A battery module structure
By designing local reinforcing plates and constraint structures, the problems of increased weight and insufficient rigidity of power battery modules were solved, achieving lightweight, high rigidity, and simplified manufacturing processes. This improved the stability and production efficiency of battery modules and reduced production costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- BATTEROTECH CO LTD
- Filing Date
- 2025-04-24
- Publication Date
- 2026-06-26
AI Technical Summary
Existing power battery module structures suffer from increased weight and insufficient rigidity, making it difficult to balance lightweight and high rigidity, and resulting in high production costs.
The design employs local reinforcing plates and constraint structures. The height of the local reinforcing plates is less than 1/3 of the total height of the cell stack and is rigidly connected to the end plates. The constraint structures apply radial constraint forces around the cell stack and are combined with welding, riveting, or bolting to form a frame structure.
This achieves lightweight, high rigidity, and simplified manufacturing processes for battery modules, improving their stability and production efficiency, reducing production costs, and extending their lifespan.
Smart Images
Figure CN224417897U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of power battery technology, and in particular to a battery module structure. Background Technology
[0002] In the structural design of existing power battery modules, the assembly method generally adopts a frame structure, that is, a rigid frame is formed by end plates and side plates, which are fixed by welding or riveting, and the cells are bonded together with structural adhesive to enhance the overall integrity. However, the current frame module design has a large side plate coverage area and high material density, which leads to a significant increase in module weight, which contradicts the lightweight requirements of new energy vehicles, and also has a high cost.
[0003] In existing technologies, modules are bound and fixed using double-rolled strips (such as steel strips or steel + plastic composite strips). However, this solution suffers from insufficient overall rigidity, especially under dynamic operating conditions (such as vibration and impact), which can easily lead to structural failure due to stress concentration, resulting in cell displacement and affecting the safety and lifespan of the battery pack.
[0004] Therefore, there is an urgent need for a battery module assembly solution that takes into account lightweight, high rigidity and simple process, in order to overcome the shortcomings of existing technologies. Utility Model Content
[0005] This application provides a battery module structure to solve the problem that current battery module structures cannot simultaneously achieve lightweight, high rigidity, and simple manufacturing processes, thus realizing the lightweight, high rigidity, and simple manufacturing processes of the battery module.
[0006] In a first aspect, this application provides a battery module structure, including a cell stack, an end plate, and a lateral fixing structure. The lateral fixing structure includes: a local reinforcing plate located at one end of the cell stack, the height of which is less than 1 / 3 of the total height of the cell stack, disposed on both sides of the cell stack and rigidly connected to the end plate; and a constraint structure located at the other end of the cell stack, which can be used to bind the cell stack around it and apply radial constraint force along the circumference of the cell stack.
[0007] Through the above scheme, the height of the local reinforcing plate is less than 1 / 3 of the total height of the cell stack, which significantly reduces the amount of material used for the reinforcing plate. For example, if the total height of the cell stack is 30 cm, the height of the local reinforcing plate may only be about 10 cm, which reduces the material usage by about 2 / 3 compared to the traditional full-height reinforcing plate, thus significantly reducing the weight of the module. The local reinforcing plate is located at one end of the cell stack and is rigidly connected to the end plate. This structure can effectively enhance the rigidity of the battery module end. When subjected to external impact or pressure, the local reinforcing plate and the end plate can jointly bear the load, preventing deformation of the cell stack end, thereby ensuring the overall structural stability of the battery module. The constraint structure adopts a wrap-around binding method, which uses relatively little material and can flexibly adjust the tightness of the binding according to actual needs, further optimizing material use and avoiding unnecessary weight increase. The constraint structure applies radial constraint force along the circumference of the cell stack, which can effectively limit the circumferential deformation of the cell stack. This constraint acts like a "tightening band," uniformly restraining the cell stack in all directions and enhancing the overall rigidity of the battery module. Even under complex operating conditions, such as bumps and vibrations during vehicle operation, the battery module maintains a stable structural state, reducing relative displacement between cells and lowering the risk of cell damage. Due to the low height of the local reinforcing plate, its installation process is relatively simple. It only needs to be placed at one end of the cell stack and rigidly connected to the end plate, without requiring complex positioning and fixing processes. This simple installation method greatly improves production efficiency and reduces production costs. The constraint structure uses a wrap-around binding method, making the operation intuitive and easy to control. Simple binding tools or equipment can be used to bind the cell stack and apply appropriate radial constraint force. This binding operation does not require complex molds or equipment and has lower requirements for the production environment, further improving the simplicity of the process. At the same time, the bound constraint structure can be adjusted as needed, facilitating quality control and optimization during production. Furthermore, by employing different structures or strengths of constraint at both ends of the cell stack, stress distribution can be better dispersed. For example, the constraint structure absorbs the expansion force of the cell, reducing direct impact on the side plates; the locally reinforced plate provides rigid support points to prevent the entire module from shaking. This method of using different structures or strengths of constraint at both ends achieves significant benefits in balancing lightweight design, high rigidity, and ease of manufacturing.
[0008] In one possible design, the local reinforcement plate is a stamped sheet metal part or an aluminum alloy profile, and the thickness of the local reinforcement plate is 0.5 to 2 mm.
[0009] Through the above-described approach, stamped sheet metal parts typically utilize high-strength steel, maintaining high strength and rigidity after stamping. The stamping process can achieve complex shapes and dimensional precision requirements, allowing for the precise manufacture of localized reinforcing plates based on the specific structural needs of the battery module. This formability enables the localized reinforcing plates to better conform to the shape of the cell stack, improving the overall structural integrity and stability. Within a thickness range of 0.5–2 mm, stamped sheet metal parts can achieve lightweight design while ensuring structural strength.
[0010] Aluminum alloys are characterized by high strength and low density, enabling them to provide sufficient strength and rigidity even in relatively thin thicknesses (0.5–2 mm). The density of aluminum alloys is approximately one-third that of steel; therefore, aluminum alloy profiles are lighter for the same strength requirements, further optimizing the lightweight design of battery modules.
[0011] In one possible design, the local reinforcing plates and end plates are connected by welding, riveting or bolting to form a local rigid frame structure.
[0012] The above methods utilize welding, riveting, and bolting to achieve high-strength connections. Welding integrates the local reinforcing plate and end plate into a single unit, with the strength of the connection approaching or reaching that of the base material, significantly improving the load-bearing capacity of the local rigid frame structure. Riveting tightly connects the two components using rivets, which provide excellent fixation and effectively transfer loads. Bolting firmly connects the local reinforcing plate and end plate using the tightening force of bolts, resulting in a high-strength and reliable connection. This high-strength connection allows the local reinforcing plate to better withstand various external forces, giving one end of the cell stack greater resistance to deformation. Under external pressure or impact, the local reinforcing plate and end plate work together to evenly distribute the load throughout the frame structure, preventing deformation caused by localized stress concentration. This enhanced resistance to deformation helps protect the cells from mechanical damage and extends the battery module's lifespan.
[0013] In one possible design, a first bending plate is provided at the bottom of the local reinforcing plate, and the first bending plate extends toward the heat dissipation base plate.
[0014] Through the above scheme, the first bending plate extends towards the bottom of the cell stack, forming a more robust connection and further enhancing the overall stability of the frame-type support structure. The design of the first bending plate creates an additional support point at the bottom of the local reinforcing plate, effectively resisting deformation caused by external loads. This design is similar to adding a "stiffener" to the structure, improving the bending and torsional resistance of the local reinforcing plate. For example, when subjected to vertical loads, the first bending plate can transfer part of the load to the bottom, reducing the bending deformation of the local reinforcing plate.
[0015] In one possible design, a heat dissipation base plate is also included. The heat dissipation base plate is located at the bottom of the cell stack and is rigidly connected to the local reinforcing plate and the end plate to form a frame-type support structure. The first bending plate is fixedly connected to the heat dissipation base plate.
[0016] With the above design, the heat dissipation base plate is located at the bottom of the cell stack, effectively supporting the weight of the cell stack and transferring the load to the bottom structure. Local reinforcing plates and end plates provide support on both sides and ends of the cell stack, forming a multi-directional load distribution system. The heat dissipation base plate is in direct contact with the cell stack, effectively conducting the heat generated by the cells during operation. Through the heat dissipation base plate, heat can be quickly transferred to the underlying heat dissipation system (such as coolant channels, heat sinks, etc.), thereby improving heat dissipation efficiency. Since the heat dissipation base plate, local reinforcing plates, and end plates form an integrated frame support structure, these components can be installed as a whole during assembly. This simplified assembly process reduces assembly time and errors, improving production efficiency. The integrated design and simplified assembly process improve the consistency of the production process. In mass production, this consistency ensures that the quality and performance of each battery module remain stable, reducing quality problems caused by assembly errors. The first bending plate extends towards the bottom of the cell stack and is fixedly connected to the heat dissipation base plate; this design increases the contact area and connection strength between the local reinforcing plate and the heat dissipation base plate. The connection between the first bent plate and the heat dissipation base plate can form a frame structure by means of welding, riveting or bolting, which improves the overall stability of the battery module.
[0017] In one possible design, a second bent plate is provided at the end of the local reinforcing plate, the second bent plate extends toward the end plate, and the second bent plate is fixedly connected to the end plate.
[0018] Through the above scheme, the second bent plate extends towards the end plate and is fixedly connected to it. This design increases the contact area and connection strength between the local reinforcing plate and the end plate. Through welding, riveting, or bolting, the second bent plate and the end plate can form a more robust connection, further enhancing the overall stability of the frame-type support structure. For example, during vehicle operation, the battery module may be subjected to forces in various directions; this enhanced connection can better withstand these forces and reduce structural deformation. The design of the second bent plate creates an additional support point at the end of the local reinforcing plate, effectively resisting deformation caused by external loads. This design is similar to adding a "stiffener" to the structure, improving the bending and torsional resistance of the local reinforcing plate. For example, when subjected to horizontal loads, the second bent plate can transfer part of the load to the end plate, reducing the bending deformation of the local reinforcing plate. The fixed connection between the second bent plate and the end plate further realizes the integrated design of the battery module. This design reduces the number of connecting parts, lowers the complexity of the connection points, and reduces potential failure points. The design of the second bent plate makes the battery module structure more compact, reducing wasted internal space. This compact design not only improves space utilization but also provides more space for cell stacking, thereby increasing the energy density of the battery module.
[0019] In one possible design, the local reinforcing plate has multiple through-holes.
[0020] The above-described design significantly reduces the material usage of the local reinforcing plates, thereby reducing the overall weight of the battery module. Despite the perforations, the local reinforcing plates maintain sufficient structural strength and rigidity through careful design of their shape and distribution. The perforation design achieves weight reduction without significantly compromising structural performance. Furthermore, the perforations increase airflow in the local reinforcing plates, effectively promoting heat dissipation. During battery module operation, the heat generated by the cells can be quickly dissipated into the surrounding environment through the perforations, further improving heat dissipation efficiency.
[0021] In one possible design, the constraint structure is at least one of cable ties, injection-molded frames, or elastic mesh.
[0022] Through the above-described method, cable ties offer a lightweight and cost-effective constraint solution. They are typically made of high-strength plastic or nylon, possessing good flexibility and tensile strength. Using cable ties can significantly reduce the weight of battery modules while lowering production costs. The installation process is very simple; simply wrap the cable tie around the cell stack and tighten it. This installation method is easy to operate, suitable for mass production, and can significantly improve production efficiency. The cable ties can be adjusted according to the actual dimensions of the cell stack, ensuring a uniform distribution of constraint force. This adjustability allows the cable ties to adapt to cell stacks of different sizes and shapes, improving versatility.
[0023] Injection-molded frames are high-strength frame structures manufactured through injection molding. They are typically made of engineering plastics or composite materials, exhibiting high rigidity and stability. Injection-molded frames provide uniform radial constraint forces, effectively limiting the deformation of the battery cell stack. The injection-molded frame can be customized to the specific structure of the battery module, enabling integrated manufacturing. This integrated design reduces the number of connecting parts, lowers the complexity of connection points, and reduces potential failure points.
[0024] Elastic meshwork is a constraint structure made of elastic material, possessing excellent flexibility and adaptability. It can automatically adjust according to the shape and size of the battery cell stack, providing uniform constraint force.
[0025] By employing at least one of cable ties, injection-molded frames, or elastic mesh, a variety of flexible constraint methods are provided to meet different application scenarios and needs. For example, cable ties can be preferred in portable devices with high weight reduction requirements, while injection-molded frames can be preferred in electric vehicles with high rigidity and stability requirements.
[0026] In one possible design, the cable ties are metal cable ties or fiber-reinforced composite cable ties; the injection-molded frame is made of fiber-reinforced nylon and is fitted around the circumference of the battery cell stack; the elastic bundle has elasticity and is constrained around the circumference of the battery cell stack after pre-stretching.
[0027] Through the above methods, metal cable ties are typically made of stainless steel or aluminum alloy, possessing high strength and good corrosion resistance. Metal cable ties can withstand significant tensile forces, ensuring the stability of the battery cell stack under various operating conditions. Fiber-reinforced composite cable ties are made of composite materials reinforced with high-strength fibers (such as carbon fiber or glass fiber), exhibiting high strength, lightweight, and good environmental resistance. These cable ties are not only high-strength but also lightweight, making them suitable for weight-sensitive applications.
[0028] The ring-shaped frame, injection-molded from fiber-reinforced nylon, possesses high rigidity and stability, providing uniform radial constraint force and effectively limiting the deformation of the cell stack. The fiber-reinforced nylon material combines the toughness of nylon with the high strength of fibers, enabling the ring-shaped frame to remain stable under heavy mechanical loads. The ring-shaped frame can be customized according to the specific structure of the battery module, achieving integrated manufacturing. This integrated design reduces the number of connecting components, lowers the complexity of connection points, and reduces potential failure points.
[0029] The flexible mesh is made of a resilient material and can automatically adjust to the shape and size of the cell stack, providing uniform constraint. This design allows the flexible mesh to adapt to cell stacks of different sizes and shapes, offering excellent versatility. The flexible mesh also has good cushioning properties, absorbing vibrations and shocks generated during operation. This cushioning helps protect the cells from mechanical damage, improving the reliability and lifespan of the battery module.
[0030] In one possible design, the cable tie is equipped with a tension adjustment mechanism to dynamically maintain the binding preload of the cable tie.
[0031] The above solutions address the fact that battery modules may be subject to various operating conditions during use, such as temperature changes, vibration, and impact. These factors can cause variations in the preload of the cable ties, affecting the stability of the cell stack. The tension adjustment mechanism dynamically maintains the preload of the cable ties, ensuring the cell stack remains under stable constraint. For example, during vehicle operation, the battery module may be affected by bumps and vibrations; the tension adjustment mechanism can adjust the preload of the cable ties in real time to prevent the cell stack from loosening. Dynamically maintaining the preload reduces damage to the cable ties and cells caused by insufficient or excessive preload. By maintaining appropriate preload, the lifespan of the cable ties and cell stack can be significantly extended. For instance, excessive preload may cause cell deformation or damage, while insufficient preload may cause cell loosening. The tension adjustment mechanism effectively avoids these problems, improving the reliability and durability of the battery module.
[0032] The tension adjustment mechanism can automatically adjust the preload of the cable ties according to actual working conditions. This automatic adjustment function can monitor the tension of the cable ties in real time and adjust it as needed. For example, a tension adjustment mechanism with a sensor can be used. The sensor can monitor the tension of the cable ties in real time and automatically adjust the tension through a controller to ensure that the cable ties are always kept in the optimal preload state. In addition to the automatic adjustment function, the tension adjustment mechanism can also provide a manual adjustment function. In some cases, users can manually adjust the preload of the cable ties as needed to adapt to different usage scenarios. For example, during the installation or maintenance of battery modules, users can manually adjust the preload of the cable ties to ensure the stability of the cell stack.
[0033] The above description is merely an overview of the technical solutions of the embodiments of this application. In order to better understand the technical means of the embodiments of this application and to implement them in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the embodiments of this application more obvious and understandable, specific implementation methods of this application are described below. Attached Figure Description
[0034] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0035] Figure 1 This is a schematic diagram of a battery module structure provided in one embodiment of this application.
[0036] Figure 2 This is a schematic diagram showing the connection position of the partial reinforcing plate and the end plate provided in one embodiment of this application.
[0037] Figure 3 This is a schematic diagram of a partial reinforcing plate in a battery module structure provided in one embodiment of this application.
[0038] Explanation of reference numerals in the attached figures:
[0039] 100. Cell stack; 110. Heat dissipation base plate; 200. End plate; 310. Local reinforcement plate; 311. First bending plate; 312. Second bending plate; 320. Constraint structure; 400. Weld. Detailed Implementation
[0040] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein in the specification of the application is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims and drawings of this application are intended to cover non-exclusive inclusion.
[0042] The term "embodiment" as used herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of the phrase "embodiment" in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0043] In this article, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists, A and B exist simultaneously, or B exists. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.
[0044] The directional terms appearing in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of this application. For example, in the description of this application, the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the figures. They are only for the convenience of describing this application and 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 this application.
[0045] Furthermore, the terms "first," "second," etc., in the specification and claims of this application or in the aforementioned drawings are used to distinguish different objects rather than to describe a specific order, and may explicitly or implicitly include one or more of the features.
[0046] In the description of this application, unless otherwise stated, "multiple" means two or more (including two), and similarly, "multiple groups" means two or more (including two groups).
[0047] In the description of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, "connection" or "joining" in mechanical structures can refer to a physical connection, such as a fixed connection, for example, a connection fixed by a partition, such as a connection fixed by screws, bolts, or other partitions; a physical connection can also be a detachable connection, such as a snap-fit or interlocking connection; a physical connection can also be an integral connection, such as a connection formed by welding, bonding, or integral molding. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0048] A battery module is a crucial component of a battery system, composed of multiple battery cells (cells) used to meet the electrical energy needs of specific devices or systems. However, the structural design of existing power battery modules presents a trade-off between lightweight design and high rigidity, failing to meet current usage requirements.
[0049] In view of this, this application provides a battery module structure, including a cell stack, an end plate, and a lateral fixing structure. The lateral fixing structure includes a local reinforcing plate and a constraint structure. The local reinforcing plate is located at one end of the cell stack, and its height is less than 1 / 3 of the total height of the cell stack. It is disposed on both sides of the cell stack and rigidly connected to the end plate. The constraint structure is located at the other end of the cell stack. The constraint structure can wrap around the cell stack to achieve binding and apply radial constraint force along the circumference of the cell stack. This use of different structures or different strengths of constraint at both ends jointly suppresses the lateral expansion and longitudinal deformation of the cell stack, achieving significant beneficial effects in balancing lightweight, high rigidity, and ease of manufacturing.
[0050] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings.
[0051] Figure 1 This is a schematic diagram of the battery module structure provided in this embodiment. Please refer to... Figure 1 The battery module structure in this embodiment includes a cell stack 100, an end plate 200, and a lateral fixing structure.
[0052] In this embodiment, the cell stack 100 is the core component of the battery module, composed of multiple cells arranged in a specific manner to form an integrated structure. The cells can be connected in series or in parallel.
[0053] End plates 200 are located at both ends of the cell stack 100 and are parallel to the axial direction of the cell stack 100. Their main function is to provide end support and prevent the cell stack 100 from deforming in the axial direction. The end plates 200 are usually rigidly connected to other components of the cell stack 100 (such as side plates, frames, constraint structures 320, etc.) to form an integral support structure.
[0054] During charging and discharging, the battery cell may undergo radial deformation due to changes in internal pressure or external loads. The lateral fixing structure provides lateral support through close contact with the battery cell stack 100, preventing radial deformation of the battery cell stack 100 and ensuring the stability of the battery cell's shape and position.
[0055] In this embodiment, the lateral fixing structure includes a local reinforcing plate 310 and a constraint structure 320. Structural adhesive is applied between the inner surface of the local reinforcing plate 310 and the cell stack 100.
[0056] The local reinforcing plate 310 is located at one end of the cell stack 100. The height of the local reinforcing plate 310 is less than 1 / 3 of the total height of the cell stack 100. It is set on both sides of the cell stack 100 and rigidly connected to the end plate 200.
[0057] The constraint structure 320 is located at the other end of the cell stack 100. The constraint structure 320 can be used to bind the cells around the cell stack 100 and apply radial constraint force along the circumference of the cell stack 100.
[0058] In this embodiment, the height of the local reinforcing plate 310 is less than one-third of the total height of the cell stack 100. This design significantly reduces the amount of material used in the reinforcing plate. For example, if the total height of the cell stack 100 is 30 cm, the height of the local reinforcing plate 310 can be set to about 10 cm. Compared with a traditional full-height reinforcing plate, the amount of material used is reduced by about two-thirds, thereby significantly reducing the weight of the module. The local reinforcing plate 310 is located at one end of the cell stack 100 and is rigidly connected to the end plate 200. This structure can effectively enhance the rigidity of the end of the battery module. When subjected to external impact or pressure, the local reinforcing plate 310 and the end plate 200 can jointly bear the load, preventing deformation of the end of the cell stack 100, thereby ensuring the overall structural stability of the battery module.
[0059] The constraint structure 320 employs a wrap-around binding method, which uses relatively little material and allows for flexible adjustment of the binding tightness according to actual needs, further optimizing material usage and avoiding unnecessary weight increases. The constraint structure 320 applies a radial constraint force along the circumference of the cell stack 100, effectively limiting the circumferential deformation of the cell stack 100. This constraint force ensures that the cell stack 100 is uniformly constrained in all directions, enhancing the overall rigidity of the battery module. Even under complex operating conditions, such as bumps and vibrations during vehicle operation, the battery module can maintain a stable structural state, reducing relative displacement between cells and lowering the risk of cell damage.
[0060] Because the local reinforcing plate 310 is relatively low in height, its installation process is relatively simple. It only needs to be placed at one end of the cell stack 100 and rigidly connected to the end plate 200, without requiring complex positioning and fixing processes. This simple installation method greatly improves production efficiency and reduces production costs. The constraint structure 320 uses a wrap-around binding method, making the operation intuitive and easy to control. The cell stack 100 can be bound using simple binding tools or equipment, applying appropriate radial constraint force. This binding operation does not require complex molds or equipment and has lower requirements for the production environment, further improving the simplicity of the process. At the same time, the bound constraint structure 320 can be adjusted as needed, facilitating quality control and optimization during production. Furthermore, because different structures or constraint strengths are used at both ends of the cell stack 100, stress distribution can be better dispersed. For example, the constraint structure 320 absorbs the cell expansion force, reducing direct impact on the side plate; the local reinforcing plate 310 provides a rigid support point at its end, preventing the entire module from shaking. This embodiment, which employs different structures or strengths at both ends of the constraint, achieves significant benefits in balancing lightweight, high rigidity, and ease of manufacturing.
[0061] In this embodiment, the local reinforcing plate 310 is a stamped sheet metal part or an aluminum alloy profile, and the thickness of the local reinforcing plate 310 is 0.5 to 2 mm.
[0062] Stamped sheet metal parts are typically made of high-strength steel, maintaining high strength and rigidity after stamping. The stamping process can achieve complex shapes and dimensional precision requirements, allowing for the precise manufacture of local reinforcing plates 310 according to the specific structural needs of the battery module. This formability enables the local reinforcing plates 310 to better conform to the shape of the cell stack 100, improving the overall structure's integrity and stability. Within a thickness range of 0.5–2 mm, stamped sheet metal parts can achieve lightweight design while ensuring structural strength.
[0063] Aluminum alloys are characterized by high strength and low density, enabling them to provide sufficient strength and rigidity even in relatively thin thicknesses (0.5–2 mm). The density of aluminum alloys is approximately one-third that of steel; therefore, aluminum alloy profiles are lighter for the same strength requirements, further optimizing the lightweight design of battery modules.
[0064] In this embodiment, the local reinforcing plate 310 and the end plate 200 can be connected by welding, riveting or bolting to form a local rigid frame structure.
[0065] The above methods demonstrate that welding, riveting, and bolting are all high-strength connection methods.
[0066] Figure 2This is a schematic diagram showing the connection position of the local reinforcing plate 310 and the end plate 200 in the battery module structure provided in this embodiment. Figure 2 As shown, in this embodiment, the local reinforcing plate 310 and the end plate 200 are fixed together by welding, and a weld 400 is provided at the connection between the local reinforcing plate 310 and the end plate 200. Welding enables the local reinforcing plate 310 and the end plate 200 to form a whole, and the strength of the connection part is close to or reaches the strength of the base material, thereby significantly improving the load-bearing capacity of the local rigid frame structure.
[0067] Riveting connects the two tightly with rivets, which provide good fixation at the connection and effectively transfer loads.
[0068] The bolted connection securely links the local reinforcing plate 310 to the end plate 200 using the tightening force of the bolts, resulting in a high and reliable connection. This high-strength connection allows the local reinforcing plate 310 to better withstand various external forces, giving one end of the cell stack 100 stronger resistance to deformation. Under external pressure or impact, the local reinforcing plate 310 and the end plate 200 work together to evenly distribute the load throughout the frame structure, preventing deformation caused by localized stress concentration. This enhanced resistance to deformation helps protect the cells from mechanical damage and extends the lifespan of the battery module.
[0069] Figure 3 This is a schematic diagram of a partial reinforcing plate 310 in the battery module structure provided in this embodiment. Figure 3 As shown, a first bending plate 311 is provided at the bottom of the local reinforcing plate 310, and the first bending plate 311 extends toward the heat dissipation base plate 110.
[0070] Through the above scheme, the first bending plate 311 extends towards the bottom of the cell stack 100, forming a more robust connection and further enhancing the overall stability of the frame-type support structure. The design of the first bending plate 311 creates an additional support point at the bottom of the local reinforcing plate 310, effectively resisting deformation caused by external loads. This design is similar to adding a "stiffener" to the structure, improving the bending and torsional resistance of the local reinforcing plate 310. For example, when subjected to a vertical load, the first bending plate 311 can transfer part of the load to the bottom, reducing the bending deformation of the local reinforcing plate 310.
[0071] In this embodiment, the battery module structure also includes a heat dissipation base plate 110, which is located at the bottom of the cell stack 100 and is rigidly connected to the local reinforcing plate 310 and the end plate 200 to form a frame-type support structure; the first bending plate 311 is fixedly connected to the heat dissipation base plate 110.
[0072] The heat dissipation base plate 110 in this embodiment may include a substrate, heat sinks, and coolant channels. The heat dissipation base plate 110 can absorb the heat generated by the battery cell and dissipate the heat to the external environment through the heat dissipation system. Through the heat dissipation base plate 110, heat can be quickly transferred to the underlying heat dissipation system (such as coolant channels, heat sinks, etc.), thereby improving heat dissipation efficiency.
[0073] With the above design, the heat dissipation base plate 110 is located at the bottom of the cell stack 100, effectively supporting the weight of the cell stack 100 and transferring the load to the bottom structure. The local reinforcing plate 310 and end plate 200 provide support on both sides and ends of the cell stack 100, forming a multi-directional load distribution system. The heat dissipation base plate 110 is in direct contact with the cell stack 100, effectively conducting the heat generated by the cells during operation. Since the heat dissipation base plate 110, local reinforcing plate 310, and end plate 200 form an integrated frame support structure, these components can be installed as a whole during assembly. This simplified assembly process reduces assembly time and errors, improving production efficiency. The integrated design and simplified assembly process improve the consistency of the production process. In mass production, this consistency ensures that the quality and performance of each battery module remain stable, reducing quality problems caused by assembly errors. The first bending plate 311 extends towards the bottom of the cell stack 100 and is fixedly connected to the heat dissipation base plate 110. This design increases the contact area and connection strength between the local reinforcing plate 310 and the heat dissipation base plate 110. By means of welding, riveting or bolting, the connection between the first bending plate 311 and the heat dissipation base plate 110 can form a frame structure, thereby improving the overall stability of the battery module.
[0074] Please continue to refer to this. Figure 3 In this embodiment, a second bending plate 312 is also provided at the end of the local reinforcing plate 310. The second bending plate 312 extends toward the end plate 200 and is fixedly connected to the end plate 200.
[0075] With the above scheme, the second bending plate 312 extends toward the end plate 200 and is fixedly connected to the end plate 200. This design increases the contact area and connection strength between the local reinforcing plate 310 and the end plate 200.
[0076] In this embodiment, a more robust connection can be formed with the end plate 200 through welding, riveting, or bolting, further enhancing the overall stability of the frame-type support structure. For example, during vehicle operation, the battery module may be subjected to forces in various directions; this enhanced connection can better withstand these forces and reduce structural deformation.
[0077] The design of the second bending plate 312 creates an additional support point at the end of the local reinforcing plate 310, effectively resisting deformation caused by external loads. This design is similar to adding a "stiffener" to the structure, improving the bending and torsional resistance of the local reinforcing plate 310. For example, under horizontal loads, the second bending plate 312 can transfer part of the load to the end plate 200, reducing the bending deformation of the local reinforcing plate 310. The fixed connection between the second bending plate 312 and the end plate 200 further realizes the integrated design of the battery module. This design reduces the number of connecting parts, lowers the complexity of the connection points, and reduces potential failure points. The design of the second bending plate 312 makes the battery module structure more compact, reducing wasted internal space. This compact design not only improves space utilization but also provides more space for the cell stack 100, increasing the energy density of the battery module.
[0078] In this embodiment, the local reinforcing plate 310 is provided with multiple through-holes.
[0079] The perforated holes can be round or elliptical. Evenly distributing multiple round or elliptical perforated holes can effectively disperse stress and avoid stress concentration, thereby reducing weight while maintaining structural stability.
[0080] Through the above-described design, the perforated hole design significantly reduces the material usage of the local reinforcing plate 310, thereby reducing the overall weight of the battery module. Despite the perforation, the local reinforcing plate 310 maintains sufficient structural strength and rigidity through a well-designed shape and distribution of the perforations. The perforation design achieves weight reduction without significantly compromising structural performance. The perforation design also increases the airflow of the local reinforcing plate 310, effectively promoting heat dissipation. During battery module operation, the heat generated by the cells can be quickly dissipated into the surrounding environment through the perforations, further improving heat dissipation efficiency.
[0081] In this embodiment, the constraint structure 320 is at least one of cable ties, injection-molded frames, or elastic mesh.
[0082] Through the above-described solution, cable ties offer a lightweight and cost-effective constraint method. They are typically made of high-strength plastic or nylon, possessing good flexibility and tensile strength. Using cable ties can significantly reduce the weight of battery modules while lowering production costs. The installation process is very simple; simply wrap the cable tie around the cell stack 100 and tighten it. This installation method is easy to operate, suitable for mass production, and can significantly improve production efficiency. The cable ties can be adjusted according to the actual dimensions of the cell stack 100, ensuring a uniform distribution of constraint force. This adjustability allows the cable ties to adapt to cell stacks 100 of different sizes and shapes, improving versatility.
[0083] Cable ties can be either metal or fiber-reinforced composite materials. Metal cable ties are typically made of stainless steel or aluminum alloy, offering high strength and good corrosion resistance. They can withstand significant tensile forces, ensuring the stability of the battery cell stack 100 under various operating conditions. Fiber-reinforced composite material cable ties are made of composite materials reinforced with high-strength fibers (such as carbon fiber or glass fiber), offering high strength, lightweight construction, and good environmental resistance. These ties are not only high-strength but also lightweight, making them suitable for weight-sensitive applications.
[0084] Injection-molded frames are high-strength frame structures manufactured through injection molding. They are typically made of engineering plastics or composite materials, exhibiting high rigidity and stability. Injection-molded frames provide uniform radial constraint forces, effectively limiting the deformation of the cell stack 100. The injection-molded frame can be customized according to the specific structure of the battery module, enabling integrated manufacturing. This integrated design reduces the number of connecting parts, lowers the complexity of connection points, and reduces potential failure points.
[0085] For example, a ring-shaped frame made of fiber-reinforced nylon is injection-molded and fitted onto the circumference of the cell stack 100. This ring-shaped frame possesses high rigidity and stability, providing uniform radial constraint force and effectively limiting the deformation of the cell stack 100. The fiber-reinforced nylon material combines the toughness of nylon with the high strength of fibers, allowing the ring-shaped frame to remain stable even under significant mechanical loads. The ring-shaped frame can be customized according to the specific structure of the battery module, enabling integrated manufacturing. This integrated design reduces the number of connecting components, lowers the complexity of the connection points, and reduces potential failure points.
[0086] The elastic mesh is a constraint structure 320 made of elastic material, possessing excellent flexibility and adaptability. It can automatically adjust to the shape and size of the cell stack 100, providing uniform constraint force. Made of a resilient material, the elastic mesh can automatically adjust to the shape and size of the cell stack 100, providing uniform constraint force. This design allows the elastic mesh to adapt to cell stacks 100 of different sizes and shapes, exhibiting good versatility. The elastic mesh also has excellent cushioning properties, absorbing vibrations and shocks generated by the cell stack 100 during operation. This cushioning property helps protect the cells from mechanical damage, improving the reliability and lifespan of the battery module.
[0087] By employing at least one of cable ties, injection-molded frames, or elastic mesh, a variety of flexible constraint methods are provided to meet different application scenarios and needs. For example, cable ties can be preferred in portable devices with high weight reduction requirements, while injection-molded frames can be preferred in electric vehicles with high rigidity and stability requirements.
[0088] In some embodiments, the cable tie may be provided with a tension adjustment mechanism to dynamically maintain the binding pretension of the cable tie.
[0089] Tension adjustment mechanisms can employ various adjustment methods, such as mechanical, hydraulic, or electric. Mechanical adjustment mechanisms are simple and reliable, suitable for cost-sensitive applications; while hydraulic and electric adjustment mechanisms offer higher adjustment accuracy and automation.
[0090] Through the above-described solution, the battery module may be affected by various operating conditions during use, such as temperature changes, vibration, and impact. These factors may cause changes in the pretension of the cable ties, thus affecting the stability of the cell stack 100. The tension adjustment mechanism can dynamically maintain the pretension of the cable ties, ensuring that the cell stack 100 is always in a stable constrained state. For example, during vehicle operation, the battery module may be affected by bumps and vibrations; the tension adjustment mechanism can adjust the pretension of the cable ties in real time to prevent the cell stack 100 from loosening. Dynamically maintaining the pretension can reduce damage to the cable ties and cells caused by insufficient or excessive pretension. By maintaining appropriate pretension, the service life of the cable ties and the cell stack 100 can be significantly extended. For example, excessive pretension may cause cell deformation or damage, while insufficient pretension may cause the cells to loosen. The tension adjustment mechanism can effectively avoid these problems, improving the reliability and durability of the battery module.
[0091] The tension adjustment mechanism can automatically adjust the preload of the cable ties according to actual working conditions. This automatic adjustment function can monitor the tension of the cable ties in real time and adjust it as needed. For example, a tension adjustment mechanism with a sensor can be used. The sensor can monitor the tension of the cable ties in real time and automatically adjust the tension through the controller to ensure that the cable ties are always kept in the optimal preload state. In addition to the automatic adjustment function, the tension adjustment mechanism can also provide a manual adjustment function. In some cases, users can manually adjust the preload of the cable ties as needed to adapt to different usage scenarios. For example, during the installation or maintenance of battery modules, users can manually adjust the preload of the cable ties to ensure the stability of the cell stack 100.
[0092] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A battery module structure, comprising a cell stack, an end plate, and a lateral fixing structure, characterized in that, The lateral fixing structure includes: A local reinforcing plate is located at one end of the cell stack. The height of the local reinforcing plate is less than 1 / 3 of the total height of the cell stack. It is disposed on both sides of the cell stack and rigidly connected to the end plate. A first bending plate is provided at the bottom of the local reinforcing plate, and the first bending plate extends towards the bottom of the cell stack. A constraint structure is located at the other end of the cell stack. The constraint structure can be used to bind the cell stack around it and apply a radial constraint force along the circumference of the cell stack. A heat dissipation base plate is located at the bottom of the battery cell stack and is rigidly connected to the local reinforcing plate and the end plate to form a frame-type support structure; the first bent plate is fixedly connected to the heat dissipation base plate.
2. The battery module structure according to claim 1, characterized in that, The local reinforcing plate is a stamped sheet metal part or an aluminum alloy profile, and the thickness of the local reinforcing plate is 0.5~2mm.
3. The battery module structure according to claim 1, characterized in that, The local reinforcing plate and the end plate are connected by welding, riveting or bolting to form a local rigid frame structure.
4. The battery module structure according to claim 1, characterized in that, The end of the local reinforcing plate is provided with a second bending plate, which extends toward the end plate and is fixedly connected to the end plate.
5. The battery module structure according to claim 1, characterized in that, The local reinforcing plate has multiple through-holes.
6. The battery module structure according to claim 1, characterized in that, The constraint structure is at least one of cable ties, injection-molded frames, or elastic mesh.
7. The battery module structure according to claim 6, characterized in that, The cable ties are metal cable ties or fiber-reinforced composite material cable ties; the injection-molded frame is made of fiber-reinforced nylon and is fitted onto the circumference of the battery cell stack; the elastic bundle has elasticity and is constrained onto the circumference of the battery cell stack after pre-stretching.
8. The battery module structure according to claim 6, characterized in that, The cable tie is equipped with a tension adjustment mechanism to dynamically maintain the binding pre-tension of the cable tie.