Energy vehicles have emerged to promote the sustainable development of the automotive industry. Energy vehicles use electricity as their power source to drive the vehicle, so the power battery in the car also determines the driving distance and speed of the new energy vehicle, directly affecting its performance.
As a protective component for electric vehicle power batteries, the battery box has high requirements for structural design, weight, and other aspects. After determining the weight and size of the battery module, there are many factors to consider when designing the battery box.
Firstly, the battery box is the carrier of the battery module, and the battery module needs to be connected to the vehicle body through it.
Secondly, power batteries are generally installed under the vehicle body. Considering the working environment of the battery module, the battery box needs to have protective functions for the module, taking into account the waterproof and dustproof properties of the module, as well as the corrosion of the battery box caused by road environments. The battery box also needs to consider withstanding vibrations and impacts during vehicle operation. According to the shape and arrangement of the battery module, combined with the position of the power battery on the vehicle body, and based on the principle of maximizing space utilization, the outer envelope of this battery box is designed as a nearly square box structure.
The main structural layer of the battery box is made of carbon fiber cloth attached and supplemented with resin. Metal joints are used at the connection points, and structural adhesive is used to connect the metal joints to the main structural layer. The battery module group and the casing are connected using metal fasteners. In order to increase the strength and mode of the parts, reinforcing ribs are a typical form of improving structural stability on some large structural surfaces, while cap shaped ribs have relatively high load-bearing efficiency and low weight. This battery box adopts convex and concave ribs similar to cap shaped ribs to strengthen the structure. Given the characteristics of continuous fiber composite materials, carbon fiber reinforced structures are designed with equal thickness at the convex and concave ribs. In terms of layer design, the carbon fiber woven fabric of the battery box adopts T300-3K and T300-12K, a combination of two weaving methods, with a total of 10 layers of carbon fiber plain weave fabric and resin design. When laying layers, the following precautions were mainly considered: the balance of layer angles, the required number of layers in the same direction, the symmetry of layers, the deviation of angles between layers, and limiting the number of consecutive layers. The battery box components are laid out in a cross pattern using 10 layers of plain weave fabric, with the laying method being [0/45/0/45/0/0/45/0/45/0]. In terms of connection design, the battery module needs to be connected to the vehicle body through the battery box. The battery box is connected at the connection point using metal fasteners, which are partially embedded. By controlling the depth of embedding, the connection point can withstand high tensile strength; Some fasteners are bonded together with the carbon fiber body using structural adhesive. In addition, finite element simulation analysis software can be used to verify the above design, and the analysis results show that the carbon fiber composite battery box fully meets the requirements in terms of structural mode, mechanical impact, and structural fatigue.
Ningbo Huayuan provides molding and processing of SMC and BMC circuit breaker insulation parts. As a comprehensive solution provider for resin based composite materials in China, Huayuan develops and produces resin based composite materials, SMC materials, BMC materials, and provides products such as power communication outdoor enclosures, power and electrical insulation components, rail transit, high-speed railway special equipment, etc., which are widely used in multiple industries and fields such as power, communication, rail transit, high-speed railway, automobile, municipal, etc. Huayuan is an important partner and supplier of Fortune 500 companies worldwide.
