An integrated injection-molded cover for new energy batteries

Abstract

This invention provides an integrated injection-molded new energy battery cover, belonging to the field of battery cover technology. It includes a cover plate, an insulating support, a terminal post, mounting holes, constraint holes, a limiting part, an insulating seal, an anti-detachment groove, a flow guide groove, and an extension part. This integrated injection-molded new energy battery cover pre-clamps the insulating seal by engaging the limiting part with the insulating support, forming a sealing zone between the terminal post and the cover plate. Simultaneously, the constraint holes limit the radial freedom of the terminal post, creating a stable pre-assembled structure between the cover plate and the terminal post. After injection molding, the back support structure formed in the extension part, along with the limiting part, supports the insulating seal, improving the long-term stability of the overall structure. Therefore, this invention not only has the advantages of simple structure, convenient installation, and ease of automated injection molding, but also high injection quality and high long-term stability.

Description

Technical Field

[0001] This invention relates to the field of battery cover technology, specifically to an integrated injection-molded new energy battery cover. Background Technology

[0002] As a core component of the battery sealing and electrode lead-out structure, the design and manufacturing quality of the battery cover are crucial to the overall performance of the battery. With the development of new energy batteries towards higher consistency and automation, cover assemblies are gradually adopting injection molding to achieve integrated connection between the electrode posts and the cover.

[0003] In the existing technology, injection molding solutions mainly include two types: one is an injection molding structure that completely removes the seal, and the other is an auxiliary injection molding structure that incorporates the seal.

[0004] For injection molding connections with completely desealed components, the poles typically rely on external structural constraints for temporary positioning during the injection molding process. They are usually in a relatively independent position from the cover plate, lacking a stable connection. This not only hinders automated handling but also makes the poles susceptible to impact forces during the injection of high-pressure molten plastic, causing them to shift, tilt, or even sink, thus affecting the quality of the injection-molded product.

[0005] For auxiliary injection molding structures combined with seals, pre-assembly with the cover plate can be achieved through the elastic deformation of the seals. However, such structures mainly rely on friction or simple extrusion for positioning, and their radial and axial constraint capabilities are limited. During handling or injection molding, there is still a risk of loosening, displacement, or even detachment, making it difficult to meet the requirements of high-precision automated production and ensuring the quality of the injection-molded product. In some technologies, to improve positioning stability, existing structures often require additional positioning or limiting components, leading to overall structural complexity, reduced assembly convenience, and hindering production efficiency.

[0006] Therefore, there is an urgent need for a battery cover structure that is simple in structure, easy to assemble, and can achieve stable positioning of the electrode post before and during injection molding, while taking into account sealing reliability and long-term stability. Summary of the Invention

[0007] This invention provides an integrated injection-molded cover plate for a new energy battery, including a cover plate, an insulating support member disposed on the back of the cover plate, and at least two terminals mounted on the cover plate. The cover plate has mounting holes corresponding to the terminals; the insulating support member has constraint holes corresponding to the mounting holes; each terminal penetrates the mounting hole, and its end on the back of the cover plate has an outwardly expanding limiting portion; an insulating seal is fitted onto each terminal, located between the cover plate and the limiting portion and simultaneously disposed within the constraint hole, constraining the terminal's freedom of movement radially by engaging with the constraint hole; the limiting portion engages with the insulating support member to axially limit the terminal and press the insulating seal, thus... The pole and the cover plate form a pre-stabilized assembly structure; the mounting hole, the circumferential surface of the pole, and the front of the insulating seal together enclose an injection molding area; the outer circumferential surface of the pole is provided with an anti-detachment groove and several guide grooves distributed circumferentially. The anti-detachment groove is an annular groove coaxial with the pole. The guide grooves are connected to the anti-detachment groove and extend to the limiting part. At the same time, the guide grooves extend radially outward at the front of the limiting part but do not penetrate the limiting part, forming an extension part; an insulating connector is formed by injection molding in the injection molding area. The part located in the anti-detachment groove forms an axial anti-detachment structure, and the part located in the extension part forms a support structure on the back of the insulating seal, which shares the axial load of the insulating seal with the limiting part.

[0008] In one possible implementation, the constraint hole and the insulating seal are stepped structures with a large-diameter region and a small-diameter region, with the small-diameter region of the insulating seal located within the mounting hole and the large-diameter region located within the small-diameter region of the constraint hole, forming a double radial constraint on the pole post.

[0009] In one possible implementation, a first snap-fit ​​flange is provided on the limiting part, and a second snap-fit ​​flange is provided in the large-diameter area of ​​the constraint hole. The second snap-fit ​​flange axially limits the first snap-fit ​​flange from the back and abuts against the limiting part in the radial direction. The contact surfaces of the first snap-fit ​​flange and the second snap-fit ​​flange are both arc-shaped structures.

[0010] In one possible implementation, the mounting hole is a stepped structure with a large-diameter area and a small-diameter area. The small-diameter area of ​​the insulating seal is located within the small-diameter area of ​​the mounting hole. Several grooves are formed on the stepped surface between the large-diameter area and the small-diameter area of ​​the mounting hole to form circumferential constraints after injection molding, thereby limiting the relative degrees of freedom between the insulating connector and the cover plate.

[0011] In one possible implementation, the guide grooves are uniformly distributed circumferentially along the pole post, and the corresponding extensions are also uniformly distributed circumferentially.

[0012] In one possible implementation, the insulating seal is made of fluororubber.

[0013] The above-mentioned one or more technical solutions in the embodiments of the present invention have the following technical effects: According to the embodiments of the present invention, an integrated injection-molded new energy battery cover plate is pre-clamped with the insulating support through the snap-fit ​​of the limiting part and the insulating seal, so that the insulating seal forms a sealing area between the pole and the cover plate on one hand, and on the other hand, under the limitation of the constraint hole, the freedom of the pole is constrained in the radial direction, so that the cover plate and the pole form a stable pre-assembled structure, thereby maintaining a stable state during handling and injection molding, facilitating automated handling and improving the stability of the injection molding process, thereby ensuring the quality of injection molding. After injection molding, the limiting part and the back support structure formed by the extension part jointly bear the insulating seal, dispersing the axial load originally borne by the limiting part alone to the insulating connector, reducing the stress level of the single structure, and improving the long-term stability of the overall structure. Therefore, the present invention not only has the advantages of simple structure, convenient installation and easy automated injection molding, but also has the advantages of good injection molding quality and high long-term stability. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of an integrated injection-molded new energy battery cover provided in an embodiment of the present invention;

[0015] Figure 2 This is a partial structural schematic diagram of an integrated injection-molded new energy battery cover provided in an embodiment of the present invention;

[0016] Figure 3 yes Figure 2 Enlarged view of point A in the middle;

[0017] Figure 4 This is a top view structural diagram of the electrode post of an integrated injection-molded new energy battery cover provided in an embodiment of the present invention.

[0018] In the diagram: 1. Cover plate; 2. Insulating support; 3. Mounting hole; 4. Pole post; 5. Constraint hole; 6. Limiting part; 7. Insulating seal; 8. Anti-detachment groove; 9. Insulating connector; 10. First snap-fit ​​flange; 11. Second snap-fit ​​flange; 12. Groove; 13. Guide groove; 14. Extension part; 15. Explosion-proof zone. Detailed Implementation

[0019] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be implemented in many other ways different from those described below, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0020] Please see Figure 1 An integrated injection-molded cover for a new energy battery includes a cover plate 1, an insulating support 2, and an electrode post 4. Figure 1 As shown, the insulating support 2 is fixedly installed on the back of the cover plate 1 by means of snap-fit ​​or welding. Two pole posts 4 are installed on the cover plate 1, with the two pole posts 4 spaced apart. One is the positive pole, made of aluminum, and the other is the negative pole, made of copper-aluminum composite. An explosion-proof zone 15 is provided on the cover plate 1, located between the two pole posts 4.

[0021] See Figure 1 and Figure 2 The cover plate 1 has mounting holes 3 corresponding to the pole posts 4 one-to-one. The pole posts 4 pass through the mounting holes 3, and one end of the pole post 4 located on the back of the cover plate 1 has an outwardly expanding limiting part 6. An insulating sealing element 7 is fitted onto the pole post 4. Figure 2 As shown, the insulating seal 7 has a stepped structure with a small diameter area at the top and a large diameter area at the bottom; the mounting hole 3 has a stepped structure with a large diameter area at the top and a small diameter area at the bottom; the insulating support 2 has constraint holes 5, which correspond one-to-one with the mounting holes 3, and the constraint holes 5 have a stepped structure with a small diameter area at the top and a large diameter area at the bottom. The diameter of the small diameter area of ​​the mounting hole 3 is smaller than that of the small diameter area of ​​the constraint hole 5, thus forming a limiting area on the back of the cover plate 1.

[0022] The stepped surface between the large-diameter and small-diameter areas of the insulating seal 7 is tightly abutted against the limiting area, forming a sealing area between the pole post 4 and the cover plate 1. The small-diameter area of ​​the insulating seal 7 is located within the small-diameter area of ​​the mounting hole 3, and the large-diameter area is located within the small-diameter area of ​​the constraint hole 5. Under the limiting effect of the constraint hole 5 and the mounting hole 3, a double radial constraint is formed on the pole post 4. On this basis, the limiting part 6 engages with the insulating support 2 to axially limit the pole post 4 and press the insulating seal 7, so that the pole post 4 and the cover plate 1 form a stable pre-assembled structure.

[0023] Based on the aforementioned structure, the pole post 4 is reliably restricted in both the radial and axial directions before injection molding, thereby maintaining a stable state during handling and injection molding, facilitating automated handling and improving the stability of the injection molding process, thus ensuring the quality of injection molding.

[0024] See Figure 2 and Figure 4 The outer circumferential surface of the pole post 4 is provided with an anti-detachment groove 8 and several guide grooves 13 evenly distributed along the circumference. The anti-detachment groove 8 is an annular structure and coaxial with the pole post 4. The upper ends of the guide grooves 13 are all connected to the anti-detachment groove 8, and the lower ends extend downward along the surface of the limiting part 6 and extend radially outward at the surface of the limiting part 6 but do not penetrate the limiting part 6, forming an extension part 14. Figure 2 As shown, the extension 14 and the guide groove 13 are L-shaped as a whole. The mounting hole 3, the circumferential surface of the pole 4, and the front side of the insulating seal 7 (the end face facing the cover plate 1) together form the injection molding area. The injection molding material is molded in the injection molding area to form the insulating connector 9, which fixes and seals the pole 4 and the cover plate 1 together. The part of the insulating connector 9 located in the anti-detachment groove 8 forms an axial anti-detachment structure to ensure that the pole 4 and the cover 1 are stably connected together; the part located in the extension 14 forms a support structure on the back of the insulating seal 7. The extension 14 is evenly distributed along the circumference, and the support structure formed therein, together with the limiting part 6, bears the load of the insulating seal 7, thereby distributing the axial load that was originally borne by the limiting part 6 alone to the insulating connector 9, reducing the stress level of the single structure, and improving the long-term stability of the overall structure.

[0025] It should be noted that: 1. The insulating seal 7 is preferably made of fluororubber (FKM) material, which can withstand short-term temperatures up to 300 degrees Celsius; the positive electrode injection molding material is conductive PPS, and the negative electrode is insulating PPS; the injection temperature of PPS and other materials is between 280℃ and 330℃. By setting the initial injection temperature and considering the temperature loss along the process, the temperature when the molten injection liquid comes into contact with the insulating seal 7 can be effectively controlled to be below 300 degrees Celsius, which is well within the temperature range that the insulating seal 7 can withstand for short periods. This ensures the feasibility of the injection molding process.

[0026] 2. In the assembled state, the insulating seal 7 covers the guide groove 13 and the extension 14, and is in a restricted compressed state under radial and axial constraints. During injection molding, the insulating seal 7 may be slightly pressed into the guide groove 13 and the extension 14, but its overall deformation is limited. Furthermore, the flow cross-section of the guide groove 13 and the extension 14 is greater than the local deformation of the insulating seal 7, allowing the molten material to flow smoothly to the extension 14 and complete molding under injection pressure. Therefore, by reasonably setting the injection molding process parameters, the smoothness of the injection molding process and the stability of the injection molding quality can be guaranteed.

[0027] See Figure 2 and Figure 3 The limiting part 6 is provided with a first snap-fit ​​flange 10, and the constraint hole 5 is provided with a second snap-fit ​​flange 11 in the large diameter area. The second snap-fit ​​flange 11 axially limits the first snap-fit ​​flange 10 from the back and abuts against the limiting part 6 in the radial direction. The contact surfaces of the two are arc-shaped, which makes it easy for the limiting part 6 to snap together with the insulating support 2. At the same time, it limits and constrains the limiting part 6 in the radial direction to a certain extent, which is conducive to further improving the stability of the pre-assembled state of the pole post 4 and the cover plate 1.

[0028] See Figure 2Several grooves 12 are provided on the step surface between the large diameter and the small diameter of the mounting hole 3. The grooves 12 are evenly distributed along the circumference. During the injection molding process, the injection molding material fills the grooves 12 and cures, thereby forming a circumferential limiting structure after injection molding. This structure is used to limit the relative rotation between the insulating connector 9 and the cover plate 1, thereby improving the connection strength and torsional resistance between the two.

[0029] Assembly process of the battery cover: First, the insulating seal 7 is fitted onto the terminal post 4 and pressed tightly against the side of the limiting part 6 facing the cover 1; then, the terminal post 4 is inserted into the corresponding mounting hole 3 from the back of the cover 1, so that the first snap-fit ​​flange 10 of the limiting part 6 engages with the second snap-fit ​​flange 11 on the insulating support 2. At this time, the insulating seal 7 is axially pressed between the cover 1 and the limiting part 6 and is located in the constraint hole 5, thereby constraining the terminal post 4 radially and axially, so that the terminal post 4 and the cover 1 form a stable pre-assembled structure.

[0030] After pre-assembly, the components are sent to the injection molding station. During injection molding, the mold applies axial clamping force to the limiting part 6 and the cover plate 1, keeping the insulating seal 7 in a compressed state and forming a closed and sealed injection space together with the injection area. Then, molten insulating material is injected into the space, filling the injection space and flowing into the expansion part 14 along the guide groove 13. After solidification, it forms the insulating connector 9.

[0031] After molding, the insulating connector 9 seals the pole post 4 and the cover plate 1 together. On the one hand, the insulating connector 9 forms an axial anti-detachment structure by filling the anti-detachment groove 8, and on the other hand, it forms a support structure on the back of the insulating seal 7 at the extension part 14. Together with the limiting part 6, it accurately bears the insulating seal 7, thereby realizing the sharing of axial load, reducing the stress level of the single structure, and improving the stability and sealing reliability of the overall structure during long-term use.

[0032] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0033] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "connected," "installed," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, an integral connection, or a sliding connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made based on the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An integrated injection-molded cover plate for a new energy battery, comprising a cover plate, an insulating support member disposed on the back of the cover plate, and at least two terminals mounted on the cover plate, wherein the cover plate is provided with mounting holes corresponding to the terminals; characterized in that: The insulating support is provided with constraint holes corresponding to the mounting holes; the pole passes through the mounting hole, and one end of it located on the back of the cover plate is provided with an outwardly expanding limiting part; An insulating seal is fitted on the pole post. The insulating seal is located between the cover plate and the limiting part and is also set in the constraint hole. By cooperating with the constraint hole, it constrains the degree of freedom of the pole post in the radial direction. The limiting part is engaged with the insulating support to limit the pole post in the axial direction and press the insulating seal, so that the pole post and the cover plate form a stable pre-assembled structure. The mounting hole, the circumferential surface of the pole, and the front of the insulating seal together enclose the injection molding area; The outer circumferential surface of the pole post is provided with an anti-detachment groove and several guide grooves distributed along the circumferential direction. The guide grooves are connected to the anti-detachment grooves and extend to the limiting part. At the same time, the guide grooves extend radially outward at the front of the limiting part but do not penetrate the limiting part, forming an extension part. An insulating connector is formed by injection molding in the injection zone. The portion located in the anti-detachment groove forms an axial anti-detachment structure, and the portion located in the extension portion forms a support structure on the back of the insulating seal, which together with the limiting portion shares the axial load of the insulating seal.

2. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The constraint hole and the insulating seal are stepped structures with a large diameter area and a small diameter area. The small diameter area of ​​the insulating seal is located inside the mounting hole, and the large diameter area is located inside the small diameter area of ​​the constraint hole, forming a double radial constraint on the pole post.

3. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The limiting part is provided with a first snap-fit ​​flange, and the large-diameter area of ​​the constraint hole is provided with a second snap-fit ​​flange. The second snap-fit ​​flange axially limits the first snap-fit ​​flange from the back and abuts against the limiting part in the radial direction.

4. The integrated injection-molded cover plate for a new energy battery according to claim 3, characterized in that: The contact surfaces of the first and second snap-fit ​​flanges are both arc-shaped.

5. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The anti-detachment groove is an annular groove coaxial with the pole post.

6. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The mounting hole has a stepped structure with a large-diameter area and a small-diameter area. The small-diameter area of ​​the insulating seal is located within the small-diameter area of ​​the mounting hole. Several grooves are provided on the stepped surface between the large-diameter area and the small-diameter area of ​​the mounting hole to form circumferential constraints after injection molding, thereby limiting the relative degrees of freedom between the insulating connector and the cover plate.

7. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The guide grooves are evenly distributed along the circumference of the pole post, and the corresponding extensions are also evenly distributed along the circumference.

8. The integrated injection-molded cover plate for a new energy battery according to claim 1, characterized in that: The insulating seal is made of fluororubber.

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