Advanced Fastening Solutions for Electric Vehicle Battery Packs and Aluminum Alloy Bodies

Advanced Fastening Solutions for Electric Vehicle Battery Packs and Aluminum Alloy Bodies

Lightweight Materials and Advanced Manufacturing for New Energy Vehicles

Nylon and Metal Fasteners in EV Components

EV battery covers and chargers commonly use PA6 or PA66 components. Nylon rivets are widely employed in automotive, industrial, and solar applications. PA6 provides high strength and rigidity, ensuring proper sealing and stability when combined with metal screws or nuts, even under long-term thermal stress or wet conditions.

For metal side plates of battery modules, bolts ensure a stable mechanical connection and maintain structural integrity under complex conditions.

High-Strength Bolts and Battery Pack Reliability

Battery pack structures utilize high-strength straight long-flange bolts, especially in buses and logistics vehicles. These bolts undergo heat treatment, straightening, and dehydrogenation to meet stringent verticality and mechanical standards. Grades 8.8 and 10.9 are commonly used, ensuring high safety and durability in the NEV market.

With modular battery pack technology maturing, manufacturers focus on:

1. Optimizing internal pack design to      reduce components and integrate multiple functions.

2. Using lightweight materials such as      aluminum, composites, and engineered plastics, including nylon rivets,      snap-in supports, and adhesive mounts, to reduce weight.

Key Components and Materials

Juxin Fasteners provides application engineering support, assisting with new designs, resolving technical challenges, and recommending cost-efficient solutions.

Lock Washers and Assembly Aids

Double-stack lock washers enhance anti-loosening performance by providing tension between the two gaskets. Material options include SUS304, SUS316, carbon steel SK5/SK7, or customer-specified European steel equivalents (EN 1.7182, EN 1.5528, 1.4462). Carbon steel surfaces may feature a zinc-magnesium (Tedacromet) coating that passes 720-hour salt spray testing.

Aluminum Alloy Battery Pack Shells

Typical aluminum alloy shells combine extrusion-profile frames and base plates, welded using stir-friction welding, MIG, blind rivet nuts, self-clinching nuts, or limited arc welding. IP67 sealing ensures waterproofing, which is critical for battery safety. Blind rivet nuts with adhesive surfaces are used to enhance sealing.

Riveting Types for Aluminum Bodies

• Compression Riveting: Serrated or      flange interlocking for stamping, extrusion, and casting parts.

• Tension Riveting: Pulls and clamps      sheet metal openings; includes tension nuts and pull-rivet pins.

• Lock Riveting (SPR, TOX): Direct or      interlocked connections with die-formed rivet legs.

• Flange Riveting: Folds and      interlocks the flange to the sheet surface under pressure.

Features and applications of threaded fasteners with anti-loosening function

Screw Depth Standards and Assembly Considerations

Screw depth typically ranges 1.5–1.6 times the screw diameter, adjusted according to screw type (e.g., M8 cup head ≥12 mm, M10 cup head ≥15 mm).

Assembly steps:

1. Tighten screws incrementally in thirds for balanced stress      distribution.

2. Maintain proper torque; avoid over- or under-tightening.

3. Use electric screwdrivers aligned precisely with screw heads.

High-Strength Bolt Pretension

Pretension compresses connected components to generate friction and transmit shear force. Key principles:

• High-strength bolts are typically permanent connections.

• Pre-stressing ensures components do not slip under axial      forces.

• Face-bearing serrated flange bolts      improve anti-loosening via teeth embedding.

• Anaerobic adhesive bolts prevent      vibration loosening under -50°C to 120°C.

Lock Nut Types and Guidelines

Process characteristics of aluminum parts processing

Advantages of High-Quality Auto Parts

1. Enhanced vehicle safety – reliable      braking and chassis stability.

2. Improved performance – efficient      motors, transmission, and suspension.

3. Reduced maintenance costs –      long-lasting durability.

4. Enhanced driving experience –      smoother handling and responsive control.

Aluminum Alloy Machining Techniques

1. Machining datum selection – align      with design, assembly, and measurement references.

2. Rough machining – milling or      planing with coolant to reduce heat-induced deformation.

3. Finishing machining – high-speed      cutting with lubricants to maintain surface quality.

4. Tool selection – consider      aluminum’s thermal conductivity and chip formation.

5. Heat and cold treatment – eliminate      residual stress and improve dimensional stability.

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