CN111261818A - Weldless lightweight battery box body and manufacturing process thereof - Google Patents
Weldless lightweight battery box body and manufacturing process thereof Download PDFInfo
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- CN111261818A CN111261818A CN202010166639.2A CN202010166639A CN111261818A CN 111261818 A CN111261818 A CN 111261818A CN 202010166639 A CN202010166639 A CN 202010166639A CN 111261818 A CN111261818 A CN 111261818A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 239000003292 glue Substances 0.000 claims abstract description 96
- 239000000853 adhesive Substances 0.000 claims abstract description 28
- 230000001070 adhesive effect Effects 0.000 claims abstract description 28
- 238000003466 welding Methods 0.000 claims abstract description 22
- 238000004026 adhesive bonding Methods 0.000 claims abstract description 17
- 230000001502 supplementing effect Effects 0.000 claims abstract description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 239000011248 coating agent Substances 0.000 claims description 12
- 238000000576 coating method Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 10
- 239000000565 sealant Substances 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 238000007789 sealing Methods 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 6
- 238000010079 rubber tapping Methods 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 4
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 230000007704 transition Effects 0.000 claims description 4
- 229920000297 Rayon Polymers 0.000 claims description 3
- 241000124033 Salix Species 0.000 claims description 3
- 239000002131 composite material Substances 0.000 claims description 3
- 238000007790 scraping Methods 0.000 claims description 3
- 239000011324 bead Substances 0.000 claims 3
- 238000000034 method Methods 0.000 abstract description 23
- 238000011019 functional design specification Methods 0.000 abstract description 12
- 230000004927 fusion Effects 0.000 abstract description 8
- 238000003756 stirring Methods 0.000 abstract description 7
- 238000010586 diagram Methods 0.000 description 6
- 238000003780 insertion Methods 0.000 description 3
- 230000037431 insertion Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 238000005336 cracking Methods 0.000 description 1
- 238000001962 electrophoresis Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- General Chemical & Material Sciences (AREA)
- Battery Mounting, Suspending (AREA)
- Sealing Battery Cases Or Jackets (AREA)
Abstract
The invention discloses a weldless lightweight battery box body and a manufacturing process thereof, and the weldless lightweight battery box body comprises frame profiles, frame corner connectors, cross beams and a bottom plate, wherein the frame profiles are assembled together through the frame corner connectors to form a frame group; the frame group is sequentially subjected to frame corner code gluing, frame corner code inserting into a frame, frame corner code inserting into another frame, clamping, assembling screws, glue supplementing or applying and curing; the beam is sequentially pre-fixed, coated with structural adhesive, assembled and cured; the bottom plate is riveted with FDS through gluing, gluing and FDS in sequence. By the mode, the weld-seam-free lightweight battery box body and the manufacturing process thereof can remove large-area fusion welding and stirring welding, greatly improve the cost and efficiency, are easy to control the dimensional precision and do not deform, reduce the equipment cost, and ensure high feasibility of an automatic production line by using the gluing process and the FDS process together.
Description
Technical Field
The invention relates to the technical field of automobile accessories, in particular to a weldless lightweight battery box body and a manufacturing process thereof.
Background
In recent years, the new energy automobile industry is rapidly developed, and aluminum extruded sections are widely applied to new energy automobile battery trays, so that the lightweight level of the whole new energy automobile is improved.
The existing box body structure is mainly formed by machining frame sectional materials, then welding the frame sectional materials in a fusion welding mode, connecting the frame sectional materials with the bottom in a friction stir welding process, and enabling the whole box body to be in a large number of fusion welding (3-5 m) and friction stir welding (5-10 m), so that the box body is long in working time, high in cost, large in product deformation, poor in stability, low in production efficiency and not easy to control.
As shown in the attached drawing 1, after a front frame 1', a left frame 2', a rear frame 3 'and a right frame 4' are assembled, 4 corners are welded by fusion, the full-weld length is 1.5-3 m (determined according to the size and height of a box body), the length and width can be shrunk by 0.5-1.0 mm, and the size is not easy to control; the beam 5' is connected to the frame through fusion welding (TIG or CMT), the material performance of the side beam is reduced, the risk of welding through exists, meanwhile, shrinkage deformation exists, and a module hole processed in advance can deviate; the prior art of the bottom plate 6' and the frame is friction stir welding.
As shown in fig. 2, the first conventional solution adopts a hollow profile, as shown in fig. 3, and the second conventional solution adopts a single-layer bottom plate, so that manufacturability and air tightness are the most reliable at present, and the main problems are that the welding seam is long, and more equipment is needed for increasing the production capacity.
Disclosure of Invention
The invention mainly solves the technical problem of providing a weldless lightweight battery box body and a manufacturing process thereof, which can remove large-area fusion welding and stir welding, replace the welding with gluing and assembling processes, greatly improve the cost and the efficiency, easily control the dimensional precision without deformation, reduce the equipment cost, use the gluing process and the FDS process together, and ensure high feasibility of an automatic production line.
In order to solve the technical problems, the invention adopts a technical scheme that: provided is a weldless lightweight battery case, including: frame section bar, frame angle sign indicating number, crossbeam and bottom plate, frame section bar assemble together through frame angle sign indicating number and form frame group, and the crossbeam transversely is installed in frame group inside and with the left and right sides locking of frame group, and the bottom plate lock joint is fixed on frame group and with frame group locking.
In a preferred embodiment of the invention, the frame section comprises a front frame, a left frame, a right frame and a rear frame, and the connecting parts of the front frame, the left frame, the right frame and the rear frame are inserted into frame corner connectors to realize locking and sealing connection to form a frame group.
In a preferred embodiment of the present invention, the frame corner brace includes a first limiting arm and a second limiting arm that are vertically disposed, the two ends of the frame corner brace further include a first corner connecting arm and a second corner connecting arm that are vertically disposed, and the first limiting arm and the second limiting arm, and the first corner connecting arm and the second corner connecting arm are respectively inserted into the corresponding frame profiles.
In a preferred embodiment of the present invention, semicircular convex points are disposed on two sides of the first limiting arm and the second limiting arm, semicircular convex points are disposed on two sides of the first corner connecting arm and the second corner connecting arm, and the first limiting arm and the second limiting arm, and the first corner connecting arm and the second corner connecting arm are slidably inserted into the frame profile through the semicircular convex points and then tightly connected.
In a preferred embodiment of the invention, the two side surfaces of the first limiting arm and the second limiting arm form a first glue overflow groove, the outer side surfaces of the first corner connecting arm and the second corner connecting arm form a first glue overflow groove,
a second glue overflow groove is formed on the outer side surface of the corner of the frame corner brace, a third glue overflow groove is formed in the center of the cross section of the corner of the frame corner brace, a fourth glue overflow groove is formed on the inner side surface of the corner of the frame corner brace,
structural glue is fully coated in the first glue overflow groove, the second glue overflow groove, the third glue overflow groove and the fourth glue overflow groove to connect the frame corner connector and the frame in a reinforcing way.
In a preferred embodiment of the invention, a clearance groove is arranged between adjacent first limiting arms, a clearance groove is also arranged between the first limiting arms and the first corner connecting arm, a clearance groove is arranged between adjacent second limiting arms, a clearance groove is also arranged between the second limiting arms and the second corner connecting arm, and steel wire thread sleeves are also embedded on the first limiting arms and the second limiting arms.
In a preferred embodiment of the invention, the beam comprises a beam base body, a first beam corner connector and a second beam corner connector, wherein the beam base body is embedded with a steel wire threaded sleeve, the first beam corner connector and the second beam corner connector are locked on two side surfaces of the end part of the beam base body through bolts, structural adhesive is coated on the binding surfaces of the first beam corner connector and the second beam corner connector and the frame group,
bolt holes are further formed in the binding faces of the first cross beam angle code, the second cross beam angle code and the frame group, and the whole cross beam is connected with the frame group in a locking mode through the first cross beam angle code and the second cross beam angle code and is enhanced in a sealing mode.
In a preferred embodiment of the invention, the bottom plate comprises a bottom plate, the surface of the bottom plate is punched to form a convex hull, the periphery of the bottom plate is punched and stretched to form a rim, the transition corner of the rim is a rounded corner, the rim is provided with an assembly hole, the two sides of the convex hull on the bottom plate are provided with fifth glue overflow grooves, and the periphery of the bottom plate is provided with sixth glue overflow grooves.
In a preferred embodiment of the present invention, the bottom plate is made of an aluminum plate, a steel plate or a steel-aluminum composite plate, the bottom plate is integrally concave, and the bottom plate is turned over and then fastened to the frame assembly.
In order to solve the technical problem, the invention adopts another technical scheme that: the manufacturing process of the weldless lightweight battery box body comprises the following steps:
a. assembling the frame group:
a0, processing of the frame profile: processing frame profiles according to the size of the battery box body to manufacture a corresponding front frame, a left frame, a right frame and a rear frame;
a1, gluing frame corner connectors: structural glue is fully coated in a first glue overflow groove, a second glue overflow groove, a third glue overflow groove and a fourth glue overflow groove of the frame corner connector, and the glue coating is uniform;
a2, insert: guiding a first limiting arm and a first corner connecting arm of a frame corner connector, then slidably inserting the first limiting arm and the first corner connecting arm into one frame profile through a semicircular salient point, guiding a second limiting arm and a second corner connecting arm of the frame corner connector, then slidably inserting the second limiting arm and the second corner connecting arm into the other frame profile through the semicircular salient point, sequentially splicing four vertex angles of a frame group together through the frame corner connector, and paying attention to the fact that glue overflows from the spliced part;
a3, clamping: the frame corner connectors at the four top corners of the frame group are pushed in place through external thrust;
a4, assembling screws: locking screws in the steel wire thread sleeves of the frame corner connectors to lock the frame sectional materials and the frame corner connectors together;
a5, glue filling or smearing: scraping off the glue overflowing from the splicing position, supplementing the glue, and leveling the glue higher than the plane;
a6, curing: gradually curing the structural adhesive, and tightly combining the frame corner connectors with corresponding frame sectional materials, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or the curing can be accelerated by adopting an oven, and the curing time is 0.4-1 hour;
b. assembling the beam group:
b1, pre-fixing: preliminarily fixing the beam corner connectors on two side surfaces of the end part of the beam base body, and not fastening at this time;
b2, coating structural adhesive: coating structural adhesive on the joint surface of the beam corner connector and the frame group, and uniformly coating the structural adhesive;
b3, assembling: aligning bolt holes on the cross beam corner connectors with corresponding mounting holes on the frame groups, then pulling core and pulling willow, and locking the cross beam with the frame groups through the cross beam corner connectors through bolts;
b4, curing: assembling all the cross beams in the frame group according to the steps b 1-b 3, gradually curing structural adhesive after placing, and tightly combining the cross beam corner connectors with the frame section bars at the corresponding positions, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or adopting an oven to accelerate the curing, and the curing time is 0.4-1 hour;
c. assembling a bottom plate group:
c1, gluing: structural sealant is coated in the fifth glue overflowing grooves on the two sides of the convex hull on the bottom plate, and sealant is coated in the sixth glue overflowing grooves on the periphery of the bottom plate;
c2, viscose: the bottom plate is buckled on the frame after being flanged, and the bottom plate is quickly adhered to the beam group;
c3, FDS riveting: screws are inserted into the assembly holes at the periphery of each bottom plate and the position of the cross beam to lock the bottom plates with the frame group and the cross beam, and the bottom plates are riveted on the frame section and the cross beam in an FDS hot melting self-tapping riveting mode.
The invention has the beneficial effects that: the non-welding seam lightweight battery box body and the manufacturing process thereof remove large-area fusion welding and stirring welding, and replace the welding seam with a gluing and assembling process, thereby greatly improving the cost and the efficiency; the dimensional accuracy is easy to control and cannot deform, so that the equipment cost is reduced; the gluing process and the FDS process are used together, so that the high feasibility of an automatic production line is ensured.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without inventive efforts, wherein:
FIG. 1 is a schematic diagram of a preferred embodiment of a battery case of the prior art;
FIG. 2 is a schematic structural diagram of a first baseplate structure in a battery box in the prior art;
FIG. 3 is a schematic structural diagram of a second bottom plate structure in a battery box of the prior art;
FIG. 4 is a schematic structural view of a preferred embodiment of the weldless lightweight battery case of the present invention;
FIG. 5 is a schematic structural view of a preferred embodiment of a corner brace of a frame in the weldless lightweight battery case of the present invention;
FIG. 6 is a schematic structural view of another preferred embodiment of a corner brace of a frame in the weldless lightweight battery case of the present invention;
FIG. 7 is a side view of a frame corner brace in the weldless lightweight battery case of the present invention;
FIG. 8 is a schematic structural view of a preferred embodiment of a cross beam in the weldless lightweight battery case of the present invention;
FIG. 9 is a schematic structural view of a preferred embodiment of the bottom plate of the weldless lightweight battery case of the present invention;
FIG. 10 is a schematic structural view of another preferred embodiment of the bottom plate of the weldless light-weight battery case of the present invention;
fig. 11 is a schematic structural view of the assembly steps a1 and a2 in the assembly process of the weldless lightweight battery case of the present invention;
fig. 12 is a schematic structural diagram of an assembly step a3 in the assembly process of the weldless lightweight battery case of the present invention;
FIG. 13 is a schematic structural diagram of assembly steps a 4-a 6 in the assembly process of the weldless lightweight battery box body;
FIG. 14 is a schematic structural diagram of assembly steps b 1-b 3 in the assembly process of the weldless lightweight battery box body of the invention;
fig. 15 is a schematic structural view of an assembly step b4 in the assembly process of the weldless lightweight battery case of the present invention;
fig. 16 is a schematic structural view of an assembly step of c1 in the assembly process of the weldless lightweight battery case of the present invention;
fig. 17 is a schematic structural view of an assembly step of c2 in the assembly process of the weldless lightweight battery case of the present invention;
fig. 18 is a schematic structural view of an assembly step of c3 in the assembly process of the weldless lightweight battery case of the present invention;
the parts in the drawings are numbered as follows: 1', a front frame, 2', a left frame, 3', a rear frame, 4', a right frame,
100. front frame, 200, left frame, 300, rear frame, 400, right frame, 500, beam, 510, base body, 520, first beam corner connector, 530, second beam corner connector, 540, bolt, 550, steel wire thread insert, 560 and bolt hole,
600. a bottom plate 610, a bottom flat plate 620, a stamping convex hull 630, a fifth glue overflow groove 640, a sixth glue overflow groove 650, edges 660, transition angles 670 and assembly holes,
700. frame angle sign indicating number, 710, first spacing arm, 720, second spacing arm, 730, semicircle bump, 740, first glue groove that overflows, 750, second glue groove that overflows, 760, third glue groove that overflows, 770, fourth glue groove that overflows, 780, first corner linking arm, 790, second corner linking arm, 7100, keep away the dead slot, 7110, screw hole.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 4 to 18, an embodiment of the present invention includes:
a weldless lightweight battery case comprising: frame section bar, frame angle sign indicating number 700, crossbeam 500 and bottom plate 600, the frame section bar assembles together through frame angle sign indicating number 700 and forms frame group, crossbeam 500 transversely install in frame group inside and with the left and right sides locking of frame group, bottom plate 600 lock joint is in frame group and with frame group locking fixed.
The frame section comprises a front frame 100, a left frame 200, a right frame 400 and a rear frame 300, and frame corner connectors 700 are inserted into the joints of the front frame 100, the left frame 200, the right frame 400 and the rear frame 300 to realize locking and sealing connection to form a frame group.
Frame angle sign indicating number 700 mainly realizes strengthening and sealed effect, and frame angle sign indicating number 700's structure is including being the first spacing arm 710 and the spacing arm 720 of second of perpendicular setting, and frame angle sign indicating number 700's both ends are still including being first corner linking arm 780 and the second corner linking arm 790 of perpendicular setting, and first spacing arm 710 and the spacing arm 720 of second and first corner linking arm 780 and second corner linking arm 790 insert in the corresponding frame section bar respectively.
Preferably, the two sides of the first and second limiting arms 710 and 720 are provided with semicircular salient points 730, the two sides of the first and second corner connecting arms 780 and 790 are provided with semicircular salient points 730, the first and second limiting arms 710 and 720 and the first and second corner connecting arms 780 and 790 are slidably inserted into the frame profile through the semicircular salient points 730, no gap exists, tight and firm connection can be formed after insertion, and the convenient and fast insertion can be ensured under the action of the semicircular salient points 730.
The surfaces of the two sides of the first limiting arm 710 and the second limiting arm 720 form a first glue overflow groove 740, the outer side surfaces of the first corner connecting arm 780 and the second corner connecting arm 790 form a first glue overflow groove 740, the outer side surface of the corner of the frame corner connector 700 forms a second glue overflow groove 750, the center of the cross section of the corner of the frame corner connector 700 forms a third glue overflow groove 760, the inner side surface of the corner of the frame corner connector 700 forms a fourth glue overflow groove 770, and structural glue is fully coated in the first glue overflow groove 740, the second glue overflow groove 750, the third glue overflow groove 760 and the fourth glue overflow groove 770 to connect the frame corner connector 700 and the frame in an enhanced manner.
The first glue overflow groove 740 is fully coated with structural glue before insertion, and is connected with the frame assembly after curing to increase the strength; the second glue overflow groove 750, the third glue overflow groove 760 and the fourth glue overflow groove 770 are filled with structural glue and are combined with the frame assembly to achieve a sealing effect.
Through the use and verification of the structural adhesive, such as 3M SA9820 structural adhesive, the tensile strength exceeds 20MPa, and through related tests, the problem of cracking does not occur, so that the structural adhesive and riveting process is adopted to manufacture the battery box body.
The initial curing time of the structural adhesive is 1 hour, so that enough time is available for gluing, inserting, clamping, screwing, glue supplementing, glue smearing and curing.
According to the difference of frame section bar height and width, will set up screw hole 7110 at frame angle sign indicating number 700, inlay the steel wire swivel nut before first spacing arm 710 and second spacing arm 720 in advance, after frame angle sign indicating number 700 inserts, the inside lock screw of frame has increased intensity.
Because the reinforcing ribs are arranged on the cross section of the frame profile and cannot be removed well, clearance grooves are formed between the adjacent first limiting arms 710, clearance grooves 7100 are also formed between the first limiting arms 710 and the first corner connecting arms 780, clearance grooves 7100 are formed between the adjacent second limiting arms, and clearance grooves 7100 are also formed between the second limiting arms 720 and the second corner connecting arms 790.
The strength of the frame corner brace section bar is higher than that of the frame section bar, the material of the frame corner brace 700 can be 6061-T6, and the tensile strength is higher than 280 Mpa. The wall thickness of frame angle sign indicating number 700 is about 10mm, and in order to match with current frame section bar size simultaneously, the width of frame angle sign indicating number 700 is about 15 mm.
The beam 500 comprises a beam base body 510, a first beam corner connector 520 and a second beam corner connector 530, wherein the beam base body 510 is machined in advance, a beam steel wire threaded sleeve 550 is embedded in the beam base body 510 in a lifting mode, and after the beam base body 510 is installed in a frame set, screws are locked in the frame, so that the strength is improved.
First crossbeam angle sign indicating number 520 and second crossbeam angle sign indicating number 530 pass through bolt 540 locking at crossbeam base member 510 tip both sides face, be scribbled the structure glue on the binding face of first crossbeam angle sign indicating number 520 and second crossbeam angle sign indicating number 530 and frame group, bolt hole 560 has still been seted up on the binding face of first crossbeam angle sign indicating number 520 and second crossbeam angle sign indicating number 530 and frame group, corresponding mounting hole on the frame group is aimed at to bolt hole 560, whole crossbeam 500 is through first crossbeam angle sign indicating number 520 and second crossbeam angle sign indicating number 530 and frame group locking connection and sealing combination reinforcing.
The bottom plate 600 includes a bottom plate 610, which has a flat plate structure, a simple mold, and a process that is easily controlled. The bottom plate 610 is made of aluminum plates, steel plates or steel-aluminum composite plates, the whole bottom plate is arranged in a concave shape, and the bottom plate is buckled on the frame assembly after being flanged.
Adopt the thickness of aluminum plate to be about 2mm, the PVC is spouted to aluminum plate bottom and is prevented stone striking and glue, and the steel sheet adopts high strength steel sheet, and thickness is about 1mm, spouts after the electrophoresis to prevent stone striking and glues.
The surface of the bottom plate 610 needs to be stamped with a convex hull 620 to increase the strength of the bottom plate; in addition, the bottom plate 610 is provided with fifth glue overflow grooves 630 at two sides of the convex hull 620, the periphery of the bottom plate 610 is provided with sixth glue overflow grooves 640, and the fifth glue overflow grooves 630 and the sixth glue overflow grooves 640 are internally coated with sealant only for sealing.
Specifically, the bottom plate 610 is made of a flat plate material, the concave shape and the frame group are integrally buckled through 2-3 times of stamping and stretching, the periphery of the bottom plate 610 is stamped and stretched to form a rim 650, and a transition corner 660 of the rim is a round corner.
The depth of the edge needs to be shallow, the box is suitable for being low in height of the lower box, the bottom plate 600 needs to be buckled on the frame after being turned over, the edge 650 is provided with an assembling hole 670, a screw is inserted into the assembling hole 670 to lock the bottom plate 600 and the frame assembly, the bottom plate 600 is riveted on the frame section bar and the cross beam 500 in an FDS hot melting self-tapping riveting mode, and the air tightness requirement is guaranteed.
A manufacturing process of a weldless lightweight battery box body comprises the following steps:
a. assembling the frame group:
a0, processing of the frame profile: processing frame profiles according to the size of the battery box body to manufacture a corresponding front frame 100, a left frame 200, a right frame 300 and a rear frame 400;
a1, gluing the frame corner connector 700: structural glue is fully coated in the first glue overflow groove 740, the second glue overflow groove 750, the third glue overflow groove 760 and the fourth glue overflow groove 770 of the frame corner connector 700, and the glue coating needs to be uniform;
a2, insert: guiding a first limiting arm 710 and a first corner connecting arm 780 of a frame corner connector 700, then slidably inserting the first limiting arm 710 and the first corner connecting arm 780 into one frame profile through a semicircular salient point 730, guiding a second limiting arm 720 and a second corner connecting arm 790 of the frame corner connector 700, then slidably inserting the second limiting arm 720 and the second corner connecting arm 790 into the other frame profile through the semicircular salient point 730, sequentially splicing four top corners of a frame group together through the frame corner connector 700, and paying attention to the fact that glue overflows at the spliced part;
a3, clamping: the frame corner connectors 700 at the four top corners of the frame group are pushed to the right position through external thrust; (all 4 corners require a push-in-place):
a4, assembling screws: screws are locked in the steel wire screw sleeves of the frame corner connectors 700, so that the frame section bars and the frame corner connectors 700 are locked together;
a5, glue filling or smearing: scraping off the glue overflowing from the splicing position, supplementing the glue, and leveling the glue higher than the plane;
a6, curing: gradually curing the structural adhesive, and tightly combining the frame corner connector 700 with a corresponding frame profile, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or the curing time is 0.4-1 hour by adopting an oven to accelerate the curing;
b. assembling the beam group:
b1, pre-fixing: preliminarily fixing the beam corner connectors on two side surfaces of the end part of the beam base body 510, wherein the beam corner connectors are not fastened at the moment;
b2, coating structural adhesive: coating structural adhesive on the joint surface of the beam corner connector and the frame group, and uniformly coating the structural adhesive;
b3, assembling: aligning bolt holes 560 on the cross beam corner connectors with corresponding mounting holes on the frame groups, then pulling core and pulling willow, and locking the cross beam with the frame groups through the cross beam corner connectors through bolts;
b4, curing: assembling all the cross beams in the frame group according to the steps b 1-b 3, gradually curing structural adhesive after placing, and tightly combining the cross beam corner connectors with the frame section bars at the corresponding positions, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or adopting an oven to accelerate the curing, and the curing time is 0.4-1 hour;
c. assembling a bottom plate group:
c1, gluing: structural sealant is coated in the fifth glue overflowing grooves 630 at two sides of the convex bulge 620 on the bottom plate 600, and sealant is coated in the sixth glue overflowing grooves 640 around the bottom plate 600;
c2, viscose: the bottom plate 600 is turned over and then buckled on the frame, and the bottom plate 600 is quickly adhered to the beam group;
c3, FDS riveting: screws are inserted into assembly holes at the periphery of each bottom plate 600 and the position of each cross beam to lock the bottom plate 600 with the frame group and the cross beams, and the bottom plates are riveted on the frame section and the cross beams in an FDS hot melting self-tapping riveting mode.
The welding seam-free lightweight battery box body and the manufacturing process thereof have the beneficial effects that:
the battery box bodies are connected by using an angle brace structure, and structural sealant is coated to keep airtightness and strength, so that fastening connection is realized;
the cross beams are connected by adopting corner connectors, structural glue is coated to increase the ground strand of the ring, and fastening connection is realized;
the bottom plate adopts a stretching cavity, is coated with structural sealant and sealant, and is riveted to the frame and the beam in an FDS hot-melt self-tapping riveting manner;
the battery box body eliminates large-area fusion welding and stirring welding, and is replaced by gluing and assembling processes, so that the cost and the efficiency are greatly improved;
the size precision is easy to control, no deformation exists, all module mounting holes, upper cover mounting holes and box body mounting holes can be processed in place in a spare state, the number of machining centers of a large gantry for finished products is reduced, and the equipment cost is reduced;
the gluing process and the FDS process are used together, and the feasibility of an automatic production line is high.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes, which are made by the present specification, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (10)
1. The utility model provides a no welding seam lightweight battery box which characterized in that includes: frame section bar, frame angle sign indicating number, crossbeam and bottom plate, frame section bar assemble together through frame angle sign indicating number and form frame group, and the crossbeam transversely is installed in frame group inside and with the left and right sides locking of frame group, and the bottom plate lock joint is fixed on frame group and with frame group locking.
2. The weldless lightweight battery box body according to claim 1, wherein the frame section comprises a front frame, a left frame, a right frame and a rear frame, and the connecting parts of the front frame, the left frame, the right frame and the rear frame are inserted into frame corner connectors to realize locking, sealing and connecting to form a frame group.
3. The weldless lightweight battery box body according to claim 1, wherein the frame corner brace comprises a first limiting arm and a second limiting arm which are vertically arranged, the two ends of the frame corner brace further comprise a first corner connecting arm and a second corner connecting arm which are vertically arranged, and the first limiting arm and the second limiting arm and the first corner connecting arm and the second corner connecting arm are respectively inserted into the corresponding frame profiles.
4. The weldless light-weight battery box body as claimed in claim 3, wherein semicircular bumps are arranged on two sides of the first limiting arm and the second limiting arm, semicircular bumps are arranged on two sides of the first corner connecting arm and the second corner connecting arm, and the first limiting arm, the second limiting arm, the first corner connecting arm and the second corner connecting arm are slidably inserted into the frame profile through the semicircular bumps and then are tightly connected.
5. The weldless light-weight battery box body as claimed in claim 4, wherein the first glue overflow groove is formed on the two side surfaces of the first limiting arm and the second limiting arm, the first glue overflow groove is formed on the outer side surface of the first corner connecting arm and the second corner connecting arm,
a second glue overflow groove is formed on the outer side surface of the corner of the frame corner brace, a third glue overflow groove is formed in the center of the cross section of the corner of the frame corner brace, a fourth glue overflow groove is formed on the inner side surface of the corner of the frame corner brace,
structural glue is fully coated in the first glue overflow groove, the second glue overflow groove, the third glue overflow groove and the fourth glue overflow groove to connect the frame corner connector and the frame in a reinforcing way.
6. The weldless lightweight battery box body according to claim 5, wherein clearance grooves are formed between adjacent first limiting arms, clearance grooves are also formed between the first limiting arms and the first corner connecting arms, clearance grooves are formed between adjacent second limiting arms, clearance grooves are also formed between the second limiting arms and the second corner connecting arms, and steel wire thread sleeves are further embedded in the first limiting arms and the second limiting arms.
7. The weldless lightweight battery box body according to claim 1, wherein the beam comprises a beam base body, a first beam corner brace and a second beam corner brace, the beam base body is embedded with a steel wire thread sleeve, the first beam corner brace and the second beam corner brace are locked on two side surfaces of the end part of the beam base body through bolts, the joint surfaces of the first beam corner brace, the second beam corner brace and the frame assembly are coated with structural adhesive,
bolt holes are further formed in the binding faces of the first cross beam angle code, the second cross beam angle code and the frame group, and the whole cross beam is connected with the frame group in a locking mode through the first cross beam angle code and the second cross beam angle code and is enhanced in a sealing mode.
8. The weldless lightweight battery box body according to claim 1, wherein the bottom plate comprises a bottom plate, the surface of the bottom plate is punched to form a convex hull, the periphery of the bottom plate is punched and stretched to form a bead, the transition corner of the bead is a round corner, an assembly hole is formed in the bead, fifth glue overflow grooves are formed in two sides of the convex hull on the bottom plate, and sixth glue overflow grooves are formed in the periphery of the bottom plate.
9. The weldless lightweight battery box body according to claim 8, wherein the bottom plate is made of an aluminum plate, a steel plate or a steel-aluminum composite plate, the bottom plate is integrally arranged in a concave shape, and the bottom plate is turned over and then buckled on the frame assembly.
10. The manufacturing process of the weldless light battery box body is characterized by comprising the following steps of:
a. assembling the frame group:
a0, processing of the frame profile: processing frame profiles according to the size of the battery box body to manufacture a corresponding front frame, a left frame, a right frame and a rear frame;
a1, gluing frame corner connectors: structural glue is fully coated in a first glue overflow groove, a second glue overflow groove, a third glue overflow groove and a fourth glue overflow groove of the frame corner connector, and the glue coating is uniform;
a2, insert: guiding a first limiting arm and a first corner connecting arm of a frame corner connector, then slidably inserting the first limiting arm and the first corner connecting arm into one frame profile through a semicircular salient point, guiding a second limiting arm and a second corner connecting arm of the frame corner connector, then slidably inserting the second limiting arm and the second corner connecting arm into the other frame profile through the semicircular salient point, sequentially splicing four vertex angles of a frame group together through the frame corner connector, and paying attention to the fact that glue overflows from the spliced part;
a3, clamping: the frame corner connectors at the four top corners of the frame group are pushed in place through external thrust;
a4, assembling screws: locking screws in the steel wire thread sleeves of the frame corner connectors to lock the frame sectional materials and the frame corner connectors together;
a5, glue filling or smearing: scraping off the glue overflowing from the splicing position, supplementing the glue, and leveling the glue higher than the plane;
a6, curing: gradually curing the structural adhesive, and tightly combining the frame corner connectors with corresponding frame sectional materials, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or the curing can be accelerated by adopting an oven, and the curing time is 0.4-1 hour;
b. assembling the beam group:
b1, pre-fixing: preliminarily fixing the beam corner connectors on two side surfaces of the end part of the beam base body, and not fastening at this time;
b2, coating structural adhesive: coating structural adhesive on the joint surface of the beam corner connector and the frame group, and uniformly coating the structural adhesive;
b3, assembling: aligning bolt holes on the cross beam corner connectors with corresponding mounting holes on the frame groups, then pulling core and pulling willow, and locking the cross beam with the frame groups through the cross beam corner connectors through bolts;
b4, curing: assembling all the cross beams in the frame group according to the steps b 1-b 3, gradually curing structural adhesive after placing, and tightly combining the cross beam corner connectors with the frame section bars at the corresponding positions, wherein the initial curing time of the structural adhesive is 1 hour, the natural complete curing time is 24 hours, or adopting an oven to accelerate the curing, and the curing time is 0.4-1 hour;
c. assembling a bottom plate group:
c1, gluing: structural sealant is coated in the fifth glue overflowing grooves on the two sides of the convex hull on the bottom plate, and sealant is coated in the sixth glue overflowing grooves on the periphery of the bottom plate;
c2, viscose: the bottom plate is buckled on the frame after being flanged, and the bottom plate is quickly adhered to the beam group;
c3, FDS riveting: screws are inserted into the assembly holes at the periphery of each bottom plate and the position of the cross beam to lock the bottom plates with the frame group and the cross beam, and the bottom plates are riveted on the frame section and the cross beam in an FDS hot melting self-tapping riveting mode.
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| CN202010166639.2A CN111261818B (en) | 2020-03-11 | 2020-03-11 | Weld-free lightweight battery box and manufacturing process thereof |
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| CN202010166639.2A CN111261818B (en) | 2020-03-11 | 2020-03-11 | Weld-free lightweight battery box and manufacturing process thereof |
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| CN115764116A (en) * | 2022-08-27 | 2023-03-07 | 浙江米皇新材股份有限公司 | Production process of full-tenon-joint new energy automobile battery tray |
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|---|---|
| CN111261818B (en) | 2024-07-05 |
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