Self-protective high-performance battery insulation packaging structure

Abstract

The utility model provides a kind of self-protection high-performance battery insulation packaging structure, including square shell, top plate, positive terminal, negative terminal, the top of square shell is covered with top plate, the inside of square shell is inserted with electric core, the positive and negative pole lug of electric core is fixedly connected with positive terminal, negative terminal respectively.The utility model has the advantages that insulation sheet is divided into outer frame and several reserved holes in the inside, and siloxane gel is filled in reserved hole aperture;Mechanical-chemical double sealing is formed in the process of cover plate press fitting: honeycomb structure provides mechanical interlocking, and shear strength is improved.Gel fills microscopic gap when being pressed.Self-repairing capability: it can independently repair filling sealing defect, form three-level sealing: first level: honeycomb wall surface mechanical interlocking;Second level: gel fills interface gap;Third level: self-repairing layer compensates microcrack, and this structure has good environmental adaptability simultaneously: maintain stable sealing state in-40 DEG C~85 DEG C.

Description

Technical Field

[0001] This utility model relates to the field of battery packaging technology, and in particular to a self-protecting high-performance battery insulation packaging structure. Background Technology

[0002] With the rapid development of new energy technologies, batteries, as a core component of energy storage, are widely used in electric vehicles, energy storage systems, and consumer electronics. However, batteries often face problems such as insufficient insulation performance, sealing failure, and poor environmental adaptability in actual use, which directly affect their safety and service life.

[0003] Traditional battery packaging typically employs a single-layer insulating sheet and a mechanically press-fit sealing structure. Existing technology uses a hot-pressing process to bond the insulating sheet to the casing. However, this type of structure is prone to interfacial gaps due to material shrinkage differences at extreme temperatures (such as -40°C or 85°C), leading to electrolyte leakage or external moisture intrusion and posing a risk of internal short circuits. Furthermore, existing insulating sheets are mostly made of homogeneous polymer materials with insufficient shear strength, making them susceptible to cracking under battery cyclic expansion stress, thus hindering the maintenance of long-term sealing integrity.

[0004] Regarding the optimization of sealing performance, while existing solutions improve short-term sealing effects, their complex structures increase assembly difficulty and cost, and they cannot achieve dynamic self-healing. During long-term charging and discharging of the battery, tab vibration and casing deformation can easily cause the propagation of microcracks at the sealing interface, and traditional sealing materials lack self-compensation capabilities, ultimately leading to sealing failure.

[0005] Therefore, there is an urgent need to develop a battery packaging structure that integrates high-efficiency insulation, dynamic sealing, self-healing and environmental adaptability to solve the problems of unreliable mechanical seals, high temperature sensitivity and high maintenance costs in existing technologies, and to meet the technical requirements of high-safety and long-life batteries. Utility Model Content

[0006] The purpose of this invention is to at least solve one of the aforementioned technical defects.

[0007] Therefore, one objective of this utility model is to propose a self-protecting high-performance battery insulation packaging structure to solve the problems mentioned in the background art and overcome the shortcomings of the existing technology.

[0008] To achieve the above objectives, one embodiment of the present invention provides a self-protecting high-performance battery insulation encapsulation structure, including a square shell, a top plate, a positive terminal, and a negative terminal, wherein the top of the square shell is covered by the top plate.

[0009] A battery cell is inserted inside the square shell, and the positive and negative terminals of the battery cell are respectively fixedly connected to the positive terminal and the negative terminal;

[0010] The top cover of the battery cell has an insulating sheet, which is divided into two parts: an outer frame and an inner part with several pre-drilled holes.

[0011] The reserved holes are arranged in a honeycomb pattern and are filled with a gel layer;

[0012] A top cover is placed over the insulating sheet, and the edge of the top cover is fixedly connected to the inner edge of the top opening of the square shell.

[0013] Preferably, in any of the above embodiments, the square shell is made of aluminum, and the top plate is bonded to the top of the square shell with adhesive.

[0014] The above technical solution is adopted, and the structure consists of:

[0015] Square Shell: A rectangular shell made of aluminum, with an adhesive-bonded top plate. Top Plate: Sealed to the top of the square shell using a special high-temperature resistant adhesive, and has through holes for the positive and negative terminals.

[0016] Battery cell: It contains a positive and negative electrode structure with stacked electrode plates. The positive electrode uses an aluminum electrode and the negative electrode uses a nickel electrode.

[0017] Insulating sheet: The external support structure is composed of a boron nitride ceramic frame, and the internal structure is set with a regular hexagonal honeycomb pre-reserved hole array, and the holes are filled with a siloxane gel layer.

[0018] Top cover: A sealing cover laser-welded to the inner edge of the top opening of the square shell, with steel ball sealing holes on the surface.

[0019] Preferably, in any of the above schemes, the positive and negative terminals pass through the top plate and are fixedly connected to the top cover.

[0020] Preferably, in any of the above embodiments, the positive and negative tabs of the battery cell are welded to the positive and negative terminals by resistance welding, the frame is made of boron nitride ceramic, and the reserved hole is hexagonal in shape.

[0021] The packaging process for this packaging structure is as follows: Cell pretreatment: The cell, after being coated with adhesive, is vertically inserted into the internal cavity of the square shell, ensuring complete contact between the bottom of the cell and the inner bottom surface of the square shell. The positive aluminum tab and the negative nickel tab of the cell pass upwards through the pre-drilled holes in the top plate.

[0022] Insulation components are installed sequentially on top of the cell: Insulation sheet: the outer edge of the frame maintains a 0.5mm gap with the inner wall of the square shell; Top cover: aligned with the top opening of the square shell by positioning pins, with its bottom surface maintaining a 0.2mm pre-compression gap with the insulation sheet;

[0023] Electrode welding: A dual-station resistance welding machine is used to complete the following: Positive electrode connection: The aluminum electrode of the battery cell is pulse-welded to the positive terminal of the top cover to form a weld point; Negative electrode connection: The nickel electrode of the battery cell is continuously welded to the nickel negative terminal of the top cover to form a strip weld.

[0024] Laser sealing welding: Welding is performed in two stages using a 3000W fiber laser: Stage 1: Intermittent spot welding (1.5mm spacing) is carried out along the edge of the top cover to form initial fixation; Stage 2: Continuous spiral welding is performed for 3 turns, with a weld width of 0.8mm and a penetration depth of 80% of the thickness of the top cover.

[0025] The gel activation process involves injecting electrolyte through the pre-drilled hole in the top cover and then drying it at 80°C for 4 hours in a vacuum oven to remove moisture. A pressure of 0.5 MPa is then applied to cause the gel layer 7 to flow and deform, filling the gaps in the honeycomb structure.

[0026] After the steel ball sealing process is completed: press a 2.5mm diameter stainless steel ball into the pre-drilled hole in the top cover; use micro-beam plasma welding to seal the circumferential seam, with a weld width ≤0.3mm.

[0027] Preferably, in any of the above embodiments, the gel layer is specifically a siloxane gel, and the top cover is laser-welded together with the inner edge of the top opening of the square shell in multiple rings.

[0028] Preferably, in any of the above solutions, a reserved hole is provided on the top cover and the hole is finally sealed with a steel ball.

[0029] The packaging process for a square-shell battery is as follows: The adhesive-coated battery cell is installed into an aluminum shell. After installation, an insulating sheet and a top cover are placed on top of the battery cell. The positive aluminum tab of the battery cell and the top cover of the aluminum shell are resistively welded to form the positive terminal of the battery. The negative nickel tab of the battery cell and the nickel stud on the top cover are resistively welded to form the negative terminal of the battery. The top cover is fixed to the shell using laser welding. Then, the top cover and the shell are continuously sealed by laser welding. After drying and electrolyte filling, the battery is pre-formed and sealed with steel balls.

[0030] The insulating sheet consists of an outer frame and several pre-drilled holes inside, filled with siloxane gel. During the press-fitting of the cover plate, a mechanical-chemical dual seal is formed: the honeycomb structure provides mechanical interlocking and enhances shear strength. Under pressure, the gel fills the microscopic gaps. Self-healing capability: It can autonomously repair and fill sealing defects, forming a three-level seal: Level 1: Mechanical interlocking of the honeycomb walls; Level 2: Gel filling of interface voids; Level 3: Self-healing layer compensating for microcracks.

[0031] This structure also has good environmental adaptability: it maintains a stable sealing state within the range of -40℃ to 85℃.

[0032] Compared with the prior art, the advantages and beneficial effects of this utility model are as follows:

[0033] This self-protective high-performance battery insulation encapsulation structure improves upon traditional insulation sheet structures. The insulation sheet consists of an outer frame and several pre-drilled holes filled with siloxane gel. During the cover plate pressing process, a mechanical-chemical dual seal is formed: the honeycomb structure provides mechanical interlocking and enhances shear strength. Under pressure, the gel fills the microscopic gaps. Self-healing capability: It can autonomously repair and fill sealing defects, forming a three-level seal: Level 1: mechanical interlocking of the honeycomb walls; Level 2: gel filling of interface voids; Level 3: self-healing layer compensating for microcracks.

[0034] This structure also has good environmental adaptability: it maintains a stable sealing state within the range of -40℃ to 85℃.

[0035] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0036] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0037] Figure 1 This is a schematic diagram of the structure of this utility model;

[0038] Figure 2 This is a schematic diagram of the structure of this utility model after it has been packaged.

[0039] Figure 3 This is a partial structural schematic diagram of the insulating sheet of this utility model.

[0040] In the diagram: 1-square shell, 2-top plate, 3-positive terminal, 4-negative terminal, 5-cell, 6-insulating sheet, 601-frame, 602-pre-drilled hole, 7-gel layer, 8-top cover. Detailed Implementation

[0041] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0042] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., 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 connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0043] like Figure 1-3 As shown, the self-protected high-performance battery insulation encapsulation structure includes a square shell 1, a top plate 2, a positive terminal 3, and a negative terminal 4. The top plate 2 covers the top of the square shell 1.

[0044] Inside the square shell 1, a battery cell 5 is inserted, and the positive and negative terminals of the battery cell 5 are respectively fixedly connected to the positive terminal 3 and the negative terminal 4.

[0045] The top cover of the battery cell 5 has an insulating sheet 6, which is divided into two parts: an outer frame 601 and an inner part with several reserved holes 602.

[0046] The reserved holes 602 are arranged in a honeycomb pattern, and the reserved holes 602 are filled with a gel layer 7;

[0047] A top cover 8 is placed on top of the insulating sheet 6, and the edge of the top cover 8 is fixedly connected to the inner edge of the top opening of the square shell 1.

[0048] Example 1: The square shell 1 is made of aluminum, and the top plate 2 is glued to the top of the square shell 1. The positive terminal 3 and the negative terminal 4 pass through the top plate 2 and are fixedly connected to the top cover 8. The positive and negative terminals of the battery cell 5 are welded to the positive terminal 3 and the negative terminal 4 by resistance welding. The frame 601 is made of boron nitride ceramic, and the pre-drilled hole 602 is hexagonal in shape. The gel layer 7 is specifically a siloxane gel, and the top cover 8 is laser-welded to the inner edge of the top opening of the square shell 1 in multiple rings. A pre-drilled hole is opened on the top cover 8 and is finally sealed with a steel ball.

[0049] Example 2: This structure consists of:

[0050] 1. Rectangular shell made of aluminum, with an adhesive-bonded top plate 2. Top plate 2: Sealed to the top of the shell 1 with a special high-temperature resistant adhesive, and has through holes for a positive terminal 3 and a negative terminal 4.

[0051] Cell 5: Includes a positive and negative electrode tab structure with stacked electrode plates. The positive electrode uses an aluminum tab, and the negative electrode uses a nickel tab.

[0052] Insulating sheet 6: The external support structure is composed of boron nitride ceramic frame 601, and the internal structure is provided with a regular hexagonal honeycomb pre-reserved hole array 602, and the holes are filled with siloxane gel layer 7.

[0053] Top cover 8: A sealing cover laser-welded to the inner edge of the top opening of the square shell 1, with steel ball sealing holes on the surface.

[0054] Example 3: One packaging process for this structure:

[0055] The working principle of this utility model is as follows:

[0056] For cell pretreatment, the glued cell 5 is vertically inserted into the internal cavity of the square shell 1, ensuring that the bottom of the cell 5 is in complete contact with the inner bottom surface of the square shell 1. The positive aluminum electrode tab and the negative nickel electrode tab of the cell 5 pass upward through the pre-drilled holes in the top plate 2.

[0057] The insulation components are installed sequentially on the top of the cell 5: Insulating sheet 6: the outer edge of the frame 601 maintains a 0.5mm gap with the inner wall of the square shell 1; Top cover 8: it is aligned with the top opening of the square shell 1 by a positioning pin, and its bottom surface maintains a 0.2mm pre-compression gap with the insulating sheet 6.

[0058] Electrode welding: A dual-station resistance welding machine is used to complete the following: Positive electrode connection: The aluminum electrode of cell 5 is pulse-welded to the positive terminal 3 of top cover 8 to form a weld point; Negative electrode connection: The nickel electrode of cell 5 is continuously welded to the nickel negative terminal 4 of top cover 8 to form a strip weld.

[0059] Laser sealing welding: Welding is carried out in two stages using a 3000W fiber laser: Stage 1: Intermittent spot welding (1.5mm spacing) is performed along the edge of the top cover 8 to form initial fixation; Stage 2: Continuous spiral welding is performed for 3 turns, with a weld width of 0.8mm and a penetration depth of 80% of the thickness of the top cover 8.

[0060] The gel activation process involves injecting electrolyte through the pre-drilled hole in the top cover 8, followed by drying at 80°C for 4 hours in a vacuum oven to remove moisture. A pressure of 0.5 MPa is then applied to cause the gel layer 7 to flow and deform, filling the gaps in the honeycomb structure.

[0061] After the steel ball sealing process is completed: press a 2.5mm diameter stainless steel ball into the pre-drilled hole 8 on the top cover; use micro-beam plasma welding to seal the circumferential seam, with a weld width ≤0.3mm.

[0062] Compared with the prior art, the present invention has the following advantages:

[0063] This self-protective high-performance battery insulation encapsulation structure improves upon the traditional insulation sheet 6 structure. The insulation sheet 6 consists of an outer frame 601 and several internal pre-drilled holes 601, with the holes 601 filled with siloxane gel. During the cover plate pressing process, a mechanical-chemical dual seal is formed: the honeycomb structure provides mechanical interlocking and improves shear strength. Under pressure, the gel fills the microscopic gaps. Self-healing capability: It can autonomously repair and fill sealing defects, forming a three-level seal: Level 1: mechanical interlocking of the honeycomb wall; Level 2: gel filling of interface voids; Level 3: self-healing layer compensating for microcracks.

[0064] This structure also has good environmental adaptability: it maintains a stable sealing state within the range of -40℃ to 85℃.

Claims

1. A self-protective high-performance battery insulation encapsulation structure, characterized in that, It includes a square shell (1), a top plate (2), a positive terminal (3), and a negative terminal (4), with the top plate (2) covering the top of the square shell (1). The inside of the square shell (1) is a battery cell (5), and the positive and negative terminals of the battery cell (5) are respectively fixedly connected to the positive terminal (3) and the negative terminal (4). The top of the battery cell (5) is covered with an insulating sheet (6), which is divided into two parts: an outer frame (601) and an inner part with several reserved holes (602). The reserved holes (602) are arranged in a honeycomb pattern, and the reserved holes (602) are filled with a gel layer (7). The insulating sheet (6) is covered by a top cover (8), and the edge of the top cover (8) is fixedly connected to the inner edge of the top opening of the square shell (1).

2. The self-protective high-performance battery insulation encapsulation structure as described in claim 1, characterized in that: The square shell (1) is made of aluminum, and the top plate (2) is bonded to the top of the square shell (1) with adhesive.

3. The self-protective high-performance battery insulation encapsulation structure as described in claim 2, characterized in that: The positive terminal (3) and negative terminal (4) pass through the top plate (2) and are fixedly connected to the top cover (8).

4. The self-protective high-performance battery insulation encapsulation structure as described in claim 3, characterized in that: The positive and negative tabs of the battery cell (5) are welded to the positive terminal (3) and the negative terminal (4) by resistance welding. The frame (601) is made of boron nitride ceramic, and the reserved hole (602) is hexagonal in shape.

5. The self-protective high-performance battery insulation encapsulation structure as described in claim 4, characterized in that: The gel layer (7) is specifically a siloxane gel, and the top cover (8) is laser-welded together with the inner edge of the top opening of the square shell (1) in multiple rings.

6. The self-protective high-performance battery insulation encapsulation structure as described in claim 5, characterized in that: The top cover (8) has a reserved hole, which is then sealed with a steel ball.

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