The lightweighting of the battery box is a crucial direction in the development of new energy vehicles and electronic equipment. Its purpose is to reduce the overall weight of the vehicle or equipment, thereby improving energy efficiency, reducing costs and extending the service life of the battery. The following are several main methods to achieve lightweighting of the battery box:
Material selection:
Aluminum alloy: Aluminum alloy has become the preferred material for lightweighting the battery box due to its light weight, high strength and good corrosion resistance. For example, the use of profiles formed by aluminum extrusion and then welding is the current mainstream process of the battery box. Compared with traditional materials, aluminum alloy can greatly reduce the weight of the battery box.
Composite materials: Such as carbon fiber composite materials, which have higher specific strength and specific stiffness, can further reduce weight while ensuring structural strength.
Structural optimization:
Reduce design levels: By optimizing the internal layout of the battery pack box and reducing the design level, such as using a module-free design (CTP), the single cell and battery management system can be directly fixed in the battery pack shell, reducing the intermediate level and improving the space utilization of the box.
Large module design: By designing a flat large-size battery cell, such as BYD's "blade battery", the mass of the structural parts shared by the single battery cell can be reduced, thereby reducing the overall weight of the battery box.
Welding technology:
Friction stir welding (FSW): Compared with traditional welding technology, FSW has the advantages of high welding joint strength and good sealing, and is widely used in the field of battery pack box welding. The use of FSW technology can reduce welding deformation and improve the flatness and precision of the battery box.
Integrated design:
Integrating multiple functional components into the battery box, such as integrating the battery management system and heat dissipation system into the battery box, can reduce external connectors and weight.
Production process improvement:
The introduction of advanced production processes and equipment, such as automated production lines and laser welding, can improve production efficiency and product quality, while reducing material waste and weight.
In summary, the lightweighting of the battery box requires comprehensive consideration from multiple aspects such as material selection, structural optimization, welding technology, integrated design, and production process. By adopting lightweight materials, optimizing structural design, improving welding technology and production processes, the weight of the battery box can be significantly reduced, and the performance and competitiveness of electric vehicles and electronic equipment can be improved.
