The design flexibility of the aluminum extruded battery tray is concentrated in its modular frame structure, adaptability to various cross-section profiles, integrated functional design, diverse connection methods, and rapid iteration capabilities. These characteristics collectively support diverse requirements ranging from lightweight to high strength.
The core design advantage of the aluminum extruded battery tray lies in its modular frame structure. By deconstructing the outer frame, inner frame, and intermediate protective surface into independent modules, designers can flexibly adjust the profile splicing method according to the battery pack size. For example, the outer frame can adapt to different wheelbase models by adding or removing longitudinal profiles, while the inner frame can support different numbers of battery modules by varying the spacing of transverse profiles. This modular design not only simplifies the production process but also allows for the creation of multiple product specifications from the same mold, significantly reducing development costs.
At the material application level, the aluminum extrusion process supports the simultaneous production of various cross-section profiles, including L-shaped, U-shaped, and rectangular shapes. L-shaped profiles, with their right-angled structure, are the preferred choice for edge beams, and their flange width can be adjusted according to load-bearing requirements. U-shaped profiles, by varying the opening direction, are applicable to scenarios requiring top mounting or bottom wiring. The U-shaped closed profiles, with their internal cavity design, maintain lightweight while improving torsional stiffness. This richness of profile selection allows designers to precisely select materials for different stress areas.
The integrated design of functional zones is another major highlight of the aluminum extruded battery tray. The central protective surface integrates multiple functions such as waterproof sealing, thermal insulation, and electromagnetic shielding through profile surface treatment or embedded structures. For example, for trays used in coastal areas, the protective surface can be anodized to enhance corrosion resistance; while in high-temperature environments, efficient thermal insulation can be achieved through pre-embedded aerogel felt. This deep integration of function and structure avoids the weight increase brought by additional components.
The diversity of connection methods further expands the design space. Friction stir welding, due to its low heat input characteristics, is widely used for connecting side beams and base plates, ensuring sealing and structural strength. For maintenance areas requiring frequent disassembly and assembly, hexagonal rivet nuts are used for quick connections. Internal wiring harness fixing points are positioned using press-fit studs, ensuring accuracy while avoiding welding damage. This "rigid-flexible" connection strategy improves local maintainability while maintaining overall rigidity.
Rapid iteration capability benefits from the standard library of aluminum extruded profiles. OEMs can select suitable side beam and support beam profiles from the library, only needing to adjust the splicing method to complete the development of new models. For example, one automaker completed the tray design in just three months when developing a new model, reducing the time by 50% compared to traditional stamping and welding processes. This "Lego-like" design mode based on standard parts significantly improves product iteration efficiency.
In practical applications, the aluminum extruded battery tray has demonstrated strong adaptability. From microcars to large SUVs, from heating needs in low-temperature regions to heat dissipation needs in high-temperature regions, the same design platform can be used to create products that meet the needs of different climates and vehicle models by adjusting profile specifications, connection methods, and functional modules. This design flexibility is the key to the rapid adoption of aluminum extruded battery trays in the new energy vehicle industry.
