Aluminum-plastic composite battery module end plate assembly capable of being freely combined

Abstract

The utility model discloses an aluminum-plastic composite battery module end plate assembly capable of being freely combined. The aluminum-plastic composite battery module end plate assembly comprises two aluminum alloy profile buckling edges, two aluminum alloy profile plates and a plastic profile middle buckling strip, the inner side edges of the aluminum alloy profile plates are clamped in the grooves in the two sides of the buckling strip in the middle of the plastic profile respectively, and the outer side edges of the two aluminum alloy profile plates are clamped with the aluminum alloy profile buckling edges respectively. The cross section of the aluminum alloy profile buckling edge is U-shaped, the cross section of the plastic profile middle buckling strip is I-shaped, and the two sides of the aluminum alloy profile plate are step-shaped. According to the aluminum-plastic composite battery module end plate assembly capable of being freely combined and the manufacturing method, on the premise that the structural strength of the end plate is not reduced, the use amount of aluminum alloy materials is greatly reduced, the product cost is greatly reduced, and the energy absorption characteristic of plastic materials can be utilized to improve the energy absorption performance of the battery module. The battery swelling stress in the use process of the battery module is effectively absorbed, so that the reliability of the battery module is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy battery system integration and grouping, in particular to a freely combinable aluminum-plastic composite battery module end plate assembly. Background Art

[0002] A battery module typically includes components such as end plates, steel strapping, insulation material, busbars, and battery cells. These end plates primarily come in various forms, including aluminum extrusion, aluminum die-cast, and injection-molded. Die-cast and injection-molded end plates are finished products, while aluminum extrusion end plates are extruded and then processed using a CNC milling machine. Patent CN220106740U discloses a battery module and a battery pack, the battery pack includes a battery module, the battery module includes a module frame, a plurality of battery cell groups, a battery connection assembly and an upper cover, the battery cell group includes a plurality of battery cells spaced apart along a second direction; the module frame includes two first end plates opposite and spaced apart along the second direction, two side plates opposite and spaced apart along a third direction and at least one second end plate, the two first end plates and the two second end plates enclose a accommodating cavity, the plurality of battery cell groups are arranged in the accommodating cavity, the second end plate is arranged between the two first end plates and spaced apart from the first end plates, the two ends of the second end plate along the third direction are respectively connected to the two side plates, and a plurality of spaced fixing portions are provided on the outward side of the side plate; the above-mentioned first end plate, second end plate and side plate are all formed by aluminum extrusion molding, the aluminum material is relatively light, and the first end plate and the second end plate are both provided with a plurality of reinforcing ribs, which can improve the structural strength of the entire module frame. The above structure can improve the structural strength of the battery module, improve the impact resistance and vibration resistance of the battery module, and thus improve the safety of the battery module.

[0003] Currently, most new energy battery modules use aluminum end plates made from aluminum alloy profiles. These aluminum end plates often have a honeycomb structure, with the profile's major surfaces being flat, and shallow grooves machined on the sides away from the battery cells. This allows expansion forces during battery use to be directed solely to the flat surface closest to the battery cells. Patent CN221009093U discloses an end plate, housing, battery, and electrical device. The end plate comprises: a first plate including a first connecting portion disposed in a closed loop along the circumferential edge of the first plate and configured to form a continuous, sealed connection with an environmental component; and a second plate stacked along a first direction with the first plate; the second plate includes a plurality of plates spaced apart along the circumferential edge of the second plate. The first connecting portion of the first plate forms a continuous, sealed connection with the environmental component, ensuring a seal between the end plate and the environmental component. The second connecting portion of the second plate is connected to the environmental component via connectors, respectively, to enhance the connection strength between the end plate and the environmental component. The first plate comprises an aluminum plate, and the second plate comprises a steel or aluminum plate. A honeycomb-shaped intermediate member is disposed between the first and second plates to provide a cushioning effect for the end plate. The end plate has fewer parts, a simple structure, is easy to connect with environmental components, has low cost and high reliability.

[0004] The processing cost of new energy battery PACK is high, and the proportion of aluminum end plates in the PACK processing cost is relatively large. Therefore, it is necessary to consider significantly reducing the structural design cost of the end plate without reducing the structural strength of the end plate. Utility Model Content

[0005] In view of this, the purpose of the present invention is to address the shortcomings of the existing technology and provide a freely combinable aluminum-plastic composite battery module end plate assembly, which greatly reduces the design and processing costs of the end plate without reducing the structural strength of the end plate, thereby optimizing the cost proportion of the aluminum end plate in the battery PACK auxiliary components and offsetting part of the battery expansion stress.

[0006] To achieve the above-mentioned purpose, the utility model adopts the following technical solution: a freely combinable aluminum-plastic composite battery module end plate assembly, comprising two aluminum alloy profile buckles, two aluminum alloy profile plates and a plastic profile middle buckle strip; the grooves on both sides of the plastic profile middle buckle strip each clamp an inner side edge of an aluminum alloy profile plate, and the outer sides of the two aluminum alloy profile plates each clamp an aluminum alloy profile buckle edge; the cross-section of the aluminum alloy profile buckle edge is U-shaped, the cross-section of the plastic profile middle buckle strip is I-shaped, and the two sides of the aluminum alloy profile plate are stepped.

[0007] Furthermore, the inner side step surface of the aluminum alloy profile plate is interference fit with the grooves on both sides of the middle buckle strip of the plastic profile, and the inner side step surface of the aluminum alloy profile plate and the inner walls of the grooves on both sides of the middle buckle strip of the plastic profile are coated with structural adhesive.

[0008] Furthermore, rivet holes penetrating the plastic profile middle buckle strip are provided on both side surfaces of the plastic profile middle buckle strip, and rivet holes penetrating the aluminum alloy profile plate are correspondingly provided on the inner side step surface of the aluminum alloy profile plate.

[0009] Furthermore, a long screw fixing hole is provided on the side of the aluminum alloy profile buckle that is not in contact with the battery, and a long screw fixing hole is provided correspondingly on the step surface of the outer side of the aluminum alloy profile plate. The side of the aluminum alloy profile buckle and the outer side of the aluminum alloy profile plate are fixed by long screws.

[0010] Furthermore, the bottom of the grooves on both sides of the middle buckle strip of the plastic profile and the bottom of the grooves on the buckle edge of the aluminum alloy profile are provided with bosses, and narrow grooves are correspondingly provided on both side edges of the aluminum alloy profile plate. The bosses of the middle buckle strip of the plastic profile and the bosses of the buckle edge of the aluminum alloy profile are both clamped in the narrow grooves of the aluminum alloy profile plate.

[0011] The beneficial effects of the utility model are:

[0012] The freely combinable aluminum-plastic composite battery module end plate assembly of the utility model is formed by freely splicing aluminum alloy profile buckle edges, aluminum alloy profile plates and plastic profile middle buckle strips. Without reducing the structural strength of the end plate, the design and processing costs of the end plate are greatly reduced, thereby optimizing the cost proportion of the aluminum end plate in the battery PACK auxiliary components, and can also offset part of the battery expansion stress.

[0013] The utility model integrates the aluminum alloy profile and the plastic profile into one by freely combining the aluminum alloy profile buckle edge, the aluminum alloy profile plate and the plastic profile middle buckle strip. The aluminum alloy profile only exists as a frame, which reduces the proportion of the aluminum profile material in the composite end plate and greatly reduces the design and processing costs of the end plate.

[0014] The utility model designs the aluminum alloy profile and the plastic profile into an interface shape that cooperates with each other. After the profile is cut and polished, the end plate components of two different materials are processed together through interference fit + bonding between the mortise and tenon connection surfaces. Since the plastic profile has high structural strength and load-bearing capacity, the plastic profile can not only ensure the structural strength of the frame, but also offset part of the battery expansion stress.

[0015] The utility model discloses an end plate assembly of an aluminum-plastic composite battery module that can be freely combined. The steel strip, the aluminum alloy profile plate and the plastic profile intermediate buckle strip are riveted together into one body. The steel strip is limited in position and is reinforced in the Z direction by riveting with steel rivets. This prevents the battery module from being damaged by strong Z-direction vibration during use, which causes mutual misalignment between the steel strip and the aluminum alloy profile plate and the plastic profile intermediate buckle strip, thereby preventing the battery module from being damaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Attachment Figure 1This is a cross-sectional view of the structure of the end plate assembly of the freely combinable aluminum-plastic composite battery module of the present invention;

[0017] Attachment Figure 2 This is a cross-sectional view of the buckle edge structure of the aluminum alloy profile component of the utility model;

[0018] Attachment Figure 3 This is a cross-sectional view of the aluminum alloy profile plate structure of the components of the utility model;

[0019] Attachment Figure 4 This is a cross-sectional view of the structure of the middle buckle strip of the plastic profile component of the utility model;

[0020] Attachment Figure 5 This is a three-dimensional diagram of the end plate assembly of the freely combinable aluminum-plastic composite battery module of the utility model;

[0021] Attachment Figure 6 This is a cross-sectional view of the end plate assembly structure of the freely combinable composite battery module of the present invention;

[0022] Attachment Figure 7 This is a three-dimensional diagram of the end plate assembly of the freely combinable composite battery module of the utility model.

[0023] Explanation of the accompanying drawings: 1-aluminum alloy profile buckle edge, 2-aluminum alloy profile plate, 3-plastic profile middle buckle strip. DETAILED DESCRIPTION

[0024] The following are specific embodiments of the present invention, which further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0025] Example 1

[0026] A freely combinable aluminum-plastic composite battery module end plate assembly, such as Figure 1 As shown, it includes two aluminum alloy profile buckles 1, two aluminum alloy profile plates 2 and a plastic profile middle buckle strip 3. The grooves on both sides of the plastic profile middle buckle strip 3 are each clamped with the inner side of an aluminum alloy profile plate 2, and the outer sides of the two aluminum alloy profile plates 2 are each clamped with an aluminum alloy profile buckle 1. The cross section of the aluminum alloy profile buckle 1 is U-shaped, as shown in FIG. Figure 2 As shown, the two sides of the aluminum alloy profile plate 2 are stepped, as shown in FIG. Figure 3 As shown, the cross section of the middle buckle strip 3 of the plastic profile is an I-shaped one. Figure 4 As shown, it is suitable for integrating double-row battery modules into groups, such as Figure 5 shown.

[0027] The plastic profile middle buckle strip 3 has high structural strength and load-bearing capacity. It can not only ensure the structural strength of the frame, but also offset part of the battery expansion stress due to the plastic material's plastic deformation function. The price of plastic profiles is generally lower than that of aluminum alloy profiles, which can greatly reduce the cost of end plate materials.

[0028] Example 2

[0029] This embodiment differs from Example 1 in that the inner stepped surface of the aluminum alloy profile plate 2 forms an interference fit with the grooves on either side of the plastic profile intermediate buckle 3. Structural adhesive is applied to both the inner stepped surface of the aluminum alloy profile plate 2 and the inner walls of the grooves on either side of the plastic profile intermediate buckle 3. This double fixation of the plastic profile intermediate buckle 3 and the aluminum alloy profile plate 2, achieved through both an interference fit and adhesive bonding, improves assembly stability between the aluminum alloy profile plate 2 and the plastic profile intermediate buckle 3.

[0030] Example 3

[0031] The difference between this embodiment and embodiment 1 is that: Figure 5 As shown, rivet holes are provided on both sides of the plastic profile intermediate buckle 3, penetrating the plastic profile intermediate buckle 3. Corresponding rivet holes are provided on the inner step surface of the aluminum alloy profile plate 2, penetrating the aluminum alloy profile plate 2. The battery module steel strip has corresponding rivet holes. After the battery module steel strip is installed, stainless steel rivets are used to penetrate the plastic profile intermediate buckle 3, the aluminum alloy profile plate 2, and the steel strip, riveting the steel strip, the aluminum alloy profile plate 2, and the plastic profile intermediate buckle 3 into one. The steel strip is limited in position to prevent the steel strip, the aluminum alloy profile plate 2, and the plastic profile intermediate buckle 3 from being misaligned due to strong Z-axis vibration during use, which could damage the battery module. At the same time, the stainless steel rivets can improve the assembly stability of the aluminum alloy profile plate 2 and the plastic profile intermediate buckle 3.

[0032] Example 4

[0033] The difference between this embodiment and embodiment 1 is that: Figure 5 As shown, a long screw fixing hole is provided on the side of the aluminum alloy profile buckle 1 that is not in contact with the battery, and a long screw fixing hole is provided corresponding to the step surface of the outer side of the aluminum alloy profile plate 2. The side of the aluminum alloy profile buckle 1 and the outer side of the aluminum alloy profile plate 2 are fixed by long screws, thereby improving the assembly stability of the aluminum alloy profile plate 2 and the aluminum alloy profile buckle 1.

[0034] Example 5

[0035] The difference between this embodiment and embodiment 1 is that: Figure 2-4As shown, the bottom of the grooves on both sides of the plastic profile middle buckle strip 3 and the bottom of the groove of the aluminum alloy profile buckle edge 1 are provided with bosses, and narrow grooves are correspondingly provided on both side edges of the aluminum alloy profile plate 2. The bosses of the plastic profile middle buckle strip 3 and the bosses of the aluminum alloy profile buckle edge 1 are both clamped into the narrow grooves of the aluminum alloy profile plate 2, thereby improving the clamping position accuracy of the plastic profile middle buckle strip 3, the aluminum alloy profile buckle edge 1 and the aluminum alloy profile plate 2, so that the plastic profile middle buckle strip 3, the aluminum alloy profile buckle edge 1 and the two aluminum alloy profile plates 2 form a flat surface after being clamped.

[0036] Example 6

[0037] This embodiment differs from Example 1 in that the plastic profile intermediate buckle strip 3 is made of PVC extruded profile, which combines excellent structural performance with plastic deformation capabilities at a low material cost. The use of aluminum alloy profile plates 2 as the left and right skeletons and PVC extruded profile as the inner core leverages the excellent plastic deformation capabilities of PVC plastic material to effectively absorb the stress generated during battery expansion, allowing sufficient deformation space for expansion and deformation during later battery use. This effectively improves battery safety during use, thereby enhancing the reliability of the battery module.

[0038] The price of PVC is approximately 40% of that of aluminum alloy, and its density is approximately 60% of that of aluminum alloy. Taking all these factors into consideration, material processing costs can be reduced by at least 50%. The low cost, high flame retardancy, and excellent elasticity of PVC extruded material significantly reduce machining requirements compared to existing aluminum alloy end plates, thereby lowering material processing costs.

[0039] Example 7

[0040] A method for manufacturing a freely combinable aluminum-plastic composite battery module end plate assembly comprises the following steps:

[0041] S1, aluminum alloy profile buckle 1, and aluminum alloy profile plate 2 are first manufactured using an aluminum profile extrusion process, and then cut into required lengths using a CNC sawing machine;

[0042] S2. Use a CNC milling machine to machine two shallow grooves on the side of the aluminum alloy profile plate 2 that is not in contact with the battery, and machine rivet holes that pass through the aluminum alloy profile plate 2;

[0043] S3, the plastic profile middle buckle strip 3 is extruded into a profile using an extruder, cut into appropriate sizes, and rivet holes are processed through the plastic profile middle buckle strip 3;

[0044] S4. Apply structural adhesive to the joints of the aluminum alloy profile buckle edge 1, the aluminum alloy profile plate 2 and the plastic profile middle buckle strip 3, and assemble the aluminum alloy profile buckle edge 1, the aluminum alloy profile plate 2 and the plastic profile middle buckle strip 3 into a complete aluminum-plastic composite end plate.

[0045] Example 8

[0046] A method for using a freely combinable aluminum-plastic composite battery module end plate assembly comprises the following steps:

[0047] S1. Open rivet holes corresponding to the battery module steel strip;

[0048] S2. Use stainless steel rivets to penetrate the plastic profile middle buckle strip 3, the aluminum alloy profile plate 2, and the steel strip, and rivet the steel strip, the aluminum alloy profile plate 2, and the plastic profile middle buckle strip 3 into one piece.

[0049] By riveting the steel strip, aluminum alloy profile plate 2, and plastic profile middle buckle 3 into one, the steel strip is limited to avoid strong Z-axis vibration damage during the use of the battery module, which causes mutual misalignment between the steel strip and the aluminum alloy profile plate 2 and the plastic profile middle buckle 3 and damages to the battery module; at the same time, the stainless steel rivets can improve the assembly stability of the aluminum alloy profile plate 2 and the plastic profile middle buckle 3.

[0050] Example 9

[0051] A freely combinable composite battery module end plate assembly, such as Figure 6 As shown, it includes two aluminum alloy profile buckles 1 and an aluminum alloy profile plate 2. The two sides of the aluminum alloy profile plate 2 are each clamped with an aluminum alloy profile buckle 1. The cross section of the aluminum alloy profile buckle 1 is U-shaped, and the two sides of the aluminum alloy profile plate 2 are stepped, which is suitable for integrating single-row battery modules into groups, such as Figure 7 shown.

[0052] Example 10

[0053] The difference between this embodiment and embodiment 9 is that: Figure 7 As shown, a long screw fixing hole is provided on the side of the aluminum alloy profile buckle 1 that is not in contact with the battery, and a long screw fixing hole is provided corresponding to the step surface of the outer side of the aluminum alloy profile plate 2. The side of the aluminum alloy profile buckle 1 and the outer side of the aluminum alloy profile plate 2 are fixed by long screws to ensure the assembly stability of the aluminum alloy profile plate 2 and the aluminum alloy profile buckle 1.

[0054] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the utility model and are not limiting. Other modifications or equivalent substitutions made to the technical solution of the utility model by ordinary technicians in this field should be included in the scope of the claims of the utility model as long as they do not depart from the spirit and scope of the technical solution of the utility model.

Claims

1. A freely combinable aluminum-plastic composite battery module end plate assembly, characterized by: The invention comprises two aluminum alloy profile buckle edges (1), two aluminum alloy profile plates (2) and a plastic profile middle buckle strip (3); the grooves on both sides of the plastic profile middle buckle strip (3) are each clamped with an inner side edge of an aluminum alloy profile plate (2), and the outer sides of the two aluminum alloy profile plates (2) are each clamped with an aluminum alloy profile buckle edge (1); the cross section of the aluminum alloy profile buckle edge (1) is U-shaped, the cross section of the plastic profile middle buckle strip (3) is I-shaped, and the two sides of the aluminum alloy profile plate (2) are stepped.

2. The freely combinable aluminum-plastic composite battery module end plate assembly according to claim 1, characterized in that: The inner side step surface of the aluminum alloy profile plate (2) is interference-fitted with the grooves on both sides of the plastic profile middle buckle strip (3), and the inner side step surface of the aluminum alloy profile plate (2) and the inner walls of the grooves on both sides of the plastic profile middle buckle strip (3) are both coated with structural adhesive.

3. The freely combinable aluminum-plastic composite battery module end plate assembly according to claim 1 or 2, characterized in that: Rivet holes penetrating the plastic profile middle buckle strip (3) are provided on both sides of the plastic profile middle buckle strip (3), and rivet holes penetrating the aluminum alloy profile plate (2) are correspondingly provided on the inner side step surface of the aluminum alloy profile plate (2).

4. The freely combinable aluminum-plastic composite battery module end plate assembly according to claim 1 or 2, characterized in that: A long screw fixing hole is provided on the side of the aluminum alloy profile buckle edge (1) that is not in contact with the battery, and a long screw fixing hole is provided on the step surface of the outer side of the aluminum alloy profile plate (2). The side of the aluminum alloy profile buckle edge (1) and the outer side of the aluminum alloy profile plate (2) are fixed by long screws.

5. The freely combinable aluminum-plastic composite battery module end plate assembly according to claim 1 or 2, characterized in that: The bottoms of the grooves on both sides of the middle buckle strip (3) of the plastic profile and the bottoms of the grooves of the buckle edge (1) of the aluminum alloy profile are both provided with bosses, and narrow grooves are correspondingly provided on both sides of the aluminum alloy profile plate (2), and the bosses of the middle buckle strip (3) of the plastic profile and the bosses of the buckle edge (1) of the aluminum alloy profile are both clamped into the narrow grooves of the aluminum alloy profile plate (2).

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