frame with a water-cooled structure according to claim 1, characterized in that, Both the base plate (1) and the water-cooled base plate (41) are rectangular plates; The length direction of the base plate (1) and the length direction of the water-cooled base plate (41) are parallel to each other; The length direction of the water-cooled cavity (42) is parallel to the length direction of the water-cooled base plate (41); Multiple water-cooled cavities (42) are spaced apart along the width direction of the water-cooled base plate (41).

9. The roll-formed battery frame with a water-cooled structure according to claim 1, characterized in that, The left longitudinal beam (2) can be any of the following profile structures: first sun-shaped structure (6), second sun-shaped structure (7), eye-shaped structure (8), L-shaped structure (9), single-mouth structure (10), double-mouth structure (11).

10. The roll-formed battery frame with a water-cooled structure according to claim 1, characterized in that, The right longitudinal beam (3) can be any of the following profile structures: first sun-shaped structure (6), second sun-shaped structure (7), eye-shaped structure (8), L-shaped structure (9), single-mouth structure (10), double-mouth structure (11).

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