A flexible battery module thermoforming bracket and protection method that adapts to cell expansion

Abstract

This invention discloses a flexible battery module thermoforming bracket and protection method with adaptive cell expansion, belonging to the field of thermoforming bracket technology. It includes a thermoforming bracket body, cell positioning cavities, an adaptive mechanism, an adjustment mechanism, a detection and movement mechanism, and a buffer mechanism. Sixteen cell positioning cavities are located at the top center of the thermoforming bracket body. The adaptive mechanism uses springs, electrical springs, resistance strain gauges, telescopic rods, and spherical blocks to actively and adaptively buffer cell expansion, preventing permanent failure of the springs and monitoring the expansion force to avoid cracking and deformation of the thermoforming bracket body. The adjustment mechanism dynamically adjusts the internal dimensions of the cell positioning cavities according to the cell expansion state by inflating and deflating the airbags, actively adapting to cell expansion and contraction, preventing cracking and deformation of the thermoforming bracket body, maintaining pre-tight positioning of the cells, preventing short circuits, and improving the structural protection of the thermoforming bracket body.

Description

Technical Field

[0001] This invention relates to the field of thermoforming bracket technology, specifically a flexible battery module thermoforming bracket and protection method that adapts to cell expansion. Background Technology

[0002] The flexible battery module vacuum forming bracket is a thin-walled, lightweight structural component made of flame-retardant and insulating materials such as PC / glass fiber reinforced PC through vacuum forming. It is specifically designed for soft-pack / flexible battery modules. Its core function is to provide precise positioning, electrical isolation, and mechanical protection for flexible cells. It also integrates mounting slots for busbars and FPC sampling boards, serving the dual function of "skeleton + insulation barrier" in the module. It is a core supporting structural component for achieving lightweight, high integration, and high safety of flexible battery modules. Existing flexible battery module vacuum forming brackets are mostly rigid thin-walled structures, which cannot adapt to the periodic expansion and contraction of soft-pack cells during charging and discharging. They are easily deformed and cracked by the cells, or short circuits may occur due to excessive gaps. Some solutions with added buffer pads lack mechanical limit and force monitoring functions, and are prone to permanent failure due to excessive deformation of the springs. They cannot accurately sense the expansion state of the cells, resulting in poor structural reliability and lack of safety warnings, making it difficult to meet the requirements of high-safety modules. The cell positioning cavities of existing flexible battery module vacuum forming brackets are mostly fixed-size structures, which can only adapt to a single specification of cell. Moreover, there is no adjustable protective structure on the side wall, which cannot dynamically adjust the positioning gap according to the size and deformation state of the cells. This can easily lead to cell shaking and positioning failure. At the same time, they lack buffer protection capabilities and cannot effectively buffer external forces when the module is impacted, making it difficult to balance the compatibility with different cells and structural protection performance. In conclusion: Existing flexible battery module vacuum forming brackets are mostly passive rigid structures. When the battery cells heat up and cause the brackets to soften, they are prone to sagging, collapsing, and sticking to the battery cells, leading to insulation failure and short circuit risks. Some solutions that add fixed support columns cannot dynamically adapt to bracket deformation, easily cracking the brackets or causing protection failure. They lack displacement monitoring and active lifting protection capabilities, making it difficult to effectively protect the bracket body under high-temperature conditions. Existing flexible battery module vacuum forming brackets are mostly one-piece rigid thin-walled structures with no effective buffer protection on all sides. During module transportation, vehicle vibration, or collision impact, the brackets are easily subjected to direct external forces, resulting in problems such as corner chipping, overall warping, and structural fatigue cracking. Some solutions that only add a single spring have a single buffer dimension, cannot adapt to multi-directional impacts, have limited protection effects, and cannot fully protect the bracket body. Summary of the Invention

[0003] Therefore, in order to overcome the above-mentioned shortcomings, the present invention provides a flexible battery module thermoforming bracket and protection method that adapts to cell expansion.

[0004] The present invention is implemented by constructing a flexible battery module vacuum forming bracket that adapts to cell expansion and a protection method thereof. The device includes a vacuum forming bracket body. The top center of the blister support body is provided with sixteen sets of battery cell positioning cavities. The inner center of the four side walls of each battery cell positioning cavity is slidably connected to an adaptive mechanism. The inner sides of the four side walls of each battery cell positioning cavity are provided with adjustment mechanisms. The bottom of the blister support body is provided with a moving mechanism. The outer walls of the moving mechanism are slidably connected with buffer mechanisms. The adaptive mechanism includes a Teflon liner. The inner center of each of the four side walls of the battery cell positioning cavity is slidably connected to one end of the Teflon liner. The other end of the Teflon liner is adhesively connected to one end of the spring. A connecting plate is fixedly connected to the side of the spring. The center of the connecting plate is fixedly connected to one end of the electric spring. Resistance strain gauges are adhesively connected to the spring wire axis at ±45°. A telescopic rod is provided on the side of the electric spring, and the telescopic rod is fixedly connected to the connecting plate. The telescopic rod is slidably connected to the outer wall of one end of the spherical block.

[0005] Preferably, a protective device for a flexible battery module thermoforming bracket that adapts to cell expansion includes mounting holes. Mounting holes are provided on both sides of the four side walls of the cell positioning cavity. Conveying pipes are provided around the cell positioning cavity at the top of the thermoforming bracket body. A sealing plug is sealed on the top of the conveying pipe. An airbag is adhesively connected inside the mounting holes. A protective pad is adhesively connected between the airbag and the cell contact surface.

[0006] Preferably, the detection movement mechanism includes a rigid support base. The bottom of the blister bracket body is provided with a rigid support base, and the top center of the rigid support base is provided with a mounting groove. Two sets of miniature ranging chips are fixedly connected inside the mounting groove. Three sets of mounting rods are equidistantly arranged inside the mounting groove. Two sets of electromagnetic blocks are fixedly connected inside the mounting rods. The electromagnetic blocks are magnetically attracted to the sliding rod. An insulating support column is fixedly connected to the top of the sliding rod, and the insulating support column is fixedly connected to the bottom of the blister bracket body.

[0007] Preferably, the buffer mechanism includes a flexible pad, and the flexible pad is slidably connected to all four sides of the outer wall of the rigid support base. The inner surface of the flexible pad is adhesively connected to one end of the first mounting plate, the other end of the first mounting plate is fixedly connected to one end of the collapse energy-absorbing box, the other end of the collapse energy-absorbing box is fixedly connected to the second mounting plate, both sides of the outer surface of the second mounting plate are fixedly connected to one end of a spring, one side of the outer surface of the second mounting plate is fixedly connected to one end of the first rotating rod, the other side of the outer surface of the second mounting plate is slidably connected to one end of the second rotating rod, the first rotating rod and the second rotating rod are rotatably connected, and a torsion spring is fixedly connected at the rotatable connection between the second rotating rod and the first rotating rod.

[0008] Preferably, the connecting plate is fixedly connected to the inside of the blister bracket body, and the other end of the electric spring is elastically connected to the spring sheet.

[0009] Preferably, the outer wall of the other end of the spherical block is elastically connected to the spring sheet, and the electric spring is electrically connected to an external power source.

[0010] Preferably, the top of the airbag is connected to a delivery pipe, and the delivery pipe is connected to an external inflation / deflation device.

[0011] Preferably, the electromagnetic block is electrically connected to an external current output device, the miniature ranging chip is electrically connected to an external control terminal, and the outer wall of the sliding rod is slidably connected to the mounting rod.

[0012] Preferably, the other end of the spring is fixedly connected to the other end of the first mounting plate, the other end of the first rotating rod is slidably connected to the other end of the first mounting plate, and the other end of the second rotating rod is fixedly connected to the other end of the first mounting plate.

[0013] Preferably, a method for protecting a flexible battery module thermoforming bracket that adapts to cell expansion includes the following steps: Step 1: Adaptive buffer limit; Through the cooperation of spring, telescopic rod and ball block, the expansion stress of the battery cell is adaptively absorbed to prevent excessive deformation of the spring. At the same time, the expansion force is monitored in real time to avoid the blister bracket body being cracked and deformed, thus achieving the dual effect of buffering and protection. Step 2: Dynamic adjustment of cavity diameter; By inflating and deflating the airbag, the inner diameter of the mounting hole is dynamically adjusted according to the expansion and contraction state of the battery cell during charging and discharging, so as to always fit the battery cell and disperse the expansion force, prevent the blister bracket body from cracking, and improve the protection of the blister bracket body. Step 3: High-temperature active lifting support; by monitoring the deformation and displacement of the blister bracket body through a micro ranging chip, the electromagnetic block is driven to move the sliding rod and the insulating support column. When the blister bracket body softens at high temperature, it is supported in time to prevent sagging, collapse and short circuit, thus achieving active protection under high-temperature conditions. Step 4: Multi-directional impact buffering and vibration reduction; through the composite buffering structure of springs and torsion springs, vibration and collision impacts are absorbed, reducing the direct effect of external forces on the thermoforming bracket body and improving the overall structural protection.

[0014] The present invention has the following advantages: The present invention provides an improved flexible battery module vacuum forming bracket and protection method that adapts to cell expansion, which has the following improvements compared to similar equipment: This invention discloses an adaptive flexible battery module thermoforming bracket and protection method for cell expansion. It incorporates an adaptive mechanism that uses springs, electrical springs, strain gauges, telescopic rods, and spherical blocks to actively and adaptively buffer cell expansion, preventing permanent failure of the springs and monitoring expansion force to avoid cracking or deformation of the thermoforming bracket body. An adjustment mechanism dynamically adjusts the internal dimensions of the cell positioning cavity based on the cell expansion state by inflating and deflating the airbag, actively adapting to cell expansion and contraction, preventing cracking or deformation of the thermoforming bracket body, maintaining cell pre-tight positioning, preventing short circuits, and improving the thermoforming efficiency. The support structure is highly protective; a detection and movement mechanism is installed, which monitors the displacement of the blister support body in real time through a micro ranging chip and lifts the blister support body to dynamically compensate for the sag of the blister support body, preventing the blister support body from collapsing and short-circuiting against the core, thus achieving active and precise protection of the blister support body; a buffer mechanism is installed, which gradually consumes and buffers external forces through the synergistic action of a collapsible energy-absorbing box, springs and torsion springs, preventing external forces from being directly transmitted to the blister support body, effectively preventing the edge and corner of the blister support body from cracking and the whole body from warping, thus achieving multi-directional impact protection for the blister support body. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the process flow of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention; Figure 3 This is a schematic diagram of the three-dimensional structure of the adaptive mechanism of the present invention; Figure 4 This is the present invention. Figure 3 Enlarged structural diagram at point A; Figure 5 This is a three-dimensional structural diagram of the adjustment mechanism of the present invention; Figure 6 This is a three-dimensional exploded view of the mounting holes and airbag structure of the present invention; Figure 7 This is a three-dimensional structural diagram of the moving mechanism of the present invention; Figure 8 This is a three-dimensional exploded view of the mounting rod and sliding rod of the present invention; Figure 9 This is a three-dimensional structural diagram of the buffer mechanism of the present invention; Figure 10 This is the present invention. Figure 9 A magnified structural diagram at point B in the middle.

[0016] The components include: blister bracket body-1, battery cell positioning cavity-2, adaptive mechanism-3, Teflon liner-31, spring sheet-32, connecting plate-33, electric spring-34, resistance strain gauge-35, telescopic rod-36, spherical block-37, adjustment mechanism-4, mounting hole-41, delivery pipe-42, sealing plug-43, airbag-44, protective pad-45, detection and movement mechanism-5, rigid support base-51, mounting groove-52, micro ranging chip-53, mounting rod-54, electromagnetic block-55, sliding rod-56, insulating support column-57, buffer mechanism-6, flexible pad-61, first mounting plate-62, collapsible energy absorption box-63, second mounting plate-64, spring-65, first rotating rod-66, second rotating rod-67, and torsion spring-68. Detailed Implementation

[0017] The following is in conjunction with the appendix Figures 1-10 The principles and features of the present invention are described below. The examples given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0018] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0019] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral 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 based on the specific circumstances. The embodiments of this invention will now be described according to its overall structure.

[0020] Example 1:

[0021] Please see Figures 1-4The present invention discloses an adaptive flexible battery module vacuum forming bracket and protection method for battery cell expansion, comprising a vacuum forming bracket body 1; sixteen battery cell positioning cavities 2 are provided at the top center of the vacuum forming bracket body 1, an adaptive mechanism 3 is slidably connected at the center of the four side walls of the battery cell positioning cavity 2, an adjustment mechanism 4 is provided on both sides of the four side walls of the battery cell positioning cavity 2, a moving mechanism 5 is provided at the bottom of the vacuum forming bracket body 1, and a buffer mechanism 6 is slidably connected around the outer wall of the moving mechanism 5.

[0022] The adaptive mechanism 3 includes a Teflon pad 31. The center of the four side walls of the battery cell positioning cavity 2 is slidably connected to one end of the Teflon pad 31. The other end of the Teflon pad 31 is adhesively connected to one end of the spring sheet 32. A connecting plate 33 is fixedly connected to the side of the spring sheet 32. When the Teflon pad 31 is subjected to force, it is easy to drive the spring sheet 32 ​​to undergo elastic deformation.

[0023] The center of the connecting plate 33 is fixedly connected to one end of the electric spring 34. Resistance strain gauges 35 are glued to each of the spring wire axes of the electric spring 34 in the ±45° direction. The side of the electric spring 34 is provided with a telescopic rod 36, which is fixedly connected to the connecting plate 33. The resistance strain gauges 35 facilitate the synchronous acquisition of deformation and pressure data of the spring sheet 32, so as to realize real-time monitoring of the expansion force of the battery cell.

[0024] The telescopic rod 36 is slidably connected to the outer wall of one end of the spherical block 37, the connecting plate 33 is fixedly connected to the inside of the blister bracket body 1, the other end of the electric spring 34 is elastically connected to the spring piece 32, the other end of the spherical block 37 is elastically connected to the spring piece 32, and the electric spring 34 is electrically connected to an external power source.

[0025] The working principle of the adaptive cell expansion flexible battery module vacuum forming bracket and protection method based on Embodiment 1 is as follows: First, when using this device, place it in the work area, and then connect it to an external power source to provide the power required for its operation. Secondly, when the battery cell expands during charging and discharging, it compresses the Teflon liner 31. The Teflon liner 31, under pressure, causes the spring 32 to undergo elastic deformation. This deformation compresses the electric spring 34, simultaneously causing the telescopic rod 36 to contract via the spherical block 37. During the compression of the electric spring 34, the resistance strain gauge 35 synchronously collects the deformation and pressure data of the spring 32, enabling real-time monitoring of the battery cell's expansion force. When the spring 32 reaches its maximum travel, the limiting structure formed by the telescopic rod 36 and the spherical block 37, i.e., the maximum contraction value of the telescopic rod 36, forcibly restricts the spring 32 from further retracting, preventing excessive deformation that could lead to permanent failure. When the battery cell contracts, the electric spring 34 releases its elastic potential energy, causing the spring 32 and the Teflon liner 31 to synchronously reset, achieving adaptive adjustment, maintaining the pre-tight positioning of the battery cell, filling the contraction gap, and preventing battery cell movement.

[0026] Example 2:

[0027] Please see Figures 5-6 The present invention provides an adaptive cell expansion flexible battery module thermoforming bracket and protection method. Compared with Embodiment 1, this embodiment further includes: an adjustment mechanism 4, which includes mounting holes 41. Mounting holes 41 are provided on both sides of the four side walls of the cell positioning cavity 2. Conveying pipes 42 are provided around the top of the cell positioning cavity 2 of the thermoforming bracket body 1. The conveying pipes 42 facilitate the conveying of gas.

[0028] The top of the delivery pipe 42 is sealed with a sealing plug 43. An air bladder 44 is glued to the inside of the mounting hole 41. A protective pad 45 is glued to the contact surface between the air bladder 44 and the battery cell. The top of the air bladder 44 is connected to the delivery pipe 42. The delivery pipe 42 is connected to an external air pumping and inflation device.

[0029] In this embodiment: An external inflation / deflation device inflates or deflates the airbag 44 via a delivery pipe 42. Gas enters the mounting hole 41 through the delivery pipe 42, causing the airbag 44 to expand or contract. When the airbag 44 expands, it causes the protective pad 45 on its surface to extend outward, reducing the internal space of the battery cell positioning cavity 2 and tightly fitting the outer wall of the battery cell, thus providing a secure positioning for the battery cell. When the airbag 44 contracts, it causes the protective pad 45 to retract, increasing the internal space of the positioning cavity to prevent the battery cell from expanding. The protective pad 45 moves synchronously with the airbag 44, achieving dynamic adjustment of the positioning cavity size, providing flexible protection for the outer wall of the battery cell, avoiding rigid compression damage to the battery cell, and improving the protection of the blister bracket body 1 and the safety of the module.

[0030] Example 3:

[0031] Please see Figures 7-8 The present invention provides an adaptive cell expansion flexible battery module blister bracket and protection method. Compared with Embodiment 1, this embodiment further includes: a detection and movement mechanism 5. The detection and movement mechanism 5 includes a rigid support base 51. The bottom of the blister bracket body 1 is provided with the rigid support base 51. The top center of the rigid support base 51 is provided with an installation groove 52. Two sets of micro ranging chips 53 are fixedly connected inside the installation groove 52. The micro ranging chips 53 facilitate real-time monitoring of the distance between the bottom of the blister bracket body 1 and the rigid support base 51.

[0032] Three sets of mounting rods 54 are equidistantly arranged inside the mounting slot 52. Two sets of electromagnetic blocks 55 are fixedly connected inside the mounting rods 54. The electromagnetic blocks 55 are magnetically attracted to the sliding rods 56. An insulating support column 57 is fixedly connected to the top of the sliding rods 56, and the insulating support column 57 is fixedly connected to the bottom of the blister bracket body 1. The insulating support column 57 can easily eliminate the risk of short circuit through its insulation characteristics.

[0033] The electromagnetic block 55 is electrically connected to the external current output device, the miniature ranging chip 53 is electrically connected to the external control terminal, and the outer wall of the sliding rod 56 is slidably connected to the mounting rod 54.

[0034] In this embodiment: During use, the distance between the bottom of the blister bracket body 1 and the rigid support base 51 is monitored in real time by the micro ranging chip 53. When the battery cell heats up, causing the bracket to soften and sag, and the distance changes, the micro ranging chip 53 transmits an electrical signal to the external control terminal. The external control terminal triggers the external current output device to supply power to the electromagnetic block 55. After the electromagnetic block 55 is energized, it generates magnetism and forms a magnetic attraction with the sliding rod 56, thereby driving the sliding rod 56 to slide upward along the inside of the mounting rod 54. When the sliding rod 56 slides upward, it drives the insulating support column 57 fixedly connected to its top to move upward synchronously. The insulating support column 57 pushes the blister bracket body 1 upward, dynamically compensating for the sag of the blister bracket body 1. When the blister bracket body 1 returns to its normal position, the electromagnetic block 55 is de-energized, and the sliding rod 56 drives the insulating support column 57 to fall back to its original position, avoiding the collapse and short circuit of the blister bracket body 1. The insulating characteristics of the insulating support column 57 also eliminate the risk of short circuit, achieving active and precise protection of the blister bracket body 1 under high temperature conditions.

[0035] Example 4:

[0036] Please see Figures 9-10 The present invention provides an adaptive cell expansion flexible battery module thermoforming bracket and protection method. Compared with Embodiment 1, this embodiment further includes: a buffer mechanism 6, which includes a flexible pad 61. The flexible pad 61 is slidably connected to the outer wall of the rigid support base 51. The inner surface of the flexible pad 61 is adhesively connected to one end of the first mounting plate 62. The other end of the first mounting plate 62 is fixedly connected to one end of the collapse energy absorption box 63. The collapse energy absorption box 63 can be controllably folded and collapsed like an accordion bellows to absorb most of the impact energy.

[0037] The other end of the collapsible energy-absorbing box 63 is fixedly connected to the second mounting plate 64. Both sides of the outer surface of the second mounting plate 64 are fixedly connected to one end of the spring 65. One side of the outer surface of the second mounting plate 64 is fixedly connected to one end of the first rotating rod 66, and the other side of the outer surface of the second mounting plate 64 is slidably connected to one end of the second rotating rod 67. The first rotating rod 66 and the second rotating rod 67 are rotatably connected, and a torsion spring 68 is fixedly connected at the rotatable connection between the second rotating rod 67 and the first rotating rod 66. The spring 65 and the torsion spring 68 facilitate the release of elastic potential energy, drive the components to reset, and restore the buffer protection capability.

[0038] The other end of the spring 65 is fixedly connected to the other end of the first mounting plate 62, the other end of the first rotating rod 66 is slidably connected to the other end of the first mounting plate 62, and the other end of the second rotating rod 67 is fixedly connected to the other end of the first mounting plate 62.

[0039] In this embodiment: When the thermoforming bracket body 1 and the rigid support base 51 are subjected to external forces such as transportation vibration and collision impact, the external force first acts on the flexible pad 61. After being subjected to force, the flexible pad 61 drives the first mounting plate 62 to move synchronously. The movement of the first mounting plate 62 causes the collapse energy absorption box 63 to collapse in a controllable manner, and at the same time, it causes the spring 65 to stretch or compress. The spring 65 initially absorbs and buffers the external force through its own elastic deformation. Meanwhile, the movement of the first mounting plate 62 causes one end of the first rotating rod 66 to slide along its surface. The rotation of the first rotating rod 66 drives the second rotating rod 67, which is hinged to it, to rotate. When the second rotating rod 67 rotates synchronously, it causes the torsion spring 68 at the connection to undergo torsional deformation. The torsion spring 68 further absorbs the impact load from multiple directions. Through the synergistic effect of the collapsible energy-absorbing box 63, the spring 65 and the torsion spring 68, the external force is gradually consumed and buffered, avoiding the direct transmission of the external force to the thermoforming bracket body 1. This effectively prevents the corners of the thermoforming bracket body 1 from cracking and the whole body from warping, achieving multi-directional impact protection for the thermoforming bracket body 1. After buffering is completed, the spring 65 and the torsion spring 68 release elastic potential energy, causing each component to reset and restoring the buffering protection capability.

[0040] Example 5:

[0041] Please see Figures 1-10 The present invention provides an adaptive flexible battery module thermoforming bracket and protection method for cell expansion. Compared with Embodiment 1, this embodiment includes the following steps: Step 1: Adaptive buffer limit; Through the cooperation of spring piece 32, telescopic rod 36 and spherical block 37, the expansion stress of the battery cell is adaptively absorbed to prevent excessive deformation of spring piece 32. At the same time, the expansion force is monitored in real time to avoid the blister bracket body 1 from being cracked and deformed, thus achieving the dual effect of buffering and protection. Step 2: Dynamic adjustment of cavity diameter; by inflating and deflating the airbag 44, the inner diameter of the mounting hole 41 is dynamically adjusted according to the expansion and contraction state of the battery cell during charging and discharging, so as to always fit the battery cell and disperse the expansion force, prevent the blister bracket body 1 from cracking, and improve the protection of the blister bracket body 1. Step 3: High-temperature active lifting support; The deformation displacement of the blister bracket body 1 is monitored by the micro ranging chip 53, and the electromagnetic block 55 drives the sliding rod 56 and the insulating support column 57 to move. When the blister bracket body 1 softens at high temperature, it is supported in time to prevent sagging, collapse and short circuit, thus achieving active protection under high temperature conditions. Step 4: Multi-directional impact buffering and vibration reduction; through the composite buffering structure of spring 65 and torsion spring 68, vibration and collision impact are absorbed, reducing the direct effect of external force on the thermoforming bracket body 1 and improving the overall structural protection.

[0042] This invention provides an improved flexible battery module thermoforming bracket and protection method that adapts to cell expansion. An adaptive mechanism 3 is incorporated, utilizing a spring 32, an electric spring 34, a strain gauge 35, a telescopic rod 36, and a spherical block 37 to actively and adaptively buffer cell expansion, preventing permanent failure of the spring 32 and monitoring expansion force to avoid cracking or deformation of the thermoforming bracket body 1. An adjustment mechanism 4 is also included, which dynamically adjusts the internal dimensions of the cell positioning cavity 2 according to the cell expansion state by inflating and deflating the airbag 44, actively adapting to cell expansion and contraction, preventing cracking or deformation of the thermoforming bracket body 1, maintaining cell pre-tight positioning, preventing short circuits, and improving overall performance. The thermoforming bracket body 1 has structural protective features; a detection and movement mechanism 5 is set up to monitor the displacement of the thermoforming bracket body 1 in real time through a micro ranging chip 53, and drive the thermoforming bracket body 1 to lift up, dynamically compensating for the sag of the thermoforming bracket body 1, avoiding the thermoforming bracket body 1 from collapsing and short-circuiting, and achieving active and precise protection of the thermoforming bracket body 1; a buffer mechanism 6 is set up to gradually consume and buffer external forces through the synergistic action of the collapse energy absorption box 63, spring 65 and torsion spring 68, avoiding the direct transmission of external forces to the thermoforming bracket body 1, effectively preventing the corners of the thermoforming bracket body 1 from cracking and the whole body from warping, and achieving multi-directional impact protection for the thermoforming bracket body 1.

[0043] The above description shows and illustrates the basic principles, main features, and advantages of the present invention. Standard parts used in the present invention can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts, and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here.

[0044] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A flexible battery module thermoforming bracket with adaptive cell expansion, characterized in that: Includes the blister support body (1); The blister support body (1) has sixteen sets of battery cell positioning cavities (2) at the top center. The four side walls of the battery cell positioning cavity (2) are all slidably connected to an adaptive mechanism (3). The four side walls of the battery cell positioning cavity (2) are all provided with an adjustment mechanism (4). The bottom of the blister support body (1) is provided with a moving mechanism (5). The outer walls of the moving mechanism (5) are all slidably connected with a buffer mechanism (6). The adaptive mechanism (3) includes a Teflon pad (31). The four sides of the battery cell positioning cavity (2) are slidably connected to one end of the Teflon pad (31) at their internal center. The other end of the Teflon pad (31) is glued to one end of the spring sheet (32). A connecting plate (33) is fixedly connected to the side of the spring sheet (32). The center of the connecting plate (33) is fixedly connected to one end of the electric spring (34). Resistance strain gauges (35) are glued to each of the ±45° directions of the spring wire axis of the electric spring (34). A telescopic rod (36) is provided on the side of the electric spring (34), and the telescopic rod (36) is fixedly connected to the connecting plate (33). The telescopic rod (36) is slidably connected to the outer wall of one end of the spherical block (37).

2. A protective device for a flexible battery module thermoforming bracket that adapts to cell expansion, used to implement the flexible battery module thermoforming bracket that adapts to cell expansion as described in claim 1, characterized in that: The battery cell positioning cavity (2) includes mounting holes (41), and mounting holes (41) are provided on both sides of the four side walls of the battery cell positioning cavity (2). The battery cell positioning cavity (2) at the top of the blister bracket body (1) is provided with a conveying pipe (42). A sealing plug (43) is provided at the top of the conveying pipe (42). An airbag (44) is glued inside the mounting hole (41). A protective pad (45) is glued to the contact surface of the battery cell.

3. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 2, characterized in that: The detection moving mechanism (5) includes a rigid support base (51). The bottom of the blister bracket body (1) is provided with a rigid support base (51). The top center of the rigid support base (51) is provided with an installation groove (52). Two sets of micro ranging chips (53) are fixedly connected inside the installation groove (52). Three sets of mounting rods (54) are equidistantly arranged inside the installation groove (52). Two sets of electromagnetic blocks (55) are fixedly connected inside the mounting rods (54). The electromagnetic blocks (55) are magnetically attracted to the sliding rod (56). An insulating support column (57) is fixedly connected to the top of the sliding rod (56), and the insulating support column (57) is fixedly connected to the bottom of the blister bracket body (1).

4. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 3, characterized in that: The buffer mechanism (6) includes a flexible pad (61). The flexible pad (61) is slidably connected to the outer wall of the rigid support base (51). The inner surface of the flexible pad (61) is bonded to one end of the first mounting plate (62). The other end of the first mounting plate (62) is fixedly connected to one end of the collapse energy absorption box (63). The other end of the collapse energy absorption box (63) is fixedly connected to the second mounting plate (64). Both sides of the outer surface of the second mounting plate (64) are fixedly connected to one end of the spring (65). One side of the outer surface of the second mounting plate (64) is fixedly connected to one end of the first rotating rod (66). The other side of the outer surface of the second mounting plate (64) is slidably connected to one end of the second rotating rod (67). The first rotating rod (66) and the second rotating rod (67) are rotatably connected. A torsion spring (68) is fixedly connected at the rotatable connection between the second rotating rod (67) and the first rotating rod (66).

5. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 4, characterized in that: The connecting plate (33) is fixedly connected to the inside of the blister bracket body (1), and the other end of the electric spring (34) is elastically connected to the spring sheet (32).

6. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 5, characterized in that: The outer wall of the other end of the spherical block (37) is elastically connected to the spring sheet (32), and the electric spring (34) is electrically connected to an external power source.

7. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 6, characterized in that: The top of the airbag (44) is connected to the delivery pipe (42), which is connected to an external inflation / inflation device.

8. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion as described in claim 7, characterized in that: The electromagnetic block (55) is electrically connected to an external current output device, the micro ranging chip (53) is electrically connected to an external control terminal, and the outer wall of the sliding rod (56) is slidably connected to the mounting rod (54).

9. The protective device for a flexible battery module thermoforming bracket with adaptive cell expansion according to claim 8, characterized in that: The other end of the spring (65) is fixedly connected to the other end of the first mounting plate (62), the other end of the first rotating rod (66) is slidably connected to the other end of the first mounting plate (62), and the other end of the second rotating rod (67) is fixedly connected to the other end of the first mounting plate (62).

10. A method for protecting a flexible battery module thermoforming bracket that adapts to cell expansion, used to implement the protective device for a flexible battery module thermoforming bracket that adapts to cell expansion as described in claim 9, characterized in that: Includes the following steps: Step 1: Adaptive buffer limit; Through the cooperation of the spring (32), telescopic rod (36) and spherical block (37), the expansion stress of the battery cell is adaptively absorbed to prevent excessive deformation of the spring (32). At the same time, the expansion force is monitored in real time to avoid the blister bracket body (1) being cracked and deformed, thus achieving the dual effect of buffering and protection. Step 2: Dynamic adjustment of cavity diameter; by inflating and deflating the airbag (44), the inner diameter of the mounting hole (41) is dynamically adjusted according to the charging and discharging expansion and contraction state of the battery cell, so as to always fit the battery cell and disperse the expansion force, prevent the blister bracket body (1) from cracking, and improve the protection of the blister bracket body (1). Step 3: High-temperature active lifting support; by monitoring the deformation displacement of the blister bracket body (1) through the micro ranging chip (53), the electromagnetic block (55) drives the sliding rod (56) and the insulating support column (57) to move, and timely support when the blister bracket body (1) softens at high temperature, to prevent sagging, collapse and short circuit, and to achieve active protection under high temperature conditions. Step 4: Multi-directional impact buffering and vibration reduction; through the composite buffering structure of spring (65) and torsion spring (68), vibration and collision impact are absorbed, reducing the direct effect of external force on the thermoforming bracket body (1) and improving the overall structure's protectiveness.

Images