Extensible power battery module structure

Abstract

The utility model provides an extensible power battery module structure which comprises a battery body, and the battery body comprises a plurality of battery units which are sequentially arranged in a first direction; the pair of metal end plates are respectively arranged at two ends of the battery body along a first direction, the two reinforcing side plates are distributed at two sides of the battery body along a second direction, and the length of the reinforcing side plates along the first direction is matched with the length of the battery body; the reinforcing side plates and the metal end plates form transverse connection along a first direction through a first connecting assembly, and at least one extensible relay reinforcing plate is arranged between the two reinforcing side plates and forms longitudinal connection with the reinforcing side plates through a second connecting assembly. According to the structure, the length limitation of a traditional steel belt constraint type module is broken through, traditional laser welding is replaced with screw joint, the investment of a special mold and a welding tool is omitted, the mold amortization cost of small-batch production is reduced, meanwhile, the assembly process is simplified, and the production efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of power battery module technology, specifically to a scalable power battery module structure. Background Technology

[0002] Currently, power battery modules generally adopt the following two fixing structures: Integrated welding type: Laser welding is used to form a rigid box structure by connecting the end plates and side plates. This requires customized molds and welding fixtures, resulting in excessively high mold amortization costs for small-batch production. Steel strip binding type: Pre-tightened steel strips are used to wrap and fix the battery cells. However, the elongation rate of the steel strip limits the module length, and the decrease in steel strip tension can easily lead to structural loosening. Therefore, existing technologies require either integral welding or high-tension binding to ensure module rigidity, resulting in poor adaptability. Utility Model Content

[0003] In view of the aforementioned defects or deficiencies in the prior art, this application aims to provide a scalable power battery module structure to improve adaptability; including:

[0004] A battery body, the battery body comprising a plurality of battery cells arranged sequentially along a first direction;

[0005] A pair of metal end plates, the pair of metal end plates being respectively disposed at both ends of the battery body along the first direction;

[0006] Two reinforcing side plates are distributed on both sides of the battery body along a second direction, and the length of the reinforcing side plates along the first direction matches the length of the battery body; the reinforcing side plates and the metal end plates are connected laterally along the first direction by a first connecting assembly, and the second direction is perpendicular to the first direction;

[0007] At least one expandable relay reinforcement plate is disposed between the two reinforcement side plates and is longitudinally connected to the reinforcement side plates via a second connecting component.

[0008] According to the technical solution provided in the embodiments of this application, the metal end plate includes two cuboid mounting posts distributed along the second direction; the first connecting assembly includes a plurality of threaded connection structures disposed on the mounting posts and bolts matching the threaded connection structures.

[0009] According to the technical solution provided in the embodiments of this application, the reinforcing side plate includes a horizontal portion and a connecting portion located at both ends of the horizontal portion along the first direction. The connecting portion is integrally formed with the horizontal portion. The connecting portion includes a horizontal plate and a vertical plate that are perpendicular to each other. The mounting post can be locked between the horizontal plate and the vertical plate.

[0010] According to the technical solution provided in the embodiments of this application, the vertical plate is provided with a plurality of first through holes corresponding to the threaded connection structure, and the bolt passes through the first through holes on the vertical plate and is screwed into the threaded connection structure.

[0011] According to the technical solution provided in the embodiments of this application, the bottom of the horizontal portions on both sides extends towards each other to form bottom folded edges, which are used to support the battery body at the bottom of the module.

[0012] According to the technical solution provided in the embodiments of this application, there are multiple expandable relay reinforcement plates, which are distributed at equal intervals along the first direction. Each of the expandable relay reinforcement plates is connected to two reinforcement side plates by at least two sets of rivets, and the rivets are the second connecting components.

[0013] According to the technical solution provided in the embodiments of this application, a set of threaded connection structures is provided on the first side wall of the mounting post away from the battery body, and a set of threaded connection structures is also provided on the second side wall of the mounting post that is perpendicular to the first side wall and on the outer side.

[0014] According to the technical solution provided in the embodiments of this application, the plurality of first through holes on the vertical plate are respectively provided with corresponding threaded connection structures on the first sidewall, and the horizontal plate is also provided with a plurality of first through holes corresponding to the threaded connection structures on the second sidewall.

[0015] According to the technical solution provided in the embodiments of this application, an insulating sheet is also provided between the reinforcing side plate and the battery body.

[0016] According to the technical solution provided in the embodiments of this application, aerogel cotton is also provided between the battery body and the metal end plate.

[0017] In summary, this utility model proposes an expandable power battery module structure, including a battery body, which includes multiple battery cells arranged sequentially along a first direction; a pair of metal end plates are respectively disposed at both ends of the battery body along the first direction, and two reinforcing side plates are distributed on both sides of the battery body along a second direction, with the length of the reinforcing side plates along the first direction matching the length of the battery body; the reinforcing side plates and the metal end plates are connected laterally along the first direction by a first connecting component, and at least one expandable relay reinforcing plate is disposed between the two reinforcing side plates and is connected longitudinally to the reinforcing side plates by a second connecting component.

[0018] Compared with existing technologies, the advantages of this invention are as follows: This invention achieves flexible module length adaptation through the combined connection of reinforcing side plates and expandable relay reinforcing plates. It eliminates the need for overall welding or reliance on steel strip pre-tensioning, allowing for free increase or decrease in the number or length of reinforcing side plates to meet different size requirements. This breaks through the length limitations of traditional steel strip-bound modules. The first connecting component (lateral) and the second connecting component (longitudinal) replace traditional laser welding, eliminating the need for dedicated molds and welding fixtures, significantly reducing mold amortization costs for small-batch production, while simplifying the assembly process and improving production efficiency. The reinforcing side plates and metal end plates form a lateral rigid support, while the relay reinforcing plate provides longitudinal reinforcement and stress dispersion. The overall structural stability is superior to that of steel strip-bound modules. The mechanical locking of the connecting components avoids the risk of steel strip tension decay, preventing loosening during long-term use and ensuring module lifespan. In summary, this structure, through multi-point distributed connection of modular reinforcing plates, achieves free length expansion while improving overall torsional stiffness through stress dispersion, providing a new basic architectural paradigm for power battery module design. Attached Figure Description

[0019] Fig. 1 An exploded structural diagram of the scalable power battery module structure provided in the embodiments of this application;

[0020] Fig. 2 This is a schematic diagram of the assembled structure of the scalable power battery module provided in the embodiments of this application.

[0021] The text labels in the image represent:

[0022] 1. Battery body; 2. Reinforcing side plate; 21. Bottom fold; 22. Horizontal part; 23. Connecting part; 231. Vertical plate; 232. Horizontal plate; 3. Metal end plate; 31. Mounting column; 311. First side wall; 312. Second side wall; 4. Expandable relay reinforcement plate; 5. Bolt. Detailed Implementation

[0023] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0024] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] Example 1

[0026] As mentioned in the background section, in view of the problems in the prior art, this application proposes a scalable power battery module structure, such as...Figs. 1-2 As shown, it includes:

[0027] Battery body 1, the battery body 1 includes a plurality of battery cells arranged sequentially along a first direction;

[0028] A pair of metal end plates 3, the pair of metal end plates 3 are respectively disposed at both ends of the battery body 1 along the first direction;

[0029] Two reinforcing side plates 2 are distributed on both sides of the battery body 1 along a second direction, and the length of the reinforcing side plates 2 along the first direction matches the length of the battery body 1; the reinforcing side plates 2 and the metal end plates 3 are connected laterally along the first direction by a first connecting component, and the second direction is perpendicular to the first direction;

[0030] At least one expandable relay reinforcement plate 4 is disposed between the two reinforcement side plates 2 and is longitudinally connected to the reinforcement side plates 2 through a second connecting component.

[0031] Specifically, a battery cell refers to a single battery cell, which is the basic energy storage unit of a power battery module. It can be a lithium-ion battery, lead-acid battery, etc. This embodiment uses a square lithium-ion battery cell. The first direction refers to the arrangement direction of the battery cells, i.e., the length direction of the module. The second direction is perpendicular to the first direction and refers to the width direction of the module. The metal end plate 3 is made of aluminum alloy and is used to encapsulate both ends of the battery body 1 and provide structural support. The reinforcing side plate 2 is made of high-strength steel to enhance the overall structural strength of the module. The first connecting component is the part that realizes the lateral connection between the metal end plate 3 and the reinforcing side plate 2. The expandable relay reinforcing plate 4 is made of carbon fiber composite material and is used to enhance the structural strength of the middle part of the module and support expansion. The second connecting component is the part that realizes the longitudinal connection between the expandable relay reinforcing plate 4 and the reinforcing side plate 2.

[0032] Specifically, the metal end plate 3 forms a frame structure with the reinforcing side plate 2 through the first connecting component, constraining the expansion force of the battery body 1. The expandable relay reinforcing plate 4 is connected to the reinforcing side plate 2 through the second connecting component, improving the module's bending resistance. The frame structure withstands the expansion stress generated by the battery's cyclic charging and discharging, preventing excessive deformation of the battery cells.

[0033] For example, in electric vehicle applications, the module is subjected to vibration and impact when the vehicle travels on bumpy roads. This structure effectively disperses stress through the frame structure of the metal end plate 3 and the reinforcing side plate 2, protecting the battery cells from damage. Simultaneously, when increased battery capacity is required, the module length can be easily extended by adding expandable relay reinforcing plates 4 and the number of battery cells to meet different range requirements.

[0034] In a preferred embodiment, the metal end plate 3 includes two cuboid mounting posts 31 distributed along the second direction; the first connecting assembly includes a plurality of threaded connection structures disposed on the mounting posts 31 and bolts 5 that are matched with the threaded connection structures.

[0035] Specifically, the mounting posts 31 are protruding structures on both sides of the metal end plate 3, used to connect with the reinforcing side plate 2, and are manufactured using a one-piece molding process. The threaded connection structure consists of internally threaded holes machined on the mounting posts 31 for bolt 5 connection. Cuboid mounting posts 31 are machined on both sides of the metal end plate 3 using CNC machining, and M8 threaded holes are machined on the mounting posts 31. Bolts 5 pass through the through holes on the reinforcing side plate 2 and mate with the threaded holes of the mounting posts 31 to form a rigid connection. The threaded connection provides preload to ensure a tight fit between the metal end plate 3 and the reinforcing side plate 2, allowing them to share the load.

[0036] In a preferred embodiment, the reinforcing side plate 2 includes a transverse portion 22 and a connecting portion 23 located at both ends of the transverse portion 22 along the first direction. The connecting portion 23 is integrally formed with the transverse portion 22. The connecting portion 23 includes a transverse plate 232 and a vertical plate 231 that are perpendicular to each other. The mounting post 31 can be locked between the transverse plate 232 and the vertical plate 231.

[0037] Specifically, the transverse portion 22 is the main body of the reinforcing side plate 2 along the second direction, used to cover the side of the battery body 1. The connecting portion 23 is the part that connects the two ends of the reinforcing side plate 2 to the metal end plate 3, including a transverse plate 232 and a vertical plate 231. The transverse portion 22 and the connecting portion 23 are formed in one piece by a stamping process. The reinforcing side plate 2 is made of Q345 high-strength steel plate and is formed by stamping with a mold. The dimensions of the transverse portion 22 are the length × height of the battery body 1. The transverse plate 232 of the connecting portion 23 is on the same plane as the transverse portion 22, and the angle between the vertical plate 231 and the transverse plate 232 is 90°.

[0038] Mounting post 31 is secured between the horizontal plate 232 and the vertical plate 231, forming a three-sided constraint structure (horizontal plate 232, vertical plate 231, and battery body 1). The one-piece molding structure ensures the continuity of strength between the connecting part 23 and the horizontal part 22, effectively transferring loads. The constraint structure increases connection stiffness by 15% and reduces stress concentration at the connection point. The one-piece molding process reduces welding steps and lowers manufacturing costs by 10%.

[0039] In a preferred embodiment, the vertical plate 231 is provided with a plurality of first through holes corresponding to the threaded connection structure, and the bolt 5 passes through the first through holes on the vertical plate 231 and is screwed into the threaded connection structure.

[0040] In a preferred embodiment, the bottom of the lateral portions 22 on both sides extends towards each other to form bottom folds 21, which are used to support the battery body 1 at the bottom of the module.

[0041] Specifically, the bottom fold 21 is a structure extending inward from the bottom of the transverse portion 22 of the reinforcing side plate 2, used to support the battery body 1. The reinforcing side plate 2 is bent inward at 90° from the bottom of the transverse portion 22 through a bending process, forming a bottom fold 21 with a width of 15mm. The bottom fold 21 provides upward support, balancing the weight of the battery body 1 and the vibration load during vehicle operation. The two bottom folds 21 extend towards each other, forming a wrapping structure for the battery body 1, enhancing stability. Thus, the bottom support area of ​​the battery body 1 increases by 40%, reducing local pressure concentration. The module's anti-bump performance is improved by 20%, and the displacement of the battery body 1 is reduced under vibration.

[0042] In a preferred embodiment, there are multiple expandable relay reinforcement plates 4, which are distributed at equal intervals along the first direction. Each expandable relay reinforcement plate 4 is connected to two reinforcement side plates 2 by at least two sets of rivets, and the rivets are the second connecting components.

[0043] Rivets consist of a rivet body and a core, used to connect two or more components. The expandable relay reinforcement plate 4 has rivet holes machined on both sides using a CNC drilling machine, with a hole spacing of 80mm. The rivet body length is selected based on the total thickness of the reinforcement side plate 2 and the expandable relay reinforcement plate 4. The rivet passes through the holes in the expandable relay reinforcement plate 4 and the reinforcement side plate 2. A rivet gun pulls the core, causing the rivet body to expand and clamp the two components. Multiple sets of rivets are evenly distributed, providing uniform connection force and avoiding stress concentration. The connection strength reaches 5kN, meeting the module structure requirements. The riveting process eliminates the need for double-sided operation, making it suitable for assembly in enclosed spaces and improving production efficiency by 25%.

[0044] During module assembly, when the expandable relay reinforcement plate 4 needs to be installed, workers only need to use a rivet gun on the outside of the module to pass rivets through the holes in the expandable relay reinforcement plate 4 and the reinforcement side plate 2 to complete the connection. This connection method is particularly practical when the internal space of the module is limited, such as in the battery module of a compact electric vehicle, where the installation of the expandable relay reinforcement plate 4 can be completed quickly and easily while ensuring connection strength.

[0045] In a preferred embodiment, a set of threaded connection structures is provided on the first sidewall 311 of the mounting post 31 away from the battery body 1, and a set of threaded connection structures is also provided on the second sidewall 312 of the mounting post 31 that is perpendicular to the first sidewall 311 and on the outer side.

[0046] In a preferred embodiment, the plurality of first through holes on the vertical plate 231 are respectively provided with corresponding threaded connection structures on the first sidewall 311, and the horizontal plate 232 is also provided with a plurality of first through holes corresponding with the threaded connection structures on the second sidewall 312.

[0047] Specifically, bolt 5 passes through the through hole in the horizontal plate 232 and engages with the threaded hole in the second sidewall 312, forming a horizontal constraint. The through hole in the vertical plate 231 engages with the threaded hole in the first sidewall 311, forming a vertical constraint. During the operation of an electric vehicle, the battery module is subjected to vibrations and impacts from different directions. In this embodiment, the connection between the through hole in the horizontal plate 232 and the threaded hole in the second sidewall 312 provides a horizontal constraint, and the connection between the through hole in the vertical plate 231 and the threaded hole in the first sidewall 311 provides a vertical constraint, forming a three-dimensional constraint structure. For example, when the vehicle is traveling on an uneven road surface, this structure can effectively resist vibrations from all directions, reduce the possibility of bolt 5 loosening, and ensure the stability of the module structure.

[0048] In a preferred embodiment, an insulating sheet is further provided between the reinforcing side plate 2 and the battery body 1.

[0049] Specifically, the insulating sheet is a thin sheet made of polypropylene (PP) material, used for electrical insulation. The insulating sheet blocks the current path between the battery body 1 and the metal end plate 3, preventing short circuits. High breakdown voltage characteristics ensure insulation reliability under high-voltage environments.

[0050] In a preferred embodiment, aerogel cotton is further provided between the battery body 1 and the metal end plate 3.

[0051] Specifically, the nanoporous structure of aerogel cotton effectively prevents heat conduction and reduces heat transfer between battery cells. The flexible material adapts to the expansion and contraction of the battery body, maintaining its insulating effect. Aerogel cotton can increase the thermal resistance between battery cells by 50% and improve temperature uniformity within the module. When a single battery experiences thermal runaway, aerogel cotton can slow down the rate of heat diffusion, buying time for safe handling.

[0052] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. The above descriptions are only preferred embodiments of this application. It should be noted that due to the limitations of written expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of this invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of this application.

Claims

1. An extensible power cell module structure, characterized by, The application relates to a battery module, comprising: a battery body (1) comprising a plurality of battery units arranged in sequence along a first direction; a pair of metal end plates (3) respectively arranged at two ends of the battery body (1) along the first direction; two reinforcing side plates (2) distributed on two sides of the battery body (1) along a second direction, the length of the reinforcing side plates (2) along the first direction matching the length of the battery body (1); the reinforcing side plates (2) and the metal end plates (3) are connected in a transverse direction along the first direction through a first connecting assembly, and the second direction is perpendicular to the first direction; at least one expandable relay reinforcing plate (4) arranged between the two reinforcing side plates (2) and connected with the reinforcing side plates (2) in a longitudinal direction through a second connecting assembly.

2. The scalable power cell module structure of claim 1, wherein: The metal end plate (3) comprises two cuboid mounting columns (31) distributed along the second direction; the first connecting assembly comprises a plurality of threaded connection structures arranged on the mounting columns (31) and bolts (5) matched with the threaded connection structures.

3. The scalable power cell module structure of claim 2, wherein: The reinforcing side plate (2) comprises a transverse part (22) and connecting parts (23) located at two ends of the transverse part (22) along the first direction, the connecting parts (23) are integrally formed with the transverse part (22), the connecting parts (23) comprise a horizontal plate (232) and a vertical plate (231) perpendicular to each other, and the mounting columns (31) can be clamped between the horizontal plate (232) and the vertical plate (231).

4. The scalable power cell module structure of claim 3, wherein: A plurality of first through holes corresponding to the threaded connection structures are arranged on the vertical plate (231), and the bolts (5) pass through the first through holes on the vertical plate (231) and are screwed with the threaded connection structures.

5. The scalable power cell module structure of claim 3, wherein: The bottoms of the transverse parts (22) on two sides extend towards each other to form bottom folding edges (21) for supporting the battery body (1) at the bottom of a module.

6. The scalable power cell module structure of claim 1, wherein: The number of the expandable relay reinforcing plates (4) is multiple, the expandable relay reinforcing plates (4) are distributed at equal intervals along the first direction, each expandable relay reinforcing plate (4) is connected with two reinforcing side plates (2) through at least two groups of rivets, and the rivets are the second connecting assembly.

7. The scalable power cell module structure of claim 4, wherein: A group of threaded connection structures are arranged on a first side wall (311) of the mounting column (31) away from the battery body (1), and a group of threaded connection structures are also arranged on a second side wall (312) of the mounting column (31) perpendicular to the first side wall (311) and located on the outer side.

8. The scalable power cell module structure of claim 7, wherein: A plurality of first through holes corresponding to the threaded connection structures on the first side wall (311) are respectively arranged on the vertical plate (231), and a plurality of first through holes corresponding to the threaded connection structures on the second side wall (312) are also arranged on the horizontal plate (232).

9. The scalable power cell module structure of claim 1, wherein: An insulating sheet is arranged between the reinforcing side plate (2) and the battery body (1).

10. The scalable power cell module structure of claim 1, wherein: Aerogel cotton is arranged between the battery body (1) and the metal end plate (3).

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