CN114583347B - Steel battery pack shell of new energy automobile - Google Patents
Steel battery pack shell of new energy automobile Download PDFInfo
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- CN114583347B CN114583347B CN202011377696.1A CN202011377696A CN114583347B CN 114583347 B CN114583347 B CN 114583347B CN 202011377696 A CN202011377696 A CN 202011377696A CN 114583347 B CN114583347 B CN 114583347B
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- battery pack
- new energy
- steel
- steel battery
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 85
- 239000010959 steel Substances 0.000 title claims abstract description 85
- 238000005096 rolling process Methods 0.000 claims abstract description 65
- 238000003466 welding Methods 0.000 claims abstract description 59
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 20
- 238000005452 bending Methods 0.000 claims description 15
- 229910000838 Al alloy Inorganic materials 0.000 claims description 10
- 239000000853 adhesive Substances 0.000 claims description 8
- 230000001070 adhesive effect Effects 0.000 claims description 8
- 238000001125 extrusion Methods 0.000 claims description 6
- 239000003292 glue Substances 0.000 claims description 5
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 238000003856 thermoforming Methods 0.000 claims description 3
- 229910000797 Ultra-high-strength steel Inorganic materials 0.000 abstract description 13
- 238000000034 method Methods 0.000 abstract description 9
- 239000000463 material Substances 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000013585 weight reducing agent Substances 0.000 description 4
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000001816 cooling Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 1
- -1 etc.) Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000009545 invasion Effects 0.000 description 1
- 229910000734 martensite Inorganic materials 0.000 description 1
- 239000002436 steel type Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
- B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
- B60L50/64—Constructional details of batteries specially adapted for electric vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
- B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
- B60L50/66—Arrangements of batteries
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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
- H01M2220/00—Batteries for particular applications
- H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
-
- 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
-
- 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
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
Abstract
A steel battery pack housing for a new energy vehicle, comprising: the body is a frame body, and at least one cross beam is arranged in the frame body along the length direction; the frame body adopts a hollow closed section with a special-shaped section, which is formed by rolling or stamping and welding a plate blank to form an upper cavity and a lower cavity; the upper cavity at the upper part of the section bar is of a triangle or quadrilateral structure, and the top surface of the upper cavity is a matching surface for connecting a cover plate of a steel battery pack shell; the lower cavity at the lower part of the section bar is an L-shaped cavity; the cover plate and the bottom plate are respectively arranged on the upper end face and the lower end face of the body frame body and are connected with the body frame body through processes such as screw connection, cementing or welding. The weight and the cost of the steel battery pack shell body which is made of the ultra-high-strength steel are lower than those of the existing aluminum or steel battery pack shell body under the same design requirements.
Description
Technical Field
The invention belongs to the technical field of new energy automobiles, and particularly relates to a steel battery pack shell of a new energy automobile and a manufacturing method thereof, which are used as supporting bodies of a BMS (battery management system), a battery module, a high-voltage charge-discharge circuit, a cooling system and the like in a battery pack.
Background
The battery pack shell (also called battery tray, battery box and the like) is used as a bearing body of a BMS, a battery module, a high-voltage charge-discharge circuit, a cooling system and the like in the battery pack, is an important structural member of the battery pack of the new energy automobile, and plays a key safety protection role on the bearing body. At present, the weight of an aluminum battery pack shell is generally lighter than that of a steel battery pack shell, and a new energy vehicle enterprise meets the specific energy requirement in the national patch policy, and even though the cost of the aluminum battery pack shell is higher, the material of the battery pack shell is mainly aluminum alloy. However, with the gradual application of ultra-high strength steel (ultra-high strength steel generally refers to steel types with tensile strength of 1500MPa or more, including martensitic steel, hot-formed steel, etc.), steel battery cases are expected to develop further.
In chinese patent 201910985769.6, although the frame beam (frame) of the battery pack case is made of ultra-high strength heat-formed steel, it is made of at least two profile members joined to each other in cross section, and such a combined frame beam is disadvantageous in terms of weight saving, cost and quality stability; meanwhile, the bearing main body of the battery pack shell is designed into a basin-shaped piece, so that the total wall thickness of the side wall of the battery pack shell is too large, and the weight reduction and the cost reduction of the battery pack shell are not facilitated.
In the chinese patent 201910323812.2, although the roll-formed frame beam (frame) of the battery pack case is integrated, it does not use ultra-high strength steel (if ultra-high strength steel is used, a single roll-forming process is also difficult to manufacture an integrated frame beam), which is not beneficial to the weight reduction of the battery pack case; meanwhile, the structure of the frame beam (frame) and the bottom of the battery pack shell are connected only through a cementing process, but the cementing process is low in strength and easy to age and fatigue, so that the connection mode of the frame beam (frame) and the bottom of the battery pack shell is low in safety, unfavorable for mass production and high in cost.
The existing battery pack shell is mainly made of aluminum alloy, but all cart enterprises have urgent weight and cost reduction demands on the battery pack shell, steel has cost advantages compared with aluminum, and the steel battery pack shell made of ultra-high strength steel is theoretically lighter than the aluminum battery pack shell, but no steel battery pack shell product or patent with good structure or process and ultra-high strength steel is available at present, and the blank needs to be filled.
Disclosure of Invention
The invention aims to provide a steel battery pack shell of a new energy automobile, which is applied to ultrahigh-strength steel, and the weight and the cost of the steel battery pack shell are lower than those of the existing aluminum or steel battery pack shell through the optimal design under the same design requirement.
In order to achieve the above purpose, the technical scheme of the invention is as follows:
a steel battery pack case for a new energy automobile, comprising:
the body is a frame body, and at least one cross beam is arranged in the frame body along the length direction; the frame body adopts a hollow closed section with a special-shaped section, and the hollow closed section with the special-shaped section is formed by rolling or stamping and welding a plate blank to form an upper cavity and a lower cavity; the upper cavity at the upper part of the section bar is of a triangle or quadrilateral structure, and the top surface of the upper cavity is a matching surface for connecting a cover plate of a steel battery pack shell; the lower cavity at the lower part of the section bar is an L-shaped cavity, a first connecting part formed by bending a plate and connected with the upper cavity is arranged between the middle part of the upper end surface of the lower cavity and the lower end of the upper cavity, and a first welding point for bending and combining the plate is arranged at the connecting part; the upper end surface of the L-shaped lower cavity outside the first connecting part is connected with a vehicle body part; the L-shaped inner side surface of the lower cavity, which is in fit connection with the inner beam of the steel battery pack shell, is in a right angle shape; the outer side surface of the lower cavity connected and assembled with the vehicle body part is an inclined surface, so that the side surface of the lower cavity forms a triangular extrusion-resistant collision surface; the middle part of the outer side surface is provided with a connecting hole; the inner side end of the bottom of the lower cavity extends outwards to form a second connecting part matched with the bottom plate of the steel battery pack shell, the second connecting part is formed by closing and connecting two ends of a plate, and a second welding point is arranged on the second connecting part; the section is formed into a section with different areas with different strengths in the cross section/length direction and in an open cross section state after a thermoforming process, namely the section has the tensile strength of 2000-2600MPa and the breaking elongation of 3-12% in the cross section of the section or in the area with higher strength in the length direction of the section, and the section has the tensile strength of 500-1200MPa and the breaking elongation of 10-20% in the area with lower strength; simultaneously, the section bar can be bent in the length direction to form a hollow closed section bar with a bending section in the length direction;
the cover plate and the bottom plate are respectively arranged on the upper end face and the lower end face of the body frame body.
Preferably, the upper end face of the lower cavity is provided with a reinforcing rib structure along the axial direction.
Preferably, the reinforcing rib structure is an upward convex or downward concave structure on the upper end face of the lower cavity.
Preferably, the outer side surface of the upper cavity is provided with a concave structure along the width direction of the profile.
Preferably, the welding mode of the first welding point and the second welding point is spot welding or laser welding.
Preferably, the cover plate and the body frame are connected in a threaded connection and an adhesive connection manner, and the bottom plate and the body frame are connected in a welding manner.
Preferably, at least one longitudinal beam is further arranged in the frame body and connected with the cross beam and the frame body.
Preferably, the cross section of the cross beam or the longitudinal beam is formed by connecting an upper rolling section bar and a lower rolling section bar, wherein the lower rolling section bar is formed by inwards bending and welding two ends of a plate material to form two rectangular cavities, so that the middle part of the section bar forms a concave structure; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded and connected with two upper ends of the opening end of the middle concave structure of the lower rolling section; the welding mode of the splice welding position of the two rectangular cavities of the rolling section bar at the lower part of the cross beam or the longitudinal beam is preferably arc welding or laser welding.
Preferably, the cross beam or the longitudinal beam is formed by connecting an upper rolling section bar and two lower rolling section bars, wherein the cross section of the lower rolling section bars is rectangular; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded with the upper ends of the opposite sides of the two rectangular lower rolling sections.
Preferably, the cross beam or the longitudinal beam is formed by connecting an upper rolling section, a lower rolling section and an extruded aluminum section, wherein the lower rolling section is formed by inwards bending and welding two ends of a plate to form two rectangular cavities, so that the middle part of the lower rolling section forms a concave structure; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded and connected with two upper ends of the opening end of the middle concave structure of the lower rolling section; the extruded aluminum profile is connected to the top surface of the upper rolling profile through a screw element, and the section of the extruded aluminum profile is rectangular or trapezoidal; the screw joint of the extruded aluminum profile and the upper rolling profile is optionally provided with a rubber pad.
Preferably, the screw element comprises a bolt, a nut, preferably a blind rivet, a blind rivet nut or a weld nut.
Preferably, the body frame is formed by welding the hollow closed section bars, and the welding mode is preferably arc welding or laser welding.
Preferably, the cross beam and the longitudinal beam are aluminum alloy extruded profiles and are connected with the bottom plate through self-punching rivet, and meanwhile, adhesive is applied to the connecting position to form adhesive joint so as to increase the connecting strength of the connecting position and ensure the air tightness of the connecting position.
Preferably, the upper portion rolling section bar and the lower portion rolling section bar are made of steel materials.
The difference compared with the prior art is that:
in chinese patent 201910985769.6, although ultra-high strength heat-formed steel is used as the frame beam (frame) of the battery pack case, the cross section of the frame beam is a combined frame beam made of at least two mutually joined profiles, and meanwhile, the carrying body of the battery pack case is designed as a basin-shaped member, which results in an excessive total wall thickness of the side wall of the battery pack case, and is unfavorable for the weight reduction and cost of the battery pack case.
In the chinese patent 201910323812.2, although the roll-formed frame beam (frame) of the battery pack case is integrated, it does not use ultra-high strength steel (if ultra-high strength steel is used, a single roll-forming process is also difficult to manufacture an integrated frame beam), which is not beneficial to the weight reduction of the battery pack case; meanwhile, the structure of the frame beam (frame) and the bottom of the battery pack shell are connected only through a cementing (adhesive) process, and the connection mode has lower connection strength and reliability, is not beneficial to mass production and has higher cost.
The steel battery pack shell body with the ultra-high strength steel is made of steel parts, and is partially made of aluminum parts and standard parts, wherein the frame beams are hollow closed sectional materials made of the ultra-high strength hot forming steel, the sectional materials have different strength in the cross section of the sectional materials or the length direction of the sectional materials, the areas with higher strength are 2000-2600MPa of tensile strength and 3-12% of elongation, the same wall thickness is 0.8-2mm in each place, and the frame beams can be bent in the length direction of the sectional materials so as to adapt to corresponding structural designs; the cross beam or the longitudinal beam adopts a rolling profile of common high-strength steel or common steel, or an aluminum alloy extrusion profile; the specific manner of connection between the parts of the steel battery pack case will be described in detail later; the weight and the cost of the steel battery pack shell body with the ultra-high strength steel are lower than those of the existing aluminum or steel battery pack shell body under the same design requirement, and the application prospect is very great.
The main advantages of the invention are as follows:
1) The frame beam of the steel battery pack shell adopts the hollow closed section bar of the ultra-high strength hot forming steel, the ultra-high strength hot forming steel has the characteristics of high strength and low elongation percentage, and is particularly suitable for the occasion of protecting the internal space of the battery pack and preventing external invasion.
2) The steel cross beam or longitudinal beam has high structural strength and simpler shape, can realize light weight while ensuring the installation space, and can also adopt aluminum alloy extruded profile or profile in steel-aluminum combined form.
3) The steel battery pack shell takes the steel section bar as the main body frame, the connection mode mainly comprises the processes of high connection strength, high reliability, such as welding, screwing, riveting and the like, and the steel battery pack shell has the advantages of high rigidity, high reliability, good light weight, low cost, good ductility (the section bar with the same section can easily adjust the length to adapt to the steel battery pack shells with different sizes) and the like.
4) The section bar forming the body frame body of the steel battery pack shell can be provided with a bending section in the length direction so as to adapt to corresponding structural design.
Drawings
Fig. 1 is a perspective view of embodiment 1 of the present invention.
Fig. 2 is an exploded perspective view of embodiment 1 of the present invention.
Fig. 3 is a perspective view of embodiment 2 of the present invention.
Fig. 4 is a perspective view of a hollow closure profile used in a frame according to an embodiment of the present invention.
Fig. 5 is a perspective view of a hollow closure profile used in a frame according to an embodiment of the present invention.
Fig. 6 is a perspective view of a hollow closed section used in a frame body according to an embodiment of the present invention, in which a curved section is provided in a length direction.
Fig. 7 is a schematic cross-sectional view of embodiment 1 of a hollow closure profile used in a frame according to an embodiment of the present invention.
Fig. 8 is a schematic structural view 1 of a hollow closed section used in a frame according to an embodiment of the present invention.
Fig. 9 is a schematic structural view 2 of a hollow closed section used in a frame according to an embodiment of the present invention.
Fig. 10 is a schematic cross-sectional view of example 2 of a hollow closure profile used in the middle frame of the present invention.
Fig. 11 is a perspective view of an embodiment 1 of a cross or stringer according to the present invention.
Fig. 12 is a schematic cross-sectional view of an embodiment 1 of a cross or stringer according to the present invention.
Fig. 13 is an exploded schematic cross-sectional view of embodiment 1 of the cross or longitudinal beam of the present invention.
Fig. 14 is a schematic cross-sectional view of embodiment 2 of the cross or longitudinal beam of the present invention.
Fig. 15 is a schematic cross-sectional view of embodiment 3 of the cross or longitudinal beam of the present invention.
Detailed Description
Referring to fig. 1 to 15, the steel battery pack case of the new energy automobile according to the present invention includes:
the body 1 is a frame body, and at least one cross beam 12 is arranged in the frame body 11 along the length direction; the frame 11 is divided into a plurality of accommodating spaces for installing the battery modules 200 by the cross beams 12;
the frame 11 is a hollow closed section with a special-shaped section, which is a hollow closed section 100 with a special-shaped section, wherein the hollow closed section consists of an upper cavity and a lower cavity which are formed by (cold) rolling or stamping and welding a hot forming plate blank; the upper cavity 101 at the upper part of the section bar is of a triangle or quadrilateral structure, and the top surface 1011 is a matching surface for connecting the cover plate of the steel battery pack shell; the lower cavity 102 positioned at the lower part of the section bar 100 is an L-shaped cavity, a first connecting part 103 formed by bending a plate and connected with the upper cavity 101 is arranged between the middle part of the upper end surface 1021 and the lower end of the upper cavity 101, and the first connecting part 103 is provided with a first welding point 1031 for bending and combining the plate; an upper end surface 1021 of the L-shaped lower cavity 102 outside the first connecting portion 103 is connected with a vehicle body component, and a reinforcing rib structure 1022 is axially arranged on the upper end surface 1021; the L-shaped inner side 1023 of the lower cavity 102, which is in fit connection with the inner beam of the steel battery pack case, is rectangular; the outer side 1024 of the lower cavity 102, which is connected and assembled with the vehicle body part, is an inclined plane, so that the side of the lower cavity 102 forms a triangular extrusion-resistant collision surface; the middle part of the outer side 1024 is provided with a connecting hole 10241; the inner side end of the bottom of the lower cavity 102 extends outwards to form a second connecting part 1025 matched with the bottom plate of the steel battery pack shell, the connecting part 1025 is formed by closing and connecting two ends of a plate, and a second welding point 10251 is arranged on the second connecting part 1025; the section 100 is formed into a section with different areas with different strengths in the cross section/length direction and in an open cross section state after a thermoforming process, namely, the section with the tensile strength of 2000-2600MPa and the breaking elongation of 3-12% in the cross section of the section or in the area with higher strength in the length direction of the section, and the section with lower strength has the tensile strength of 500-1200MPa and the breaking elongation of 10-20%; at the same time, the profile 100 can be bent in the longitudinal direction to form a hollow closure profile with a bending section 6 in the longitudinal direction.
The battery module 200 is connected with the frame 11 and the cross beam 12 or the longitudinal beam 13 through the screw element 4;
the cover plate 2 is arranged on the upper end surface of the frame 11 and is in threaded connection with the frame 11 through the threaded element 4, and meanwhile, the inner side of the threaded connection part is glued by using the adhesive 5 around the whole periphery of the frame 11, and the gluing function is to ensure the internal air tightness of the steel battery pack shell and increase the connection strength of the cover plate 2 and the frame 11.
The bottom plate 3 is provided on the lower end surface of the frame 11, and is connected to the frame 11 by a welding process.
Preferably, the rib structures 1022 of the profile 100 are protruding or recessed structures on the upper end surface of the lower cavity 102.
Preferably, the wall thickness of the profile 100 is 0.8-2 mm.
Preferably, the welding mode of the first welding point 1031 and the second welding point 10251 of the profile 100 is spot welding or laser welding.
Preferably, the cover plate 2 and the frame 11 are connected by screw connection, glue connection, etc., and the bottom plate 3 and the frame 11 are connected by welding.
Referring to fig. 3, at least one longitudinal beam 13 is further disposed in the frame 11 and connected to the cross beam 12 and the frame 11.
Referring to fig. 9, the cross beam 12 and the longitudinal beam 13 are aluminum alloy extruded profiles, and are connected with the bottom plate 3 through self-piercing riveting (SPR) rivets 8, and meanwhile, an adhesive 5 is applied at the connection position to form glue joint, so that the connection strength of the connection position is increased, and the air tightness of the connection position is ensured.
Referring to fig. 10, the outer side surface of the upper cavity 101 of the profile 100 is provided with a concave structure 1012 along the width direction of the profile.
Referring to fig. 11 to 13, the cross beam 12 is formed by connecting an upper rolling profile 121 and a lower rolling profile 122, wherein the lower rolling profile 122 is formed by bending two ends of a plate inwards and welding two rectangular cavities 1221 and 1222 in a splice manner, so that a concave structure 1223 is formed in the middle of the profile 122; the section of the upper rolling section bar 121 is in an inverted U shape, and two ends of the opening side of the upper rolling section bar 121 are welded and connected with two upper ends of the opening end of the middle concave structure 1223 of the lower rolling section bar 122.
Preferably, the welding mode of the welding position of the two rectangular cavities 1221, 1222 of the lower rolled profile 122 of the cross beam 12 is preferably arc welding or laser welding.
Referring to fig. 14, the cross beam 12 is formed by connecting an upper rolled section 121 and two lower rolled sections 122, wherein the cross section of the lower rolled section 122 is rectangular; the cross section of the upper rolling profile 121 is in an inverted U shape, and two ends of the opening side of the upper rolling profile 121 are welded with the upper ends of the opposite sides of the two rectangular lower rolling profiles 122.
Referring to fig. 15, the cross beam 12 is formed by connecting an upper rolled section 121, a lower rolled section 122 and an extruded aluminum section 123, wherein the lower rolled section 122 is a plate with two ends bent inwards and welded together to form two rectangular cavities 1221 and 1222, so that a concave structure 1223 is formed in the middle of the lower rolled section 122; the section of the upper rolling section bar 121 is in an inverted U shape, and two ends of the opening side of the upper rolling section bar 121 are welded with two upper ends of the opening end of the middle concave structure 1223 of the lower rolling section bar 122; the extruded aluminum profile 123 is connected to the top surface of the upper rolling profile 121 through the screw connection element 4, the cross section of the extruded aluminum profile 123 is rectangular or trapezoidal, the screw connection part of the extruded aluminum profile 123 and the upper rolling profile 121 is optionally provided with a rubber pad 7, and the rubber pad 7 plays a role in reducing the influence of assembly errors and/or guaranteeing the air tightness of the connection part.
Preferably, the screw element 4 comprises a bolt, a nut, preferably a blind rivet, a blind rivet nut or a weld nut.
Preferably, the frame 11 of the body 1 is formed by welding the hollow closed section bar, and the welding mode is preferably arc welding or laser welding.
The steel battery pack shell is characterized in that a main body adopts steel parts, and is partially made of aluminum parts and standard parts, wherein frame beams are hollow closed sectional materials made of ultra-high strength hot forming steel, the sectional materials have different strength in the cross section of the sectional materials or in the length direction of the sectional materials, the areas with higher strength are 2000-2600MPa of tensile strength and 3-12% of elongation, and the same wall thickness is 0.8-2mm in each part, so that the frame beams can be bent in the length direction of the sectional materials to adapt to corresponding structural designs; the cross beam or the longitudinal beam is a rolling profile of ordinary high-strength steel or ordinary steel, or an aluminum alloy extrusion profile, or a combination form of a steel rolling profile and an aluminum alloy extrusion profile; the main connection modes of the steel battery pack shell are welding and screwing, and steel-aluminum connection modes such as screwing, cementing, self-punching riveting (SPR) and the like are adopted between the steel part and the aluminum part. The weight and the cost of the steel battery pack shell body using the ultra-high strength steel are lower than those of the existing aluminum or steel battery pack shell body under the same design requirement.
Claims (22)
1. A steel battery pack housing of a new energy automobile, comprising:
the body is a frame body, and at least one cross beam is arranged in the frame body along the length direction; the frame body adopts a hollow closed section with a special-shaped section, and the hollow closed section with the special-shaped section is formed by rolling or stamping and welding a plate blank to form an upper cavity and a lower cavity; the upper cavity at the upper part of the section bar is of a triangle or quadrilateral structure, and the top surface of the upper cavity is a matching surface for connecting a cover plate of a steel battery pack shell; the lower cavity at the lower part of the section bar is an L-shaped cavity, a first connecting part formed by bending a plate and connected with the upper cavity is arranged between the middle part of the upper end surface of the lower cavity and the lower end of the upper cavity, and a first welding point for bending and combining the plate is arranged at the connecting part; the upper end surface of the L-shaped lower cavity outside the first connecting part is connected with a vehicle body part; the L-shaped inner side surface of the lower cavity, which is in fit connection with the inner beam of the steel battery pack shell, is in a right angle shape; the outer side surface of the lower cavity connected and assembled with the vehicle body part is an inclined surface, so that the side surface of the lower cavity forms a triangular extrusion-resistant collision surface; the middle part of the outer side surface is provided with a connecting hole; the inner side end of the bottom of the lower cavity extends outwards to form a second connecting part matched with the bottom plate of the steel battery pack shell, the second connecting part is formed by closing and connecting two ends of a plate, and a second welding point is arranged on the second connecting part; the section is formed into a section with different areas with different strengths in the cross section/length direction and in an open cross section state after a thermoforming process, namely the section has the tensile strength of 2000-2600MPa and the breaking elongation of 3-12% in the cross section of the section or in the area with higher strength in the length direction of the section, and the section has the tensile strength of 500-1200MPa and the breaking elongation of 10-20% in the area with lower strength; simultaneously, the section bar can be bent in the length direction to form a hollow closed section bar with a bending section in the length direction;
the cover plate and the bottom plate are respectively arranged on the upper end face and the lower end face of the body frame body.
2. The steel battery pack case of a new energy automobile as claimed in claim 1, wherein the lower cavity has a rib structure provided on an upper end surface thereof in an axial direction.
3. The steel battery pack case of a new energy automobile as claimed in claim 2, wherein the reinforcing rib structure is a convex or concave structure on the upper end surface of the lower cavity.
4. The steel battery pack case of a new energy automobile as claimed in claim 1, wherein the outer side surface of the upper cavity is provided with a concave structure along the width direction of the profile.
5. The steel battery pack case of a new energy automobile as claimed in claim 1, wherein the first and second welding points are welded by spot welding or laser welding.
6. The steel battery pack case of a new energy automobile according to claim 1, wherein the cover plate and the body frame are connected in a screw joint and a glue joint, and the base plate and the body frame are connected in a welding manner.
7. The steel battery pack case of a new energy automobile of claim 1, wherein at least one longitudinal beam is further provided in the frame body and connected to the cross beam and the frame body.
8. The steel battery pack shell of the new energy automobile as claimed in claim 1 or 7, wherein the cross section of the cross beam or the longitudinal beam is formed by connecting an upper rolling profile and a lower rolling profile, wherein the lower rolling profile is formed by bending two ends of a plate inwards and welding two rectangular cavities so that the middle part of the profile forms a concave structure; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded and connected with two upper ends of the opening end of the middle concave structure of the lower rolling section.
9. The steel battery pack case of a new energy automobile according to claim 8, wherein the welding mode of the splice welding of the two rectangular cavities of the lower rolled section bar of the cross beam or the longitudinal beam is arc welding or laser welding.
10. The steel battery pack case of a new energy automobile according to claim 1 or 7, wherein the cross beam or the longitudinal beam is formed by connecting an upper rolling profile and two lower rolling profiles, wherein the cross section of the lower rolling profile is rectangular; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded and connected with the upper ends of the opposite sides of the lower rolling section.
11. The steel battery pack shell of the new energy automobile as claimed in claim 1 or 7, wherein the cross beam or the longitudinal beam is formed by connecting an upper rolling profile, a lower rolling profile and an extruded aluminum profile, wherein the lower rolling profile is formed by bending two ends of a plate inwards and welding two rectangular cavities, so that the middle part of the lower rolling profile forms a concave structure; the section of the upper rolling section is in an inverted U shape, and two ends of the opening side of the upper rolling section are welded and connected with two upper ends of the opening end of the middle concave structure of the lower rolling section; the extruded aluminum profile is connected to the top surface of the upper rolling profile through the screw-connection element, and the section of the extruded aluminum profile is rectangular or trapezoidal.
12. The steel battery pack case of a new energy automobile as claimed in claim 11, wherein a rubber pad is provided at the screw joint of the extruded aluminum profile and the upper roll profile.
13. The steel battery pack housing of a new energy vehicle of claim 11, wherein said threaded member comprises a bolt, a nut.
14. The steel battery pack housing of a new energy vehicle of claim 11, wherein the threaded element is a blind rivet stud, a blind rivet nut, or a weld nut.
15. The steel battery pack case of a new energy automobile as claimed in claim 1, wherein the body frame is formed by welding the hollow closed profile.
16. The steel battery pack case of a new energy automobile as claimed in claim 15, wherein the welding means is arc welding or laser welding.
17. The steel battery pack case of a new energy automobile according to claim 1 or 7, wherein the cross member or the longitudinal member is an aluminum alloy extruded profile, is connected to the bottom plate by self-piercing SPR rivets, and simultaneously, an adhesive is applied to the connection to form a glue joint to increase the connection strength of the connection and to secure the air tightness of the connection.
18. The steel battery pack case of a new energy automobile according to claim 8, wherein the cross member or the longitudinal member is an aluminum alloy extruded section, is connected to the bottom plate by self-piercing SPR rivets, and simultaneously, an adhesive is applied to the connection to form a glue joint so as to increase the connection strength of the connection and ensure the air tightness of the connection.
19. The steel battery pack case of a new energy automobile according to claim 8, wherein the upper and lower roll-in profiles are made of steel.
20. The steel battery pack case of a new energy automobile as claimed in claim 9, wherein the upper and lower roll profiles are made of steel.
21. The steel battery pack case of a new energy automobile as claimed in claim 10, wherein the upper and lower roll profiles are made of steel.
22. The steel battery pack case of a new energy automobile as claimed in claim 11, wherein the upper and lower roll profiles are made of steel.
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| CN202011377696.1A CN114583347B (en) | 2020-11-30 | 2020-11-30 | Steel battery pack shell of new energy automobile |
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| CN202011377696.1A CN114583347B (en) | 2020-11-30 | 2020-11-30 | Steel battery pack shell of new energy automobile |
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| CN114976419A (en) * | 2022-06-28 | 2022-08-30 | 上海交通大学 | Power battery pack shell frame structure based on light weight and design method |
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| CN114583347A (en) | 2022-06-03 |
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