Injection molded pole structure

Abstract

The injection-molded pole post structure is formed by a metal ring, the pole post and the sealing ring are arranged in the pole post fixing cavity of the metal ring, the sealing ring is arranged between the bottom of the ring and the pole post fixing part of the pole post, the outer side wall of the ring wall and the inner side wall between the pole post and the ring wall are injection-molded to form an injection-molded part, and the pole post is fixed to the pole post fixing cavity of the metal ring through the injection-molded part after cooling. When the injection-molded pole post is obtained by using the injection-molded pole post forming method, the material performance (such as ductility) of the top cover sheet does not need to be considered too much, the design and manufacturing process of the battery top cover is simplified, the manufacturing efficiency of the battery top cover is improved, and the manufacturing cost is correspondingly reduced.

Description

Technical Field

[0001] This invention relates to the field of battery component manufacturing technology for new energy vehicles, specifically to injection-molded electrode structures. Background Technology

[0002] Power batteries are a crucial component of new energy vehicles, with most existing new energy batteries using lithium-ion batteries. For power lithium batteries, besides key components such as the cell and BMS, the battery casing structure is also a significant factor in safety. The terminals are a component of the battery module. Traditionally, terminals are assembled by first fitting them into terminal holes, then using welding, riveting, or injection molding to form a complex connection structure between the terminals and the top cover plate, thus securing the terminals to the top cover plate. However, the connection structure formation process is relatively complex and requires consideration of the top cover plate material properties, making the battery top cover design and manufacturing process cumbersome. This results in low manufacturing efficiency and high production costs for the battery top cover. Based on these problems, the inventors, through research and improvement, finally developed the terminal structure of this invention. Summary of the Invention

[0003] To address at least one of the aforementioned technical deficiencies, the present invention provides the following technical solution:

[0004] The injection-molded pole structure designed in this application is obtained by the following steps:

[0005] Step S1, metal ring forming step; specifically includes:

[0006] Step S11: The pre-forming area with a central hole on the metal sheet is stamped and stretched to form a pre-forming blank with a convex hull. After the pre-forming blank is formed, the central hole is located on the bottom of the convex hull.

[0007] Step S12: Punch the area with the protrusion on the preform blank to form a metal ring; the metal ring includes a ring bottom and a ring wall formed on the ring bottom, the inner sidewall of the ring bottom and the inner sidewall of the ring wall form a pole fixing cavity, and the center hole is formed on the ring bottom after the metal ring is formed;

[0008] Step S2: Place the pole and the sealing ring into the pole fixing cavity, with the sealing ring located between the bottom of the ring and the pole fixing part of the pole;

[0009] Step S3: Injection molding is performed between the outer wall of the ring wall and the inner wall of the pole and the ring wall to form an injection molded part. After cooling, the pole is fixed to the pole fixing cavity of the metal ring through the injection molded part, and the injection molded part at least partially covers the metal ring and the pole.

[0010] According to the injection-molded pole structure described above, after the metal ring is formed, a plurality of limiting grooves are formed on the ring wall; the injection-molded part includes a pole covering part, a metal ring covering part, and a limiting part that fits in the limiting grooves. The pole covering part is located between the pole and the inner sidewall of the ring wall, and the metal ring covering part covers the outer sidewall of the ring wall. The pole end face of the pole is exposed. The limiting part is formed on the outer wall of the pole covering part or the inner wall of the metal ring covering part, or the limiting part passes through the limiting groove and is connected to the pole covering part and the metal ring covering part respectively.

[0011] According to the injection-molded pole structure described above, a cavity is formed on the inner wall of the pole covering part, and a protrusion is formed on the outer wall of the pole fixing part along its circumference, and the protrusion is embedded in the cavity for fixation.

[0012] According to the injection-molded pole structure described above, a protrusion is formed on the inner wall of the cavity, and a plurality of recesses are formed on the edge of the protrusion of the pole, with the protrusion embedded in the recesses.

[0013] According to the injection-molded pole structure described above, a flange is formed on the outer side wall of the ring wall, and a positioning recess is formed on the inner side wall of the metal ring covering part, and the flange is embedded in the positioning recess.

[0014] According to the injection-molded pole structure described above, after the metal ring is formed, a convex ring is formed by extending downward along the outer wall of the ring bottom or the lower edge of the central hole.

[0015] According to the injection-molded pole structure described above, there is a step of forming the convex ring between step S11 and step S12. The edge of the central hole at the bottom of the convex bulge is stamped to form the downwardly bent convex ring. After the metal ring is formed, the convex ring is formed at the lower edge of the central hole at the bottom of the ring.

[0016] According to the injection-molded pole structure described above, the sealing ring includes a sealing ring sheet and a sealing ring body formed on the lower surface of the sealing ring sheet. The outer wall of the sealing ring body fits against the inner wall of the central hole. The pole fixing part of the pole is positioned in the inner hole of the sealing ring sheet, and the sealing ring sheet is located between the pole fixing part and the bottom of the ring.

[0017] According to the injection-molded pole structure described above, after the metal ring is formed, a second convex ring is formed on the inner wall of the ring bottom or the upper edge of the central hole, and a ring groove is formed on the lower surface of the sealing ring, and the second convex ring is embedded in the ring groove.

[0018] According to the injection-molded pole structure described above, before step S11, there is a metal sheet forming step with the central hole and the limiting groove, in which the single metal sheet is punched and the central hole and a plurality of limiting grooves are formed on the metal sheet; after the preform blank is formed, the limiting groove is formed on the convex wall of the convex hull; after the metal ring is formed, the central hole is formed on the bottom of the ring and the limiting groove is formed on the ring wall.

[0019] Compared with the prior art, the injection-molded pole structure designed in this invention has the following advantages:

[0020] 1. When using injection molding to obtain the injection-molded terminal structure, there is no need to consider the material properties of the top cover sheet (such as ductility), which simplifies the design and manufacturing process of the battery top cover, thereby improving the efficiency of battery top cover manufacturing and correspondingly reducing manufacturing costs.

[0021] 2. Several limiting grooves are formed on the metal ring so that after the injection molded part is formed, the limiting part of the injection molded part is located in the limiting groove. When the protrusion of the cavity is embedded in the recess of the pole fixing part, the torque force is increased to prevent relative rotation between the injection molded part and the metal ring, and between the pole and the injection molded part, so as to meet the product function and meet the design requirements.

[0022] 3. Under continuous pressure, the injection molded part is formed so that the sealing ring can reach 30% compression after the electrode is fixed to the metal ring, thereby meeting the airtightness requirements.

[0023] 4. The convex ring is mainly used for welding with the terminal hole on the top cover plate. After welding, the power battery top cover can be obtained. The welding between the terminal structure and the top cover plate is more robust and reliable, which enables the power battery top cover to be assembled in modules and simplifies the manufacturing process of the power battery top cover.

[0024] 5. The setting of the convex ring embedded in the ring groove, and the setting of the sealing ring plate located at the pole fixing part and the bottom of the ring, improve the sealing performance between the pole and the bottom of the ring, so that the sealing performance of the injection molded pole meets the design requirements. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the layout and forming of the pole column structure (I);

[0026] Figure 2 This is a schematic diagram of the pole structure;

[0027] Figure 3 This is a schematic diagram of the layout and forming of the pole column structure (II);

[0028] Figure 4 This is a schematic diagram of the layout and forming of the pole column structure (III);

[0029] Figure 5 This is an exploded view of the pole structure (I);

[0030] Figure 6 This is an exploded view of the pole structure (II).

[0031] In the figure: First forming station 1, metal sheet 11, center hole 12, convex ring one 121, convex ring two 122, limiting groove 13;

[0032] Second forming station 2, preformed blank 21, convex bulge 22, convex bulge wall 221, convex bulge bottom 222;

[0033] Third forming station 3;

[0034] Fourth forming station 4, metal ring 41, ring bottom 411, ring wall 412, pole post fixing cavity 413, flange 414;

[0035] Fifth forming station 5;

[0036] pole 6, pole part 61, pole fixing part 62, convex part 621, concave part 622;

[0037] 7. Sealing ring 71, sealing ring plate 72, sealing ring body 72, ring groove 711;

[0038] Injection molding station 8, injection molded part 81, metal ring covering part 811, pole post covering part 812, limiting part 813, cavity 814, positioning cavity 815. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0040] Example 1:

[0041] like Figures 1-6As shown, the injection-molded pole structure described in this embodiment employs a stamping machine and an injection molding machine during molding. The stamping machine includes a first forming station 1 for forming a metal sheet 11 with a center hole 12 and a limiting groove 13, a second forming station 2 for forming a preformed blank 21 with a convex bulge 22, a third forming station 3 for forming a convex ring 121, and a fourth forming station 4 for forming a metal ring 41. An injection molding machine is installed after the fourth forming station as an injection molding station 8. The stamping machine can also be a cold stamping machine (i.e., a cold heading machine). Therefore, the stamping machine and the injection molding machine work together to form the pole structure. The injection-molded pole structure is manufactured according to the following steps:

[0042] Step S1, Metal Ring 41 Forming Step: This step specifically includes:

[0043] The metal sheet forming step with a center hole 12 and a limiting groove 13 involves punching a single metal sheet 11 and forming a center hole 12 and a plurality of limiting grooves 13 around the center hole 12 on the metal sheet 11. The positions of the center hole 12 and the limiting grooves 13 are pre-defined, thus preparing the metal ring 41 with the center hole 12 and the limiting grooves 13 for forming.

[0044] Step S11: The pre-forming area of ​​the metal sheet 11, which has a central hole 12 and several limiting grooves 13, is subjected to stamping and stretching to form a pre-forming blank 21 with a convex 22. After the convex 22 is formed, the limiting grooves 13 are located on the convex wall 221 of the convex 22, and the central hole 12 is located on the convex bottom 222 of the convex 22. The limiting grooves 13 are multiple, and after forming, the multiple limiting grooves 13 are arranged in a ring array. The metal sheet 11 is made of aluminum.

[0045] Step S12: The area with the protrusion 22 on the preformed blank 21 is punched to form a metal ring 41. The metal ring 41 includes a ring bottom 411 and a ring wall 412 formed on the ring bottom 411. The inner sidewall of the ring bottom 411 and the inner sidewall of the ring wall 412 form a pole fixing cavity 413. After the metal ring 41 is formed, the central hole 12 is formed on the ring bottom 411 and the limiting groove 13 is formed on the ring wall 412. At the same time, a protruding ring 121 is formed extending downward from the outer wall of the ring bottom 411 or the lower edge of the central hole 12. The protruding ring 121 is mainly used for positioning and welding to the pole hole of the top cover plate.

[0046] In this embodiment, there is a step of forming the convex ring 121 between step S11 and step S12, in which the edge of the central hole 12 of the ring bottom 411 is stamped to form a downwardly bent convex ring 121; so that the convex ring 121 is formed at the lower edge of the central hole 12 of the ring bottom 411 after the metal ring 41 is formed.

[0047] Step S2: Place the electrode post 6 and the sealing ring 7 into the electrode post fixing cavity 413, with the sealing ring 7 located between the ring bottom 411 and the electrode post fixing part 62 of the electrode post 6, so that a reliable seal is obtained between the ring bottom 411 and the electrode post fixing part 62 of the electrode post 6. There is a height difference between the end face of the electrode post part 61 of the electrode post 6 and the end face of the ring wall 412, so that the electrode post part 61 of the electrode post 6 is higher than the end face of the ring wall 412, so that the electrode post part 61 can still be exposed after the injection molding of the injection molded part 81 for pre-preparation. The electrode post 6 can be an aluminum electrode post made of aluminum material, or it can be a copper-aluminum alloy electrode post made of copper-aluminum alloy material. The sealing ring 7 is made of fluororubber material.

[0048] Step S3: Injection molding is performed on the outer wall of the ring wall 412 and the inner wall of the ring wall 412 to form an injection molded part 81 after cooling. The injection molded part 81 is used to fix the electrode 6 to the electrode fixing cavity 413 of the metal ring 41. The injection molded part 81 at least partially covers the metal ring 41 and the electrode 6. There is a height difference between the end face of the electrode part 61 of the electrode 6 and the upper end face of the injection molded part 81, so that the end face of the electrode part 61 of the electrode 6 is higher than the upper end face of the injection molded part 81, so that the end face of the electrode part 61 of the electrode 6 protrudes to the outside, thereby obtaining the electrode structure. If the electrode 6 in the electrode structure is made of aluminum, it is used as the positive electrode. If the electrode 6 in the electrode structure is made of copper-aluminum alloy, it is used as the negative electrode.

[0049] In this embodiment, the injection molded part 81 includes an electrode post covering portion 812, a metal ring covering portion 811, and a limiting portion 813 that fits into the limiting groove 13. The electrode post covering portion 812 is located between the electrode post 6 and the inner wall of the ring wall 412, and the metal ring covering portion 811 covers the outer wall of the ring wall 412. The end face of the electrode post portion 61 of the electrode post 6 is exposed. The limiting portion 813 is formed on the outer wall of the electrode post covering portion 812, and correspondingly, the limiting groove 13 is formed on the inner wall of the ring wall 412. The metal ring covering part 811 is provided on the upper side; or the metal ring covering part 811 is provided on the inner wall, and the corresponding limiting groove 13 is formed on the outer wall of the ring wall 412; or the limiting part 813 passes through the limiting groove 13 and is connected to the pole post covering part 812 and the metal ring covering part 811 respectively and is grounded. At the same time, the limiting part 813, the metal ring covering part 811 and the pole post covering part 812 are combined into an integral structure, and the bottom surface of the metal ring covering part 811 of the injection molded part 81 is flush with the inner wall of the ring bottom 411.

[0050] In this embodiment, a cavity 814 is formed on the inner wall of the pole cover portion 812. The cavity 814 is arranged circumferentially along the inner wall of the pole cover portion 812. A protrusion 621 is formed on the outer wall of the pole fixing portion 62 of the pole 6 along its circumferential direction. The protrusion 621 is embedded in the cavity 814 for fixation, so as to limit the pole 6 in the axial direction and prevent the pole 6 from moving up and down axially.

[0051] In this embodiment, the outer wall of the protrusion 621 and the inner wall of the cavity 814 are provided in a concave-convex fit so that the pole post 6 is radially limited in the pole post fixing cavity 413; further, a protrusion is formed on the inner wall of the cavity 814, and a plurality of recesses 622 are formed on the edge of the protrusion 621 of the pole post 6, and the protrusion is embedded in the recesses 622. This structure increases the torque between the pole post 6 and the injection molded part 81, and further prevents relative rotation between the pole post 6 and the injection molded part 81.

[0052] In this embodiment, a flange 414 is formed on the outer side wall of the ring wall 412, and a positioning recess 815 is formed on the inner side wall of the metal ring covering part 811. The flange 414 is embedded in the positioning recess 815. Both the flange 414 and the positioning recess 815 are arranged in a ring shape. The structure allows the metal ring 41 and the injection molded part 81 to be axially limited, preventing the metal ring 41 and the injection molded part 81 from moving up and down relative to each other in the axial direction.

[0053] In this embodiment, the sealing ring 7 includes a sealing ring plate 71 and a sealing ring body 72 formed on the lower surface of the sealing ring plate 71. The outer wall of the sealing ring body 72 fits against the inner wall of the central hole 12. The sealing ring plate 71 is located between the pole post fixing part 62 and the ring bottom 411. The pole post fixing part 62 of the pole post 6 is positioned in the inner hole of the sealing ring plate 71, which allows the pole post fixing part 62 to be reliably positioned in the pole post fixing cavity 413 before injection molding. The setting of the sealing ring body 72 fitting against the inner wall of the central hole 12 of the metal ring 41 allows the sealing ring 7 to be reliably positioned in the pole post fixing cavity 413. Thus, before the injection molded part 81 is formed, the sealing ring 7 and the pole post 6 can be reliably positioned in the pole post fixing cavity 413 to prevent the sealing ring 7 and the pole post 6 from shifting in the pole post fixing cavity 413, so that the quality of the formed pole post structure is reliable.

[0054] During injection molding, pressure is applied to the electrode post 6 to mold the sealing ring 7 into the injection molded part 81 under pressure and compression. The pressure is maintained until the injection molded part 81 cools down. This injection molding method ensures that the sealing ring 7 can achieve a compression of 30% after the electrode post 6 is fixed to the metal ring 41, thereby meeting the airtightness requirements. The injection molded part 81 is made of PSS material.

[0055] In this embodiment, a second protruding ring 122 is formed on the upper edge of the central hole 12 of the ring bottom 411, and an annular groove 711 is formed on the lower surface of the sealing ring 71. The second protruding ring 122 is embedded in the annular groove 711. The structure is designed to limit the sealing ring 71 on the ring bottom 411 and also improve the sealing performance between the sealing ring 71 and the ring bottom 411.

[0056] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A type of injection-molded pole structure, characterized in that, The injection-molded pole structure is obtained according to the following steps: Step S1, metal ring (41) forming step; specifically includes: Step S11: The preformed area with a central hole (12) on the metal sheet (11) is stamped and stretched to form a preformed blank (21) with a convex hull (22). After the preformed blank (21) is formed, the central hole (12) is located on the bottom (222) of the convex hull (22). Step S12: The area with the protrusion (22) on the preformed blank (21) is punched to form a metal ring (41); the metal ring (41) includes a ring bottom (411) and a ring wall (412) formed on the ring bottom (411), the inner sidewall of the ring bottom (411) and the inner sidewall of the ring wall (412) form a pole fixing cavity (413), and the center hole (12) is formed on the ring bottom (411) after the metal ring (41) is formed; A convex ring (121) extends downward from the outer wall of the ring bottom or the lower edge of the central hole. The convex ring (121) is used to be positioned and welded to the pole hole of the top cover plate. Step S2: Place the pole post (6) and the sealing ring (7) into the pole post fixing cavity (413), and the sealing ring (7) is located between the bottom of the ring (411) and the pole post fixing part (62) of the pole post (6); Step S3: The outer wall of the ring wall (412) and the inner wall of the pole post (6) are injection molded to form an injection molded part (81). After cooling, the pole post (6) is fixed to the pole post fixing cavity (413) of the metal ring (41) through the injection molded part (81), and the injection molded part (81) at least partially covers the metal ring (41) and the pole post (6).

2. The injection-molded pole structure according to claim 1, characterized in that, After the metal ring (41) is formed, a plurality of limiting grooves (13) are formed on the ring wall; the injection molded part (81) includes a pole covering part (812), a metal ring covering part (811), and a limiting part (813) that fits in the limiting groove (13). The pole covering part (812) is located between the pole (6) and the inner sidewall of the ring wall (412). The metal ring covering part (811) covers the outer sidewall of the ring wall (412). The end face of the pole part (61) of the pole (6) is exposed. The limiting part (813) is formed on the outer wall of the pole covering part (812) or the inner wall of the metal ring covering part (811). Alternatively, the limiting part (813) passes through the limiting groove (13) and is connected to the pole covering part (812) and the metal ring covering part (811) respectively.

3. The injection-molded pole structure according to claim 2, characterized in that, A cavity (814) is formed on the inner wall of the pole cover (812), and a protrusion (621) is formed on the outer wall of the pole fixing part (62) of the pole (6) along its circumference, and the protrusion (621) is embedded in the cavity (814) for fixation.

4. The injection-molded pole structure according to claim 3, characterized in that, The inner wall of the cavity (814) is formed with a protrusion, and the edge of the protrusion (621) of the pole post (6) is formed with a plurality of recesses (622), and the protrusion is embedded in the recesses (622).

5. The injection-molded pole structure according to claim 2, characterized in that, A flange (414) is formed on the outer sidewall of the ring wall (412), and a positioning recess (815) is formed on the inner sidewall of the metal ring covering part (811), and the flange (414) is embedded in the positioning recess (815).

6. The injection-molded pole structure according to claim 1, characterized in that, Between steps S11 and S12, there is a step of forming the first convex ring (121), in which the edge of the central hole (12) on the bottom (222) of the convex bulge (22) is stamped to form the first convex ring (121) bent downward; after the metal ring (41) is formed, the first convex ring is formed at the lower edge of the central hole of the bottom of the ring.

7. The injection-molded pole structure according to claim 1, characterized in that, The sealing ring (7) includes a sealing ring plate (71) and a sealing ring body (72) formed on the lower surface of the sealing ring plate (71). The outer wall of the sealing ring body (72) is in contact with the inner wall of the central hole (12). The pole fixing part (62) of the pole (6) is positioned in the inner hole of the sealing ring plate (71), and the sealing ring plate (71) is located between the pole fixing part (62) and the ring bottom (411).

8. The injection-molded pole structure according to claim 7, characterized in that, After the metal ring (41) is formed, a second protruding ring (122) is formed on the inner wall of the ring bottom (411) or the upper edge of the central hole (12), and a ring groove (711) is formed on the lower surface of the sealing ring (71), and the second protruding ring (122) is embedded in the ring groove (711).

9. The injection-molded pole structure according to claim 2, characterized in that, Before step S11, there is a metal sheet (11) forming step with the center hole (12) and the limiting groove (13), a single metal sheet (11) is punched, and the center hole (12) and a plurality of limiting grooves (13) are formed on the metal sheet (11). After the preformed blank (21) is formed, the limiting groove (13) is formed on the convex wall (221) of the convex hull (22). After the metal ring (41) is formed, the center hole is formed on the bottom of the ring (411), and the limiting groove (13) is formed on the ring wall (412).

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