Functional packaging module for lithium battery pack

Abstract

This invention relates to the field of encapsulation technology for lithium battery packs, and discloses a functional encapsulation module for lithium battery packs, including an inner wire cluster and an outer wire cluster. After the ends of the inner and outer wire clusters are stripped, the bare copper wires at the ends are ultrasonically welded together. The module also includes: a positioning fixture disposed at the connection point of the inner and outer wire clusters, with a wire-holding groove in the middle for positioning the inner and outer wire clusters; and a bracket fixedly disposed at the connection point of the inner and outer wire clusters, formed in two injection molding stages using a tooling mold. The inner and outer wire clusters are connected together by ultrasonically welding the bare copper wires at the ends, and the positioning fixture is used to clamp and separate the connected wire clusters. Then, the positioning fixture and the clamped inner and outer wire clusters are placed on the tooling mold, and injection molding is performed using a coating machine to fill the gaps, forming the bracket.

Description

Technical Field

[0001] This invention relates to the field of packaging technology for lithium battery packs, specifically a functional packaging module for lithium battery packs. Background Technology

[0002] In the production of dual-shell lightweight power battery packs, waterproofing is the most critical issue in the encapsulation process. The circuit board inside the battery needs to communicate with the outside world via wire harnesses to transmit power or signals. Therefore, a wire harness encapsulation module needs to be installed on the inner battery shell, which encapsulates the circuit board, to both secure the wire harnesses and ensure the airtightness of the inner battery shell. However, the currently used wire harness encapsulation modules have the following shortcomings:

[0003] The current method for blocking water ingress in wire harness packaging modules involves first stripping the cable, then manually soldering sufficient solder to form a sealed section between the bare wire bundles, and finally manually sealing with heat-shrink tubing with adhesive on the inner wall. This process is complex, and it is difficult to completely wet the soldered area. This method has disadvantages such as low production efficiency, environmental unfriendliness, high soldering cost, high labor intensity, and the inability to fully guarantee welding reliability due to manual skill. Furthermore, adhesive sealing is required between the bracket and the cable, which is unfriendly, inefficient, and unreliable, often resulting in adhesive leakage. If the adhesive is not applied evenly, it can cause leaks in the seal, affecting the subsequent waterproofing. Therefore, there is an urgent need for a functional packaging module with good waterproofing for lithium battery packs. Summary of the Invention

[0004] This invention provides a functional packaging module for lithium battery packs, which has the advantages of good sealing performance and simple operation, and solves the problems in the background art mentioned above.

[0005] The present invention provides the following technical solution: a functional packaging module for lithium battery packs, comprising an inner wire cluster and an outer wire cluster, wherein the ends of the inner wire cluster and the outer wire cluster are stripped and the bare copper wires at the ends are welded together by ultrasonic metal welding; the module further comprises: a positioning fixture, which is disposed at the connection between the ends of the inner wire cluster and the outer wire cluster and has a wire-holding groove in the middle for positioning the inner wire cluster and the outer wire cluster; and a bracket, which is fixedly disposed at the connection between the ends of the inner wire cluster and the outer wire cluster and is formed by two injection molding processes using a tooling mold.

[0006] Preferably, the positioning fixture is divided into upper and lower parts, and the shape and size of the wire-locking groove in the middle part are the same as the shape and size of the bare copper wire of the inner wire cluster and the outer wire cluster connector. It is wrapped in the bracket during the first injection molding of the bracket, and is taken out after the bracket is formed for a second injection molding.

[0007] Preferably, the bracket includes a support shell, and a connecting sleeve is fixedly provided in the middle of the support shell, covering the ends of the inner wire cluster and the outer wire cluster. The support shell is provided with a secondary injection cavity, which is a secondary injection hole reserved after the positioning jig is pulled out. I-shaped holes are opened at the front and rear ends of the support shell.

[0008] Preferably, the overall shape of the support shell is a trapezoidal shape, and its left end face and right end face have the same shape, but their area ratio is ;.

[0009] Preferably, an inner sleeve is movably disposed on the inner wire cluster, an outer sleeve is movably disposed on the outer wire cluster, and a connecting screw is movably disposed inside the I-shaped hole, the connecting screw being movably sleeved with the inner sleeve and the outer sleeve respectively.

[0010] Preferably, the outer sleeve includes a sealing ring that can be fitted onto the connecting sleeve. Both ends of the sealing ring are fixedly provided with rubber sleeves that can fit into I-shaped holes, and the rubber sleeves are fitted onto the connecting screws. One side of the sealing ring is fixedly provided with a sealing sleeve that fits onto the outer wiring cluster. The diameter of the sealing sleeve is larger than that of the outer wiring cluster, and it can shrink at high temperatures.

[0011] Preferably, the outer diameter of the rubber sleeve is the same as the diameter of the I-shaped hole, and an arc-shaped rubber ring is fixedly installed on one side of the rubber sleeve.

[0012] Preferably, the inner sleeve includes a support ring, a rubber bladder is fixedly installed on one side of the support ring, the rubber bladder is movably sleeved with an I-shaped hole, and an annular groove is opened inside the rubber bladder. A nut is movably provided on the other side of the support ring, and the nut can be threadedly connected to a connecting screw.

[0013] Preferably, the left end of the connecting screw is threaded, and the right end of the thread has a smooth area, which is used for the nut to reach the smooth area after being engaged by the thread.

[0014] Preferably, the left side of the support shell is provided with an annular groove, and a raised rib is provided in the annular groove.

[0015] The present invention has the following beneficial effects:

[0016] The inner and outer wire bundles are connected by ultrasonic metal welding of bare copper wire ends. They are then arranged as required and clamped using positioning fixtures to separate and position the connected wire bundles, preventing wire bridging during injection molding. The positioning fixtures and clamped inner and outer wire bundles are then placed on a tooling mold and injection molded using a coating machine to form a support. This directly connects the support to the inner and outer wire bundles, creating a single unit. Therefore, there are no gaps between the cables and the support, forming a sealed body. This eliminates the need for subsequent adhesive application between the cables and the support, reducing material usage, improving the waterproofness of the packaging equipment, and, with the help of specialized mold fixtures, achieving controllable dimensions and high compression tightness. This simplifies the lithium battery packaging process, using specialized equipment for packaging, thereby improving the precision and professionalism of the packaging and reducing defects caused by insufficient skill in manual packaging operations. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0018] Figure 2 This is a schematic diagram of the ultrasonic metal welding of the inner wire cluster and the outer wire cluster in the structural shell of the present invention.

[0019] Figure 3 This is a schematic diagram of the structural support of the present invention after the first injection molding;

[0020] Figure 4 This is a schematic diagram of the structural support of the present invention;

[0021] Figure 5 This is a side view of the structural positioning fixture of the present invention after installation;

[0022] Figure 6 This is an exploded view of the structure of the present invention;

[0023] Figure 7 This is a side view of the inner sleeve of the present invention.

[0024] Figure 8 This is a side view of the outer casing of the present invention.

[0025] Figure 9 This is a partial cross-sectional schematic diagram of the inner and outer sleeves of the present invention;

[0026] Figure 10 This is a schematic diagram of the installation of the structural support and battery inner shell of the present invention.

[0027] In the diagram: 1. Inner wire cluster; 2. Outer wire cluster; 3. Positioning clamp; 4. Bracket; 41. Support shell; 42. Connecting sleeve; 43. Secondary injection cavity; 44. I-shaped hole; 5. Inner sleeve; 51. Support ring; 52. Rubber bladder; 53. Nut; 6. Outer sleeve; 61. Sealing ring; 62. Rubber sleeve; 63. Sealing sleeve; 7. Connecting screw; 8. Raised rib. Detailed Implementation

[0028] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Please see Figure 1-10 A functional packaging module for a lithium battery pack includes an inner wire cluster 1 and an outer wire cluster 2. After the ends of the inner wire cluster 1 and the outer wire cluster 2 are stripped, the bare copper wires at the ends are welded together by ultrasonic metal welding. The module also includes: a positioning clamp 3, which is set at the connection between the ends of the inner wire cluster 1 and the outer wire cluster 2, and has a wire-holding groove in the middle for positioning the inner wire cluster 1 and the outer wire cluster 2; and a bracket 4, which is fixedly set at the connection between the ends of the inner wire cluster 1 and the outer wire cluster 2, and is formed by two injection molding processes using a tooling mold.

[0030] First, the wire ends of the inner wire cluster 1 and the outer wire cluster 2 are stripped. Then, they are matched one by one and the bare copper wire ends are welded together by ultrasonic metal welding. The two are then arranged according to requirements and clamped using positioning fixture 3. The connected wire clusters are then separated and positioned. Next, positioning fixture 3 and the clamped inner wire cluster 1 and outer wire cluster 2 are placed on a tooling mold and injection molded using a coating machine to form bracket 4. In this way, bracket 4 is directly connected to inner wire cluster 1 and outer wire cluster 2 to form a whole. Therefore, there is no gap between the cable and the bracket, forming a sealed body. There is no need to apply glue between the cable and the bracket, reducing the use of materials, improving the waterproofness of the packaging equipment, and with the help of special mold fixtures, the size can be controlled and the compression tightness is high.

[0031] The positioning clamp 3 is divided into upper and lower parts, and the shape and size of the wire-holding groove in the middle are the same as the shape and size of the bare copper wire of the connector of the inner wire bundle 1 and the outer wire bundle 2. When the bracket 4 is first injection molded, it is wrapped in the bracket 4. After the bracket 4 is formed, it is taken out and the bracket 4 is injected a second time to divide the positioning clamp 3 into upper and lower parts. Therefore, after the first injection molding is completed, the positioning clamp 3 is taken out from the bracket 4. At this time, the wire bundle has been limited and fixed by the bracket 4. Then, the bracket 4 is injected a second time through the coating machine to fill the area occupied by the positioning clamp 3, thereby wrapping the connection between the inner wire bundle 1 and the outer wire bundle 2 in all directions.

[0032] The bracket 4 includes a support shell 41. A connecting sleeve 42 is fixedly installed in the middle of the support shell 41, covering the ends of the inner wire cluster 1 and the outer wire cluster 2. The support shell 41 is provided with a secondary injection cavity 43, which is a secondary injection hole reserved after the positioning clamp 3 is pulled out. I-shaped holes 44 are opened at the front and rear ends of the support shell 41. The connecting sleeve 42 wraps the connection between the inner wire cluster 1 and the outer wire cluster 2, and the two are sealed together by the rubber particles and their outer skin, which effectively forms a waterproof effect. The secondary injection cavity 43 is the area formed after the positioning clamp 3 is pulled out, which is the main area that needs to be injected again. Through secondary injection, the remaining space inside the bracket 4 is filled to prevent copper wires from leaking out. The I-shaped hole 44 is used to install the connecting screw 7. The connecting screw 7 is inserted into the I-shaped hole 44 and then connected to the threaded sleeve of the battery inner shell, thereby fixing the support shell 41 to the battery inner shell.

[0033] The support shell 41 has a trapezoidal shape, and its left and right ends have the same shape, but the area ratio is 4:5. With the trapezoidal shape of the support shell 41, when installing it with the battery inner shell, the left end can be inserted into the battery inner shell first. Due to the trapezoidal design, as it is gradually inserted, the support shell 41 can fit better with the battery inner shell and lock in place, ensuring a tight connection between the support shell 41 and the battery outer shell to meet waterproofing requirements.

[0034] An inner sleeve 5 is movably disposed on the inner wire cluster 1, and an outer sleeve 6 is movably disposed on the outer wire cluster 2. A connecting screw 7 is movably disposed inside the I-shaped hole 44. The connecting screw 7 is movably sleeved with the inner sleeve 5 and the outer sleeve 6 respectively. The inner sleeve 5 and the outer sleeve 6 can block the left and right sides of the I-shaped hole 44, and at the same time seal the connection screw 7 and the bracket 4, thereby preventing external moisture from entering the battery inner shell through the threaded groove on the connecting screw 7.

[0035] The outer sleeve 6 includes a sealing ring 61 that can be fitted onto the connecting sleeve 42. Both ends of the sealing ring 61 are fixedly fitted with rubber sleeves 62 that can engage with the I-shaped holes 44, and the rubber sleeves 62 are fitted onto the connecting screws 7. One side of the sealing ring 61 is fixedly fitted with a sealing sleeve 63 that engages with the outer wiring cluster 2. The diameter of the sealing sleeve 63 is larger than that of the outer wiring cluster 2, and it can shrink at high temperatures. The sealing ring 61 engages with the connecting sleeve 42, and then, through high temperature, the sealing sleeve 63 shrinks and precisely fits onto the surface of the outer wiring cluster 2. Since the connecting sleeve 42 is formed by injection molding and is directly connected to the insulation layer of the outer wiring cluster 2, the insulation layer at the connection between the connecting sleeve 42 and the outer wiring cluster 2 is easily torn and damaged if the outer wiring cluster 2 is subjected to external force. Therefore, the sealing ring 61 and the sealing sleeve 63 again provide a plastic seal at the connection between the connecting sleeve 42 and the outer wiring cluster 2, increasing the flexibility of the seal and preventing seal failure due to the rupture of the insulation at the connection point during use.

[0036] The outer diameter of the rubber sleeve 62 is the same as the diameter of the I-shaped hole 44, and an arc-shaped rubber ring is fixedly installed on one side of the rubber sleeve 62. The rubber sleeve 62 is fitted onto the I-shaped hole 44, and during the subsequent threaded connection of the connecting screw 7 to the inner shell of the battery and continuous tightening, pressure is continuously applied to the rubber sleeve 62. The connecting screw 7 applies pressure to the arc-shaped rubber ring on one side of the rubber sleeve 62, causing it to converge towards the center under the obstruction of the support shell 41. This can provide an annular seal for the connecting screw 7 and fill the gap between the connecting screw 7 and the I-shaped hole 44, effectively isolating the inside of the battery inner shell from the outside, and further strengthening the protection of the circuit board installed inside the battery inner shell.

[0037] The inner sleeve 5 includes a support ring 51. A rubber bladder 52 is fixedly installed on one side of the support ring 51. The rubber bladder 52 is movably sleeved with the I-shaped hole 44, and an annular groove is opened inside the rubber bladder 52. A nut 53 is movably installed on the other side of the support ring 51, and the nut 53 can be threadedly connected to the connecting screw 7. When the connecting screw 7 is engaged with the inner sleeve 5, it first connects to the connecting screw 7 through the nut 53 and the end of the connecting screw 7, thereby gradually locking the rubber bladder 52 and the rubber sleeve 62, so that they enter the I-shaped hole 44 respectively. They are then squeezed and deformed, filling the gap between the I-shaped hole 44 and the connecting screw 7, and then completely sealing the channel of the I-shaped hole 44 to prevent external moisture from entering and improve the protection level.

[0038] The left end of the connecting screw 7 is threaded, and the right end of the thread has a smooth area. After the nut 53 is engaged by the thread, it reaches the smooth area. As the nut 53 gradually tightens the rubber bladder 52 and rubber sleeve 62 under the action of the thread of the connecting screw 7, it disengages from the threaded area of ​​the connecting screw 7 after reaching the smooth area. This process can, on the one hand, combine the inner sleeve 5 and the outer sleeve 6 with the bracket 4, lock the outer sleeve 6, and block the channel formed by the I-shaped hole 44. On the other hand, the connecting screw 7 can rotate freely after disengagement, so that it can be connected and fixed to the inner shell of the battery in the next step.

[0039] The left side of the support shell 41 has an annular groove, and a raised rib 8 is provided in the annular groove. When the bracket 4 is connected to the inner shell of the battery, the raised rib 8 can form a seal between the two.

[0040] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A functional packaging module for a lithium battery pack, comprising an inner wire cluster (1) and an outer wire cluster (2), wherein the ends of the inner wire cluster (1) and the outer wire cluster (2) are stripped and then ultrasonically welded to bare copper wires, characterized in that: Also includes: The positioning fixture (3) is set at the end connection of the inner wire cluster (1) and the outer wire cluster (2), and has a wire-locking groove in the middle for positioning the inner wire cluster (1) and the outer wire cluster (2); The bracket (4) is fixedly installed at the end connection of the inner wire cluster (1) and the outer wire cluster (2), and is formed by two injection molding processes using a tooling mold.

2. The functional packaging module for a lithium battery pack according to claim 1, characterized in that: The positioning fixture (3) is divided into upper and lower parts, and the shape and size of the wire slot in the middle are the same as the shape and size of the bare copper wire of the inner wire cluster (1) and the outer wire cluster (2). When the bracket (4) is first injection molded, it is wrapped in the bracket (4). After the bracket (4) is formed, it is taken out and the bracket (4) is injection molded a second time.

3. The functional packaging module for a lithium battery pack according to claim 2, characterized in that: The bracket (4) includes a support shell (41). A connecting sleeve (42) is fixedly provided in the middle of the support shell (41) and covers the ends of the inner wire cluster (1) and the outer wire cluster (2). The support shell (41) is provided with a secondary injection cavity (43), which is a secondary injection hole reserved after the positioning fixture (3) is pulled out. I-shaped holes (44) are opened at the front and rear ends of the support shell (41).

4. The functional packaging module for a lithium battery pack according to claim 3, characterized in that: The support shell (41) has a trapezoidal shape, and its left and right end faces have the same shape, but their area ratio is 4:

5.

5. A functional packaging module for a lithium battery pack according to claim 3, characterized in that: An inner sleeve (5) is movably disposed on the inner wire cluster (1), an outer sleeve (6) is movably disposed on the outer wire cluster (2), and a connecting screw (7) is movably disposed inside the I-shaped hole (44). The connecting screw (7) is movably sleeved with the inner sleeve (5) and the outer sleeve (6) respectively.

6. A functional packaging module for a lithium battery pack according to claim 5, characterized in that: The outer sleeve (6) includes a sealing ring (61) that can be fitted onto the connecting sleeve (42). Both ends of the sealing ring (61) are fixedly provided with rubber sleeves (62) that can be fitted onto the I-shaped hole (44), and the rubber sleeves (62) are fitted onto the connecting screw (7). One side of the sealing ring (61) is fixedly provided with a sealing sleeve (63) that fits onto the outer wiring cluster (2). The diameter of the sealing sleeve (63) is larger than that of the outer wiring cluster (2), and it can shrink at high temperature.

7. A functional packaging module for a lithium battery pack according to claim 6, characterized in that: The outer diameter of the rubber sleeve (62) is the same as the diameter of the I-shaped hole (44), and an arc-shaped rubber ring is fixedly installed on one side of the rubber sleeve (62).

8. A functional packaging module for a lithium battery pack according to claim 5, characterized in that: The inner sleeve (5) includes a support ring (51), on one side of which a rubber bladder (52) is fixedly installed. The rubber bladder (52) is movably sleeved with the I-shaped hole (44), and an annular groove is provided inside the rubber bladder (52). A nut (53) is movably provided on the other side of the support ring (51), and the nut (53) can be threadedly connected to the connecting screw (7).

9. A functional packaging module for a lithium battery pack according to claim 8, characterized in that: The left end of the connecting screw (7) is threaded, and the right end of the thread has a smooth area, which is used for the nut (53) to reach the smooth area after the thread is engaged.

10. A functional packaging module for a lithium battery pack according to claim 3, characterized in that: The left side of the support shell (41) is provided with an annular groove, and a rib (8) is provided in the annular groove.

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