End module, battery pack, and battery pack assembly method
By using expandable and deformable end modules, the problems of complex structure and numerous parts in the existing technology are solved, and efficient assembly and cost reduction of battery pack assembly are achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- BEIJING CHEHEJIA AUTOMOBILE TECH CO LTD
- Filing Date
- 2024-12-02
- Publication Date
- 2026-06-02
AI Technical Summary
The existing end module has a complex structure and a large number of parts, resulting in low efficiency in the battery pack assembly process.
The end module, which can expand and deform, includes an internal core and an encapsulation film. By puncturing the encapsulation film, it expands and thickens, simplifying the structure and providing preload.
It simplifies and lightens the end module, reduces parts, lowers costs, improves the efficiency of the box-in process, and simplifies assembly.
Smart Images
Figure CN122136540A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of battery pack, in particular to an end module, a battery pack and a battery pack assembling method. BACKGROUND
[0002] The power assembly of a new energy vehicle includes a power battery system, a motor and gearbox system and an electronic control system, wherein the power battery system, as an important component of the new energy vehicle, is the energy source of the vehicle. The power battery system, i.e. the battery pack, includes a cover body, a battery pack and a box body, the battery pack is arranged in the box body, and the cover body covers the opening of the box body.
[0003] The in-box process is an important link in the production and manufacturing process of the battery pack, specifically referring to assembling the battery pack into the box body. In the in-box process, one end of the battery pack abuts against the cross beam in the box body through the end module. The existing end module has a complex structure, a large number of parts and a complicated assembly operation process, which affects the efficiency of the in-box process. SUMMARY
[0004] The present application aims to provide an end module, a battery pack and a battery pack assembling method, which can simplify the structure and assembly operation process of the end module and improve the efficiency of the in-box process.
[0005] To achieve this goal, the present application adopts the following technical solutions:
[0006] The end module includes:
[0007] An internal core material;
[0008] An encapsulation film, the encapsulation film has a covering state and a release state, in the covering state, the encapsulation film covers the outside of the internal core material, in the release state, the encapsulation film is broken, and the internal core material expands.
[0009] As a preferred, the internal core material includes foam, and the foam is in a compressed state when the encapsulation film is in the covering state.
[0010] As a preferred, the internal core material includes a water-absorbing core body, and the water-absorbing core body expands after absorbing water when the encapsulation film is in the release state.
[0011] As a preferred, the outer wall of the internal core material is provided with a sealing waterproof layer.
[0012] As a preferred, the internal core material includes a first core part and a second core part, a diaphragm is arranged between the first core part and the second core part, the diaphragm is broken when the encapsulation film is in the release state, and the first core part and the second core part react and expand after mixing.
[0013] Preferably, the first core and the second core are arranged side by side along the width direction of the internal core material.
[0014] Preferably, the size of the first core is smaller than the size of the second core along the width direction of the inner core material.
[0015] Preferably, when the encapsulation film is in the covered state, the thickness of the end module is T1, and when the encapsulation film is in the released state, the maximum thickness of the end module that can freely expand is T2, where T1 < T2 < 10 * T1.
[0016] The battery pack includes a battery pack, a crossbeam, and the aforementioned end module. The end module is located between the battery pack and the crossbeam, and after the internal core material of the end module expands, the end module abuts against the battery pack and the crossbeam respectively.
[0017] Preferably, when the encapsulation film is in the covered state, the thickness of the end module is T1, and when the encapsulation film is in the released state, the maximum thickness of the end module that can freely expand is T2, and the interval between the battery pack and the crossbeam is W1, where T1 < W1 < T2.
[0018] Preferably, when the encapsulation film is in the covered state, the thickness of the end module is T1, and the interval between the battery pack and the crossbeam is W1, where W1 < 5 * T1.
[0019] Preferably, when the encapsulation film is in the covered state, the height of the end module is H1, and when the encapsulation film is in the released state, the maximum height of the end module that can freely expand is H2. H1 is less than the height of the battery pack or the crossbeam, and H2 is not greater than the height of the battery pack or the crossbeam.
[0020] A battery pack assembly method for assembling the aforementioned battery pack, the battery pack assembly method comprising:
[0021] The battery pack is installed into the housing, with the battery pack and the crossbeams inside the housing spaced apart.
[0022] With the encapsulation film in a covered state, the end module is inserted between the battery pack and the crossbeam. The thickness of the end module is less than the gap between the battery pack and the crossbeam inside the box.
[0023] The encapsulation film is punctured, releasing it and allowing the end module to expand until it presses firmly against both the battery pack and the crossbeam.
[0024] The beneficial effects of this invention are:
[0025] The internal core material and the encapsulation film work together to form an expandable and deformable end module. Before assembly, it is small in size, which is easy to assemble. After assembly, it can expand and thicken to provide reliable pre-tightening force to the battery pack. This simplifies the end module structure, achieves lightweighting, reduces the number of parts, and lowers costs. Compared with the existing technology that requires multiple operations such as gluing, assembly, applying glue, and curing, this application only requires placing the end module between the battery pack and the crossbeam and then puncturing the encapsulation film. This saves time and effort, reduces assembly difficulty, and improves the efficiency of the battery pack loading process by utilizing the expansion characteristics to achieve high compatibility. Attached Figure Description
[0026] Figure 1 This is a schematic diagram of the structure in the existing design where the end module, battery pack, and crossbeam work together.
[0027] Figure 2 This is a schematic diagram of the structure of the unexpanded end module, battery pack, and crossbeam as described in Embodiment 1 of the present invention.
[0028] Figure 3 This is a schematic diagram of the disassembled structure of the unexpanded end module, battery pack, and crossbeam as described in Embodiment 1 of the present invention.
[0029] Figure 4 This is a top view of the unexpanded end module in conjunction with the battery pack and crossbeam as described in Embodiment 1 of the present invention;
[0030] Figure 5 yes Figure 4 Sectional view along axis AA;
[0031] Figure 6 This is a schematic diagram of the structure of the expanded end module cooperating with the battery pack and crossbeam as described in Embodiment 1 of the present invention;
[0032] Figure 7 This is a top view of the expanded end module in conjunction with the battery pack and crossbeam as described in Embodiment 1 of the present invention;
[0033] Figure 8 yes Figure 7 BB-direction sectional view;
[0034] Figure 9 This is a schematic diagram of the structure of the unexpanded end module according to Embodiment 1 of the present invention;
[0035] Figure 10 yes Figure 9 CC-direction sectional view;
[0036] Figure 11 yes Figure 10 Enlarged view at point D;
[0037] Figure 12This is a cross-sectional view of the unexpanded end module described in Embodiment 3 of the present invention.
[0038] In the picture:
[0039] 10. Plastic baffle; 20. Potting compound; 30. U-shaped sealing strip;
[0040] 100. End module;
[0041] 1. Internal core material; 11. First core part; 12. Second core part; 13. Diaphragm;
[0042] 2. Encapsulation film;
[0043] 200. Battery pack;
[0044] 300. Crossbeam. Detailed Implementation
[0045] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.
[0046] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium; or the internal communication of two components or the interaction 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.
[0047] In the description of this invention, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.
[0048] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.
[0049] Example 1
[0050] like Figure 1 As shown, the existing design includes a plastic baffle 10, potting compound 20, and a U-shaped sealing strip 30. The plastic baffle 10 abuts against one end of the battery pack 200, and the U-shaped sealing strip 30 confines the potting compound 20 between the plastic baffle 10 and the crossbeam 300, ultimately enabling the battery pack 200 to be installed in the box. The above-mentioned end module has a complex structure, a large number of parts, and a complicated assembly process, which affects the efficiency of the box insertion process.
[0051] like Figures 2-11 As shown, the present invention provides an end module 100, including an inner core material 1 and an encapsulation film 2. The encapsulation film 2 has a covered state and a released state. In the covered state, the encapsulation film 2 covers the outside of the inner core material 1. In the released state, the encapsulation film 2 ruptures, and the inner core material 1 can expand and thicken.
[0052] In this invention, the internal core material 1 and the encapsulation film 2 cooperate to form an expandable and deformable end module 100. Before assembly, it is small in size, which is convenient for assembly. After assembly, it can expand and thicken to provide reliable pre-tightening force to the battery pack 200. This simplifies the structure of the end module 100, achieves lightweighting, reduces the number of parts, and lowers costs. Compared with the prior art, which requires multiple operations such as gluing, assembly, applying glue, and curing, this application only requires placing the end module 100 between the battery pack 200 and the crossbeam 300 and then puncturing the encapsulation film 2. This saves time and effort, reduces assembly difficulty, and improves the efficiency of the battery pack assembly process by utilizing the expansion characteristics to achieve high compatibility.
[0053] In this embodiment, the inner core material 1 is plate-shaped, thus forming a plate-shaped end module 100 after being covered with the encapsulation film 2. In other embodiments, the inner core material 1 can also be strip-shaped, block-shaped, or other irregular shapes, as long as it ensures that the end module 100 formed after being covered with the encapsulation film 2 can be inserted between the battery pack 200 and the crossbeam 300, and that when the encapsulation film 2 is in the released state, the end module 100 can expand to abut against both the battery pack 200 and the crossbeam 300.
[0054] Specifically, the internal core material 1 can be expanded and thickened by physical, chemical, or a combination of physical and chemical methods.
[0055] In this embodiment, the inner core material 1 expands and thickens physically. The inner core material 1 includes foam, and when the encapsulation film 2 is in the covering state, the foam is in a compressed state. This configuration results in lower cost and more reliable expansion and deformation of the inner core material 1.
[0056] Specifically, the foam is silicone rubber foam, and the encapsulation film 2 is PET film. The silicone rubber foam is vacuum-sealed with PET film to achieve thickness compression. When the PET film is punctured, the silicone rubber foam absorbs air and expands. In addition to the silicone rubber foam mentioned above, other types of foam materials can be selected as needed.
[0057] More specifically, when the encapsulation film 2 is in the covered state, the thickness of the end module 100 is T1, and when the encapsulation film 2 is in the released state, the maximum thickness of the end module 100 that can freely expand is T2, where T1 < T2 < 10 * T1. This configuration ensures that the end module 100 has sufficient expansion and deformation capacity to meet the requirement of providing sufficient preload.
[0058] Example 2
[0059] This embodiment provides an end module 100, whose components are the same as or corresponding to those in Embodiment 1, and are referred to by the same or corresponding reference numerals as those in Embodiment 1. For simplicity, only the differences between this embodiment and Embodiment 1 are described below.
[0060] The difference between this embodiment and Embodiment 1 is that the internal core material 1 expands and thickens physically. The internal core material 1 includes a water-absorbing core. When the encapsulation film 2 is in the released state, the water-absorbing core can expand after absorbing water. With the above setup, the internal core material 1 can usually expand simply by injecting water, making the operation simple and controllable.
[0061] Specifically, the absorbent core is a core that expands after absorbing water, made of bentonite. The encapsulating film 2 is a PET film, and the absorbent core is vacuum-sealed with the PET film. In use, the PET film is punctured with a needle to inject water into the absorbent core, causing it to absorb water and expand. In addition to the above configuration, the absorbent core can also be made of expanded cork.
[0062] More specifically, the outer wall of the inner core material 1 is provided with a sealed waterproof layer. The above-mentioned arrangement prevents water injected into the water-absorbing core from flowing into the box and affecting the normal operation of the battery pack 200.
[0063] In this embodiment, for the end module 100 that is vertically inserted between the battery pack 200 and the crossbeam 300, the sealing and waterproof layer is a conventional setting in the art, such as a waterproofing agent coating, and is set on the side wall and bottom wall of the inner core material 1, which effectively achieves the effect of sealing and waterproofing, and prevents water from overflowing and flowing into the box.
[0064] Example 3
[0065] like Figure 12 As shown, this embodiment provides an end module 100, whose components are the same as or corresponding to those in Embodiment 1 and are referred to by the same or corresponding reference numerals as those in Embodiment 1. For simplicity, only the differences between this embodiment and Embodiment 1 will be described below.
[0066] The difference between this embodiment and Embodiment 1 is that the internal core material 1 expands and thickens through chemical means. The internal core material 1 includes a first core 11 and a second core 12, with a diaphragm 13 disposed between the first core 11 and the second core 12. When the encapsulation film 2 is in the released state, the diaphragm 13 ruptures, and the first core 11 and the second core 12 mix and expand. This arrangement, through the chemical reaction between the first core 11 and the second core 12, results in high expansion efficiency and controllable expansion size.
[0067] Specifically, the diaphragm 13 is a PET film. In a first feasible embodiment, the first core 11 is an isocyanate, and the second core 12 is a polyol. In a second feasible embodiment, the first core 11 is a phenolic resin, and the second core 12 is an acidic catalyst and a foaming agent. In a third feasible embodiment, the first core 11 is a silicone polymer, and the second core 12 is a crosslinking agent. Besides the above configurations, the first core 11 and the second core 12 can also be made of other high-molecular-weight organic materials, as long as they can achieve the mixing reaction and expansion.
[0068] More specifically, the first core 11 and the second core 12 are arranged side by side along the width direction of the inner core material 1, such as... Figure 12 As shown in the X direction. The above arrangement allows the width direction to be the vertical direction when the end module 100 is vertically inserted between the battery pack 200 and the crossbeam 300. The first core 11 and the second core 12 are stacked in the vertical direction. After the separator 13 is broken, the first core 11 and the second core 12 can be efficiently mixed under the action of gravity.
[0069] More specifically, along the width direction of the inner core material 1, the size of the first core 11 is smaller than the size of the second core 12. This arrangement ensures that when the end module 100 is vertically inserted between the battery pack 200 and the crossbeam 300, the narrower first core 11 is positioned above the second core 12, facilitating the use of needles or other components to puncture the separator 13.
[0070] Example 4
[0071] This embodiment provides an end module 100, whose components are the same as or corresponding to those in Embodiment 1, and are referred to by the same or corresponding reference numerals as those in Embodiment 1. For simplicity, only the differences between this embodiment and Embodiment 1 are described below.
[0072] The difference between this embodiment and Embodiment 1 is that the internal core material 1 expands and thickens through a combination of physical and chemical processes. In the thickness direction, the first core 11 and the second core 12 are arranged side by side on one side of the foam or absorbent core. This arrangement allows the first core 11 and the second core 12 to deform based on the foam or absorbent core after mixing, resulting in greater stability and reliability.
[0073] Example 5
[0074] The present invention provides a battery pack including a battery pack 200, a crossbeam 300 and an end module 100 of any of the above embodiments. The end module 100 is located between the battery pack 200 and the crossbeam 300, and after the internal core material 1 of the end module 100 expands, the end module 100 abuts against the battery pack 200 and the crossbeam 300 respectively.
[0075] In the battery pack of the present invention, the internal core material 1 and the encapsulation film 2 cooperate to form an expandable and deformable end module 100. Before assembly, the end module 100 is small in size and easy to assemble. After assembly, it can expand and thicken to provide reliable pre-tightening force to the battery pack 200. This simplifies the structure of the end module 100, achieves weight reduction, reduces the number of parts, and lowers costs. Compared with the prior art, which requires multiple operations such as gluing, assembly, applying glue, and curing, this application only requires placing the end module 100 between the battery pack 200 and the crossbeam 300 and then puncturing the encapsulation film 2. This saves time and effort, reduces assembly difficulty, and improves the efficiency of the battery pack assembly process by utilizing the expansion characteristic to achieve high compatibility.
[0076] In this embodiment, the battery pack includes a cover, a battery pack 200, and a housing. A crossbeam 300 is disposed in the housing. During assembly, the battery pack 200 is first placed in the housing, such that the ends of the crossbeam 300 and the battery pack 200 are spaced apart. Then, the end module 100 is inserted between the battery pack 200 and the crossbeam 300. Finally, the encapsulation film 2 is punctured, causing the end module 100 to expand and deform to press against the battery pack 200.
[0077] Specifically, when the encapsulation film 2 is in the covered state, the thickness of the end module 100 is T1; when the encapsulation film 2 is in the released state, the maximum thickness of the end module 100 that can freely expand is T2; and the interval between the battery pack 200 and the crossbeam 300 is W1, where T1 < W1 < T2. This configuration, while ensuring that the end module 100 can be smoothly inserted between the battery pack 200 and the crossbeam 300, also guarantees that the end module 100 can provide reliable preload force to the battery pack 200 after assembly.
[0078] More specifically, the interval between the battery pack 200 and the crossbeam 300 is W1, where W1 < 5 * T1. This configuration allows for the use of an end module 100 with a reasonable thickness value of T1 based on the size of W1, giving the end module 100 sufficient adaptability. Even with fluctuations in the size of W1, the thickness of the end module 100 can remain unchanged, thus providing sufficient redundancy and simplifying the design.
[0079] More specifically, when the encapsulation film 2 is in the covered state, the height of the end module 100 is H1. When the encapsulation film 2 is in the released state, the maximum height of the end module 100 that can freely expand is H2. H1 is less than the height of the battery pack 200 or the crossbeam 300, and H2 is not greater than the height of the battery pack 200 or the crossbeam 300. The above arrangement avoids the end module 100 from being higher than the battery pack 200 or the crossbeam 300 after assembly, thus preventing it from affecting the assembly of the cover and the box.
[0080] In this embodiment, W1 > 0, allowing the battery pack 200 to be smoothly inserted into the casing. When the encapsulation film 2 is in the covered state, the length of the end module 100 is L1. When the encapsulation film 2 is in the released state, the maximum length of the end module 100 that can freely expand is L2. L1 is less than the length of the battery pack 200 or the crossbeam 300, and L2 is not greater than the length of the battery pack 200 or the crossbeam 300. One end module 100 or multiple end modules can be set between the battery pack 200 and the crossbeam 300 as needed. The modules 100 are laid side by side along the length direction. When multiple end modules 100 are laid side by side, L1 is the total length of the multiple end modules 100 before expansion, L2 is the total length of the multiple end modules 100 after expansion, W1 is 3mm to ensure that the end modules 100 can be smoothly inserted into the box, T1 is 2mm to ensure smooth assembly, and T2 is 6mm to give the end modules 100 a three-fold expansion rate. The end modules 100 provide the battery pack 200 with a suitable preload range of 3KN-4KN.
[0081] Example 6
[0082] This embodiment provides a battery pack assembly method for assembling the battery pack in Embodiment 5, including:
[0083] Step 1: Install the battery pack 200 into the housing, so that the battery pack 200 and the crossbeam 300 inside the housing are spaced apart.
[0084] Step 2: With the encapsulation film 2 in a covered state, insert the end module 100 between the battery pack 200 and the crossbeam 300. The thickness of the end module 100 is less than the gap between the battery pack 200 and the crossbeam 300 inside the box.
[0085] Step 3: Puncture the encapsulation film 2 to release the encapsulation film 2, and the end module 100 expands to press against the battery pack 200 and the crossbeam 300.
[0086] In this embodiment, the internal core material 1 and the encapsulation film 2 cooperate to form an expandable and deformable end module 100. Before assembly, it is small in size and easy to assemble. After assembly, it can expand and thicken to provide reliable pre-tightening force to the battery pack 200. This simplifies the structure of the end module 100, achieves lightweighting, reduces the number of parts, and lowers costs. Compared with the prior art, which requires multiple operations such as gluing, assembly, applying glue, and curing, this application only requires placing the end module 100 between the battery pack 200 and the crossbeam 300 and then piercing the encapsulation film 2. This saves time and effort, reduces assembly difficulty, and improves the efficiency of the battery pack installation process by utilizing the expansion characteristic to achieve high compatibility.
[0087] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.
Claims
1. An end module, characterized in that, include: internal core(1); The encapsulation film (2) has a covered state and a released state. In the covered state, the encapsulation film (2) covers the outside of the inner core material (1). In the released state, the encapsulation film (2) breaks and the inner core material (1) expands.
2. The end module according to claim 1, characterized in that, The internal core material (1) includes foam, and when the encapsulation film (2) is in the covered state, the foam is in a compressed state.
3. The end module according to claim 1, characterized in that, The internal core material (1) includes a water-absorbing core. When the encapsulation film (2) is in the released state, the water-absorbing core expands after absorbing water.
4. The end module according to claim 3, characterized in that, The outer wall of the inner core material (1) is provided with a sealing and waterproof layer.
5. The end module according to claim 1, characterized in that, The internal core material (1) includes a first core (11) and a second core (12). A diaphragm (13) is provided between the first core (11) and the second core (12). When the encapsulation film (2) is in the released state, the diaphragm (13) ruptures, and the first core (11) and the second core (12) react and expand after mixing.
6. The end module according to claim 5, characterized in that, The first core (11) and the second core (12) are arranged side by side along the width direction of the inner core material (1).
7. The end module according to claim 5 or 6, characterized in that, Along the width direction of the inner core material (1), the size of the first core (11) is smaller than the size of the second core (12).
8. The end module according to any one of claims 1-7, characterized in that, When the encapsulation film (2) is in the covered state, the thickness of the end module is T1. When the encapsulation film (2) is in the released state, the maximum thickness of the end module that can freely expand is T2, where T1 < T2 < 10 * T1.
9. A battery pack, characterized in that, The device includes a battery pack (200), a crossbeam (300), and an end module as described in any one of claims 1-8. The end module is located between the battery pack (200) and the crossbeam (300), and after the internal core material (1) of the end module expands, the end module abuts against the battery pack (200) and the crossbeam (300) respectively.
10. The battery pack according to claim 9, characterized in that, When the encapsulation film (2) is in the covered state, the thickness of the end module is T1. When the encapsulation film (2) is in the released state, the maximum thickness of the end module that can freely expand is T2. The interval between the battery pack (200) and the crossbeam (300) is W1, and T1 < W1 < T2.
11. The battery pack according to claim 9, characterized in that, When the encapsulation film (2) is in the covered state, the thickness of the end module is T1, and the interval between the battery pack (200) and the crossbeam (300) is W1, where W1 < 5 * T1.
12. The battery pack according to any one of claims 9-11, characterized in that, When the encapsulation film (2) is in the covered state, the height of the end module is H1. When the encapsulation film (2) is in the released state, the maximum height of the end module that can freely expand is H2. H1 is less than the height of the battery pack (200) or the crossbeam (300), and H2 is not greater than the height of the battery pack (200) or the crossbeam (300).
13. A battery pack assembly method, characterized in that, The battery pack assembly method for assembling the battery pack according to any one of claims 9-12 includes: The battery pack (200) is installed into the housing, such that the battery pack (200) and the crossbeam (300) inside the housing are spaced apart; The encapsulation film (2) is in a covered state, and the end module is inserted between the battery pack (200) and the crossbeam (300). The thickness of the end module is less than the gap between the battery pack (200) and the crossbeam (300) inside the box. The encapsulation film (2) is punctured, so that the encapsulation film (2) is in a released state, and the end module expands to abut against the battery pack (200) and the crossbeam (300).