产品名称：新型轻量化集成式电池箱  

推荐企业：渤海汽车系统股份有限公司 

新型轻量化集成式电池箱 

技术特点

该产品是一款高强度、轻量化、高安全、低成本的电池箱，集成箱体与水冷系统于一体。与常规电池箱相比，该新型电池箱通过新材料、新结构及新工艺等多方面升级优化，具备诸多优势。

产品优势：

1.轻量化效果明显：

高强铝合金材料：应用360MPa级高强铝合金作为箱体框架材料，相比常规6系铝合金，成本相当，强度提高40%，同等强度下可以做到更薄壁厚。

集成式水冷底板：将水冷板与箱体底板集成设计，减少零件数量实现减重。该产品利用型材内部型腔作为冷却液流道，通过流道截面设计，在满足机械强度的同时能满足压降、均温性、冷却量等热管理要求。

另外，由于零件数量的减少，可以释放更多空间，提高箱体的空间利用率，携带更多电芯增加电量。

热熔钻工艺：利用摩擦生热的原理，在边梁上制作衬套孔，攻牙后可作为螺母应用，螺纹的牙数和强度都显著提高，可以替代焊接螺母，解决薄壁钻孔连接的问题。该工艺利用边梁自身材料流动形成螺纹，可减少零件数量，进而实现减重效果。同时该工艺相较焊接工艺，可大大减少焊接热带来的零件变形，从而提高尺寸精度。

2.平台化程度高：

该产品简化电池箱设计，采用铝合金型材拼接的工艺，与传统箱体通过模具成型相比，通过调整型材长度和截面就可以更加灵活更改尺寸和形状，可以为各类车辆提供标准化产品。在新车型的开发过程中，动力电池的箱体灵活变化，降低了整车的开发周期和成本，有助于推动电动汽车底盘一体化设计应用开发。

3.安全性高：

该产品性能除满足国内行业标准外，同时能满足耐久、Z向挤压、承压、吊装等新增6项性能要求，相比同类产品具有更高的安全性能。

4.应用价值

对于新能源纯电动汽车，汽车整备质量每减少10%，电耗下降5%左右。同时汽车质量的降低可减小汽车制动距离，提高安全性能。所以，汽车轻量化研究具有重要意义，电池箱轻量化一直是行业研究的热点。

铝的密度是钢的1/3，质量更轻，具有较高的比强度、很好的耐压性和耐腐蚀性，并且可以高度回收，所以铝合金材料是一种优异的电池箱轻量化材料。其中铝型材箱体拥有尺寸设计范围大、模具开发成本低、材料性能优越等优点。 

市场表现 

2019年我国新能源汽车产销量超过120万辆，且根据《汽车产业中长期发展规划》预测，2025年纯电动车销量达到493万辆。随着新能源汽车产量持续增长，新能源汽车电池箱市场空间快速扩容，2019年电池箱市场规模达到25亿元，预计到2025年中国新能源乘用车电池箱市场空间约为130亿元，2020-2025年复合年增长率为39%。 

 Technical innovation points:

新型轻量化集成式电池箱 

This product is a high-strength, lightweight, high safety, low-cost battery box, integrated the water-cooling system in it. Compared with the ordinary battery box, this new battery box has many advantages through the optimization of new materials, new structure and new technology.

2、 Product advantages:

1.   Significant lightweight effect

① High strength aluminum alloy material: 360MPa high strength aluminum alloy is used as the box frame material. Compared with the conventional 6 series aluminum alloy, the cost is equivalent, the strength is increased by 40%. And the Wall thickness can be reducing under the same strength.

② Bottom plate integrated water cooling system: integrated design of water cooling plate and box bottom plate can reduce the number of parts and realize weight reduction. The product uses the internal cavity of the profile as the coolant channel. Through the cross-section design of the channel, it can meet the 

thermal management requirements such as pressure drop, temperature uniformity and cooling capacity while meeting the mechanical strength.

In addition, due to the reduction of the number of parts, more space can be released, the space utilization rate of the box can be improved, and more cells can be carried to increase the power consumption.

③ Hot melt drilling technology: using the principle of friction heat generation, the bushing holes are made on the side beam. After tapping, it can be used as a nut. The number of teeth and strength of the thread are significantly improved. It can replace the welding nut and solve the problem of thin-wall drilling connection. This process uses the material flow of the beam to form thread, which can reduce the number of parts and realize weight reduction. At the same time, compared with the welding process, this process can greatly reduce the deformation of the parts from the welding strip, so as to improve the dimensional accuracy.

2.   High platform level:

This product simplifies the design of the battery box and adopts the splicing process of aluminum alloy profiles. Compared with the traditional box formed by mold, the size and shape can be changed more flexibly by adjusting the length and section of the profile, which can provide standardized products for various vehicles. In the development process of new model, the box of power battery can be changes flexibly, which reduces the development cycle and cost of the whole vehicle, It’s helps to promote the integrated design development of electric vehicle chassis.

3.   High safety:

The performance of the product not only meets the domestic industry standards, but also meets six new performance requirements, such as durability, Z-direction crush, leaktightness and assembly load case, and has higher safety performance than similar products.

3、 Application value

For pure electric vehicles, the power consumption will decrease by about 5% for every 10% reduction of vehicle curb weight. At the same time, the reduction of vehicle mass can reduce the braking distance and improve the safety performance. Therefore, the research of automobile lightweight is of great significance, and the lightweight of battery box has always been the hot spot of industry research.

The density of aluminum is 1 / 3 of that of steel, the weight is lighter, it has high specific strength, good extreme pressure and corrosion resistance, and can be recycled. Therefore, aluminum alloy material is an excellent lightweight material for battery box. The aluminum profile box has the advantages of large size design range, low mold development cost and superior material performance. 

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