[China Aluminum] Net weight reduction is an issue that cannot be solved for electric vehicles. In addition to the weight reduction of the body structure, the battery pack itself needs to be lightweight. Among them, the lightweight of the battery box is one of the directions of the efforts.

Especially for battery packs for pure electric vehicles, pursuing high driving mileage under the premise of current development level of lithium-ion batteries will inevitably require all possible means to reduce the weight of the battery box (the incentive for subsidy policy is also a double-edged sword. To a certain extent, it encourages manufacturers to develop high energy density and objectively promotes the development of certain aspects of battery technology. On the other hand, blindly pursuing high energy density in battery packs has caused individual manufacturers to unilaterally pursue single indicators and narrow propaganda; some energy High-density battery packs, in addition to high energy density, are in no way related to a good battery pack design.

The starting point of the subsidy policy is benign, and the policy blind spot is used to a certain extent uncontrollable. After lessons have been learned, the policy can be corrected and improved. At the same time, it is necessary to ensure a higher structural strength. Lighter aluminum alloys are used than steel materials. The general weight loss can be about 10 - 30%, can reduce the overall weight of the battery pack to a certain extent.

The process of aluminum alloy box is generally die-casting and extrusion. The die-cast box can be integrally formed (flatness and accuracy are affected. In particular, if the sealing interface is required for the installation interface, it may require post-processing to handle). Welding requires a large tonnage die casting machine to achieve, generally limited by size, the size of the box will not be too large, generally used for battery tray tray (or lower box). When the size is larger, the tailoring welding process can be added to make up for it. This type of box can well meet the IP67. Here are some examples of battery trays for die-cast aluminum alloys.

The GM Cadillac CT6PHEV battery pack box adopts the stamping and high pressure casting process (below), and the tray Tray uses the aluminum high pressure casting (HPDC).

The following figure shows the battery case of the BMW X5 xDrive 40e. The lower case tray is made of aluminum high pressure die casting, aluminum alloy AlSi10MnMg, and weighs 6.4 kg. It is developed and manufactured by a European casting supplier.

The supplier also announced in September 2016 a large order for a battery box valued at 77million euros from a customer of a French automobile manufacturer. It will be delivered in 2019 (the figure below is only an example). The tray of the box is integrated. Cooling function.

The following figure uses the low pressure die casting of aluminum low-pressure casting. The material is aluminum alloy AlSi7Mg and also integrates the cooling function.

In general, the application of die-cast aluminum alloy in trays can be either low-pressure casting or high-pressure casting. According to different requirements, cooling functions can also be integrated inside, and a separate cooling plate is omitted. This may be one of the trends in the future.

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