A solderless screwless battery module

Abstract

The utility model belongs to the battery module of no welding and screwing of new energy power battery technical field. Including module frame (1), upper cover (2), module frame (1) side sets up the extension (3) that extends upwards, upper cover (2) side sets up cover opening (4), module body (5) is located in module frame (1) inside, upper cover (3) buckle and install on module body (5) upper portion, the extension (3) upper portion of module frame (1) passes through cover opening (4) after downward bending site forms the bending part (6). The utility model discloses the battery module of no welding and screwing, simple structure, need not to depend on sheet metal structural member welding and screw locking and can realize module body integration, form the reliable battery module of structure, the strong anti -vibration, the strong anti -impact ability, not easy to loosen, cancel screw and reduce overall weight and cost.

Description

Technical Field

[0001] This utility model belongs to the field of new energy power battery technology, and more specifically, it relates to a weld-free and screwless battery module. Background Technology

[0002] With the rapid development of new energy vehicles and energy storage power stations, higher requirements are being placed on the energy density, safety, production efficiency, and recyclability of battery modules. Current power battery energy storage module structural designs generally suffer from the following pain points: 1. Heavy reliance on sheet metal welding structures: End plates, side plates, and module shells largely utilize welded sheet metal parts, formed through bending and welding. This results in heavy modules, low specific energy, high production costs, and limited shape design. 2. Screw fastening: Used to fix module shells, end plates, electrical covers, etc. The process is cumbersome, carries the risk of loosening, and the screws themselves increase weight and cost. Therefore, existing battery module structures suffer from technical challenges such as heavy weight, complex processes, and poor maintainability.

[0003] Existing technology includes a specification titled "Module Housing, Soft-Pack Lithium Battery Module" with publication number "CN111554848A". This specification discloses a module housing and a soft-pack lithium battery module. The module housing includes a base plate, a cover plate, a pair of oppositely arranged end plates, and a pair of oppositely arranged side plates. The end plates and side plates surround the periphery of the base plate to form a cavity. The cover plate covers the top of the end plates and side plates. The cover plate and / or at least one side plate is composed of a busbar support plate. The busbar support plate is provided with a busbar, which has multiple tab connection ports penetrating the busbar support plate. This invention eliminates the middle frame, reduces the structural components of the battery module, simplifies the structure, reduces the cost and weight of the module, improves the structural strength, and enhances the module's bending and torsional resistance along its length.

[0004] However, this technology does not address the technical issues and solutions of this application. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide a battery module with a simple structure that can be integrated into the module body without relying on the welding of sheet metal structural parts and screw fastening, forming a reliable battery module with strong vibration and impact resistance, not easy to loosen, and eliminating screws to reduce the overall weight and cost.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: This utility model is a weld-free and screwless battery module, including a module frame and a top cover. The module frame has an upwardly extending extension on its side, and the top cover has a cover opening on its side. The module body is located inside the module frame, and the top cover is fastened to the upper part of the module body. The upper part of the extension of the module frame passes through the cover opening and then bends downward to form a bent part.

[0007] The module frame has multiple first extensions on one side, with connecting strips on the upper part of the first extensions, and multiple second extensions on the other side, with connecting strips on the upper part of the second extensions.

[0008] The upper cover plate has a first folded edge on one side, and multiple cover plate openings are provided at the joint between the upper cover plate and the first folded edge. The upper cover plate has a second folded edge on the other side, and multiple cover plate openings are provided at the joint between the upper cover plate and the second folded edge.

[0009] The module body has a structural adhesive strip and an insulating silicone strip on its upper part, and a heating element and an insulating epoxy board on its side.

[0010] The number and position of the first extension on one side of the module frame and the cover plate opening on the upper cover plate correspond, and the connecting strip on the upper part of each first extension passes through the corresponding cover plate opening and then bends to form a bent part.

[0011] The number and position of the second extension on the other side of the module frame and the cover plate opening on one side of the upper cover plate correspond. The connecting strip on the upper part of each second extension passes through the corresponding cover plate opening and then bends to form a bent part.

[0012] The module frame and the top cover are both made of thin metal plates.

[0013] The module body has an aluminum busbar on its side, which is connected to the electrode post.

[0014] The module frame, top cover, and module body are connected and installed into the battery box, and a box cover is provided on the top of the battery box.

[0015] The working principle and beneficial effects of this utility model are as follows: The weld-free, screwless battery module of this utility model is constructed by separately manufacturing a module frame and a top cover. The bottom area of ​​the module frame is equal to the bottom area of ​​the module body. The bottom plate of the module frame is used to place the module body. Each side of the module frame has an upwardly extending portion, the height of which is higher than the height of the module body. When assembling, the module body is placed inside the module frame, and the top cover is fastened to the upper part of the module body. Because the top cover has a cover opening on its side, the upper part of the extension on each side of the module frame passes through the corresponding cover opening and then bends downward to form a bending portion, realizing the interlocking connection between the module frame and the top cover. The module frame and the top cover reliably constrain the battery, and the bending and interlocking form a permanent housing with strong vibration and impact resistance, making it less prone to loosening and improving the overall reliability of the structure. In the above-described structure of the battery module of this utility model, the connection between the module frame and the top cover plate does not require welding or screw fastening, thus avoiding the problem of material performance degradation caused by heat during battery operation, while improving assembly efficiency and disassembly and maintenance capabilities. Specifically, the elimination of welding eliminates the risks of poor welding contact and aging loosening, and the elimination of screws saves a large number of unnecessary parts such as screws and brackets, significantly improving the system energy density of the battery. Attached Figure Description

[0016] The following is a brief explanation of the contents depicted in the accompanying drawings and the markings therein: Figure 1 This is a schematic diagram of the structure of the weld-free and screwless battery module described in this utility model; Figure 2 This is an exploded structural diagram of the weld-free, screwless battery module described in this utility model; The labels in the attached drawings are as follows: 1. Module frame; 2. Top cover plate; 3. Extension; 4. Cover plate opening; 5. Module body; 6. Bending part; 7. First extension; 8. Connecting strip; 9. Second extension; 11. Structural adhesive strip; 12. Heating element; 13. Insulating epoxy board; 14. First folded edge; 15. Second folded edge; 16. Aluminum busbar. Detailed Implementation

[0017] The following description, with reference to the accompanying drawings, provides a more detailed explanation of the specific embodiments of this utility model, including the shape and structure of each component, the relative positions and connections between the parts, the functions and working principles of each part: As attached Figure 1 Appendix Figure 2As shown, this utility model is a weld-free, screwless battery module, including a module frame 1 and an upper cover plate 2. The module frame 1 has an upwardly extending portion 3 on its side, and the upper cover plate 2 has a cover opening 4 on its side. The module body 5 is located inside the module frame 1, and the upper cover plate 2 is fastened to the upper part of the module body 5. The upper part of the extension portion 3 of the module frame 1 passes through the cover opening 4 and then bends downward to form a bent portion 6. This structure addresses the shortcomings of existing technologies by proposing an improved technical solution. During structural setup, a module frame 1 and an upper cover plate 2 are fabricated separately. The bottom area of ​​the module frame 1 is equal to the bottom area of ​​the module body 5. The bottom plate of the module frame 1 is used to place the module body 5. Each side of the module frame 1 is provided with an upwardly extending part 3. The height of the extension part 3 is higher than the height of the module body 5. When assembling, the module body 5 is placed inside the module frame 1, and the upper cover plate 2 is fastened onto the upper part of the module body 5. Because the upper cover plate 2 has a cover plate opening 4 on its side, the upper part of the extension part 3 on each side of the module frame 1 passes through the corresponding cover plate opening 4. The part that passes through the cover plate opening 4 and then bends downward to form a bending part 6, realizing the interlocking connection between the module frame 1 and the upper cover plate 2. The interlocking connection effectively ensures mechanical strength and production efficiency, while the module frame 1 and the upper cover plate 2 reliably constrain the battery. The bending and interlocking form a permanent housing with strong vibration and impact resistance, and it is not easy to loosen, thus improving the overall reliability of the structure. In the above-described structure of the battery module of this utility model, the connection between the module frame 1 and the upper cover plate 2 requires neither welding nor screw fastening, avoiding the problem of material performance degradation caused by heat during battery operation, while improving assembly efficiency and disassembly and maintenance capabilities. Specifically, the elimination of welding fundamentally eliminates the risks of poor welding contact and aging loosening. The elimination of screws saves a large number of unnecessary parts such as screws and brackets, significantly improving the system energy density of the battery. The weld-free and screwless battery module of this utility model has a simple structure, achieving module body integration without relying on sheet metal structural component welding and screw fastening, forming a structurally reliable battery module with strong vibration and impact resistance, and is not easily loosened. Eliminating screws reduces overall weight and cost.

[0018] The module frame 1 has multiple first extensions 7 on one side of its base plate, with connecting strips 8 on the upper part of each first extension 7. The module frame 1 also has multiple second extensions 9 on the other side, with connecting strips 8 on the upper part of each second extension 9. In this structure, the first extensions 7, second extensions 9, and base plate are integrated, simplifying processing and providing strong connection. Each extension has multiple connecting strips on its upper part, and each cover plate opening 4 includes multiple small openings. Each connecting strip passes through the corresponding small opening of the corresponding cover plate opening and then bends outward to form an interlocking connection with the upper cover plate.

[0019] The upper cover plate 2 has a first folded edge 14 on one side, and multiple cover plate openings 4 at the joint between the upper cover plate 2 and the first folded edge 14. The upper cover plate 2 also has a second folded edge 15 on the other side, with multiple cover plate openings 4 at the joint between the upper cover plate 2 and the second folded edge 15. With this structure, after the upper cover plate is fastened to the upper part of the module body 5, the first folded edge 14 is located on one side of the module body 5, and the second folded edge 15 is located on the other side of the module body 5, ensuring that the upper cover plate is accurately fastened to the upper part of the module body. Then, the connecting strip of each extension passes through the corresponding cover plate opening.

[0020] The module body 5 has a structural adhesive strip 11 and an insulating silicone strip on its upper part, and a heating element 12 and an insulating epoxy board 13 on its side. In this structure, the structural adhesive strip 11 is adhered between the upper cover and the module body, providing a buffering effect to prevent damage to the battery from vibration or impact, while also conducting heat generated during battery module operation to the outside. The insulating silicone strip has electrical insulation properties, isolating the circuit from contact with the external environment and ensuring electrical safety. The heating element 12 is attached to the side of the module body and bonded to the insulating epoxy board 13. The main function of the heating element 12 is to ensure that the lithium battery operates within the optimal temperature range through an active temperature control strategy, solving the problem of battery performance degradation in low-temperature environments. The insulating epoxy board 13 can block abnormal current conduction between the cell and the metal plate, preventing short circuits.

[0021] The number and position of the first extension 7 on one side of the module frame 1 and the cover plate opening 4 on one side of the upper cover plate 2 correspond. The connecting strip 8 on the upper part of each first extension 7 passes through the corresponding cover plate opening 4 and is bent to form a bent part 6. The number and position of the second extension 9 on the other side of the module frame 1 and the cover plate opening 4 on one side of the upper cover plate 2 correspond. The connecting strip 8 on the upper part of each second extension 9 passes through the corresponding cover plate opening 4 and is bent to form a bent part 6. With the above structure, the connecting strip can reliably pass through the corresponding cover plate opening and then bend to achieve an interlocking connection.

[0022] Both the module frame 1 and the top cover plate 2 are made of thin metal sheets. This structure, utilizing thin-walled sheet metal, achieves a balance between lightweight and high strength. An aluminum busbar 16 is mounted on the side of the module body 5, connecting to the terminal posts of the module body. The aluminum busbar 16 is laser-welded to the terminal posts of the battery cells to achieve conductivity. After the module frame 1, top cover plate 2, and module body 5 are connected, they are installed into a battery box, with a cover plate on the top of the battery box. The battery box provides external protection for the module body.

[0023] When assembling the weldless, screwless battery module described in this utility model, the following steps are taken: 1. Step 1: Module body placement: Place the pre-assembled module body (cell array) into the base plate of the integrated sheet metal module frame. 2. Step 2: Aluminum busbar laser welding: Precisely position the cell terminals and aluminum busbars, and form a stable electrical connection through laser welding. 3. Step 3: Top cover locking: Place the top cover in place, align the cover opening with the corresponding extension on the module frame, pass the connecting strip of the corresponding extension through the cover opening, and then bend the connecting strip to complete the edge locking of the top cover. The technical effects of the weldless, screwless battery module described in this utility model are: 1. Solving the defects of "bulky structure and complex connection": Using thin-walled sheet metal, a balance between lightweight and high strength is achieved. One bending and locking action replaces dozens or even hundreds of screws, greatly simplifying the structure and reducing the number of parts. 2. The ultimate solution to "low production efficiency and high cost": The final assembly process is simplified to the ultimate "place-cover-bend". The bending and interlocking process is linear speed or second-level, effectively improving production efficiency, suitable for large-scale automated production, and significantly reducing the manufacturing cost per module. 3. Achieving "supreme structural strength and reliability": The all-metal structure itself has high rigidity. Continuous metal edging provides a permanent, non-loosening, and aging-resistant connection, with vibration and impact resistance far exceeding any screw or plastic clip connection. The metal shell also provides excellent electromagnetic shielding (EMI). 4. Optimized "thermal management performance": The metal sheet shell itself is a huge heat sink, quickly and evenly conducting the heat generated by the battery cells to the entire surface, and its coordination with external cooling systems is more efficient. 5. Balancing "production efficiency" and "maintainability": This design places "production efficiency and reliability" as the highest priority. Although the bending and interlocking is irreversible, this precisely ensures unparalleled reliability throughout the product's lifecycle. The maintenance strategy is clearly defined as module-level replacement: after a failed module is returned to the factory, it can be repaired by cutting along the edge, or the entire module can be replaced at the system level. This achieves a perfect combination of "maximizing manufacturing efficiency" and "maximizing operational reliability." This utility model's "all-metal sheet metal bending and interlocking" battery module represents an industrial solution. By cross-industry integration of mature sheet metal stamping and bending processes with lithium battery PACK technology, it creates a perfect product form that achieves top-level performance in production efficiency, structural strength, lightweighting, thermal management, and cost control, marking a benchmark innovation in the field of lithium battery structure.

[0024] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A solderless, screwless battery module, characterized in that: The module includes a module frame (1) and an upper cover plate (2). The module frame (1) has an upward extension (3) on its side, and the upper cover plate (2) has a cover plate opening (4) on its side. The module body (5) is located inside the module frame (1). The upper cover plate (2) is fastened to the upper part of the module body (5). The upper part of the extension (3) of the module frame (1) passes through the cover plate opening (4) and then bends downward to form a bending part (6).

2. The weld-free, screwless battery module according to claim 1, characterized in that: The module frame (1) has multiple first extensions (7) on one side, and a connecting strip (8) on the upper part of the first extension (7). The module frame (1) has multiple second extensions (9) on the other side, and a connecting strip (8) on the upper part of the second extension (9).

3. The weld-free, screwless battery module according to claim 1 or 2, characterized in that: The upper cover plate (2) is provided with a first folded edge (14) on one side, and multiple cover plate openings (4) are provided at the joint between the upper cover plate (2) and the first folded edge (14). The upper cover plate (2) is provided with a second folded edge (15) on the other side, and multiple cover plate openings (4) are provided at the joint between the upper cover plate (2) and the second folded edge (15).

4. The weld-free, screwless battery module according to claim 1 or 2, characterized in that: The module body (5) is provided with a structural adhesive strip (11) and an insulating silicone strip on the upper part, and a heating element (12) and an insulating epoxy board (13) are provided on the side of the module body (5).

5. The weld-free, screwless battery module according to claim 3, characterized in that: The number and position of the first extension (7) on one side of the module frame (1) and the cover plate opening (4) on one side of the upper cover plate (2) correspond. The connecting strip (8) on the upper part of each first extension (7) passes through the corresponding cover plate opening (4) and then bends to form a bent part (6).

6. The weld-free, screwless battery module according to claim 3, characterized in that: The number and position of the second extension (9) on the other side of the module frame (1) and the cover plate opening (4) on the side of the upper cover plate (2) correspond. The connecting strip (8) on the upper part of each second extension (9) passes through the corresponding cover plate opening (4) and then bends to form a bent part (6).

7. The weld-free, screwless battery module according to claim 1 or 2, characterized in that: The module frame (1) and the top cover plate (2) are both made of thin metal plates.

8. The weld-free, screwless battery module according to claim 1 or 2, characterized in that: The module body (5) is provided with an aluminum busbar (16) on its side, and the aluminum busbar (16) is connected to the pole post.

9. The weld-free, screwless battery module according to claim 1 or 2, characterized in that: The module frame (1), the upper cover plate (2), and the module body (5) are connected and installed into the battery box, and a box cover plate is provided on the upper part of the battery box.

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