How to Select Blind Rivets for EV Battery Pack

How to Select Blind Rivets for EV Battery Pack Cooling Plate Fixing

Professional guide to selecting aluminum or steel blind rivets for fixing EV battery pack cooling plates. Improve lightweight design, vibration resistance, and structural reliability with automotive-grade fastening solutions.

Structural Characteristics of EV Battery Pack Enclosures

In modern electric vehicles (EVs), the battery pack is typically constructed with stamped aluminum enclosures and internal liquid-cooling plates. These cooling systems ensure the thermal stability of battery modules under high-charge and high-discharge conditions.

The internal structure usually features:

Aluminum stamped housing

Aluminum cooling plates

Multi-point fastening design

High vibration exposure during vehicle operation

Although internal components are generally protected from direct moisture exposure, fasteners must still ensure long-term mechanical stability, lightweight performance, and manufacturing efficiency.

Key Engineering Requirements for Blind Rivets in EV Battery Packs

When selecting blind rivets for fixing cooling plates inside the battery enclosure, engineers typically evaluate the following factors:

1. Structural Strength

The rivet must provide sufficient shear and tensile strength to withstand vehicle vibration and long-term fatigue loads.

2. Lightweight Design

Lightweight construction is a critical target in EV development. Fastener material selection directly impacts total battery pack weight, especially in high-volume applications.

3. Compatibility with Aluminum Structures

Since most battery enclosures and cooling plates are aluminum, material compatibility must be evaluated to prevent structural weakening.

4. Production Efficiency

Blind rivets are widely used because they allow one-side installation, making them ideal for closed battery housing assemblies.

Aluminum vs Steel Blind Rivets in EV Applications

Aluminum Blind Rivets

Advantages:

Approximately 1/3 the weight of steel rivets

Good compatibility with aluminum structures

Adequate strength for non-load-bearing fixing

Cost-effective for high-volume production

Recommended for:

Cooling plate positioning, internal non-structural fixing, lightweight-focused designs.

Steel Blind Rivets

Advantages:

Higher tensile and shear strength

Better performance under high vibration loads

Suitable for semi-structural or reinforced areas

Recommended for:

Connection points that require higher mechanical performance or where additional structural rigidity is required.

When Corrosion Is Not the Primary Concern

For internal battery pack applications where:

The enclosure is fully sealed

No direct exposure to external humidity

No coolant leakage risk

Material selection may prioritize mechanical strength and weight optimization rather than corrosion resistance alone.

However, automotive-grade surface treatment and consistent quality control remain essential for long-term reliability.

Recommended Riveting Solutions for EV Battery Cooling Systems

At Juxin Fasteners, we provide automotive-grade blind riveting solutions tailored for EV battery pack applications:

Aluminum open-end and closed-end blind rivets

High-strength steel blind rivets

Customized grip range for multi-layer aluminum assemblies

PPAP-supported production

OEM fastener customization

With over 23 years of experience in industrial and automotive fastening systems, we support EV manufacturers with reliable, high-volume, and precision fastening solutions.

Conclusion

Selecting the right blind rivet for EV battery pack cooling plate fixing requires balancing:

Structural load requirements

Lightweight targets

Vibration resistance

Manufacturing efficiency

Aluminum blind rivets are typically preferred for lightweight internal fixing, while steel blind rivets are selected when higher structural strength is required.

Proper engineering evaluation ensures long-term battery pack stability and production efficiency.