One-step induction welding assembly arrangement for battery housings

Abstract

A one-step induction welding assembly arrangement for a battery housing includes a tray comprised of a thermoplastic composite material. The tray is part of a battery case. The one-step induction welding assembly arrangement also includes a cooling component comprised of one of a thermoplastic composite and a metal, where the cooling component is bonded to the tray at a bonding interface, and the cooling component is part of the battery housing. The one-step induction welding assembly configuration also includes a plurality of induction coils energized to generate an electromagnetic field that generates heat and joins the tray and the cooling component together at the joining interface, a layer of electrically insulating material disposed directly below the plurality of induction coils, and a mold disposed directly below the plurality of induction coils. The die applies a clamping force to a tray of a battery case.

Description

TECHNICAL FIELD

[0001] The present invention relates to a one-step induction welding assembly configuration for a battery enclosure, and to a battery enclosure manufactured by the one-step induction welding assembly configuration. BACKGROUND

[0002] Battery enclosures for electric vehicles have traditionally been constructed from metallic materials, such as aluminum and steel. However, it should be appreciated that metals tend to add significant mass to electric vehicles. Moreover, the complex shapes often required to form battery enclosures from metals can be challenging. As such, battery enclosures can also be made from materials other than metals, such as thermoplastic composites.

[0003] There are currently a variety of joining techniques that can be used to join thermoplastic parts together or to another metallic part, however, existing joining techniques can have drawbacks. For example, one joining technique that can be used is resistance welding. However, resistance welding requires a resistive element, such as a metal or carbon fiber, to be retained in the weld. Another joining technique is ultrasonic welding, which requires an energy director to be installed at the weld interface. Laser welding is another joining technique that can be employed. However, laser welding requires at least one adhesive to be transparent to the laser. Another joining technique that is currently available is adhesive bonding. However, adhesive bonding introduces material into the battery enclosure, which adds mass and volume to the vehicle. Moreover, adhesive bonding also makes it more difficult to separate the material for recycling at the end of its useful life.

[0004] Accordingly, while battery enclosures achieve their intended purpose, there is a need in the art for an improved method of manufacturing battery enclosures. SUMMARY

[0005] According to aspects, a one-step induction welding assembly configuration for a battery enclosure is disclosed and includes a tray constructed from a thermoplastic composite, wherein the tray is a part of the battery enclosure. The one-step induction welding assembly configuration also includes a cooling plate constructed from one of: the thermoplastic composite and a metal, wherein the cooling plate is joined to the tray at a joint interface, and wherein the cooling plate is a part of the battery enclosure. The one-step induction welding assembly configuration includes a plurality of induction coils energized to generate an electromagnetic field that generates heat and joins the tray and the cooling plate together at the joint interface, a layer of electrically insulating material disposed directly below the plurality of induction coils, and a die that exerts a clamping force on the tray of the battery enclosure, wherein the plurality of induction coils exert a force directly opposite the clamping force to hold the tray and the cooling plate in place.

[0006] In another aspect, the cooling plate is constructed from the thermoplastic composite.

[0007] In yet another aspect, the one-step induction welding assembly configuration includes an electrically conductive plate including an upper surface and a lower surface, wherein the upper surface of the electrically conductive plate contacts the lower surface of the electrically insulating material layer, and the lower surface of the electrically conductive plate contacts the upper surface of the cooling plate.

[0008] In another aspect, the thermal resistance through the cooling plate does not exceed 3.0 x 10 -3 m 2 KW -1 .

[0009] In yet another aspect, the cooling plate is composed of a metal.

[0010] In an aspect, the lower surface of the electrically insulating material layer contacts the upper surface of the cooling plate.

[0011] In another aspect, the tray includes a base, and wherein the plurality of cooling features extend along at least a portion of the base.

[0012] In yet another aspect, the plurality of cooling features includes a plurality of cooling channels, and wherein each cooling channel is a channel shaped to receive a cooling medium.

[0013] In an aspect, the raised surface is disposed between the plurality of cooling channels disposed along the base of the tray.

[0014] In another aspect, the raised surface disposed between the plurality of cooling channels positioned along the base of the tray contacts the lower surface of the cooling plate at the interface.

[0015] In yet another aspect, the raised surface of the tray includes one of: a higher average surface roughness value when compared to a remaining portion of the tray, and an increased surface energy when compared to a remaining portion of the tray.

[0016] In an aspect, the cooling plate includes an upper surface including one of: a higher average surface roughness value when compared to a remaining portion of the cooling plate, and an increased surface energy when compared to a remaining portion of the cooling plate.

[0017] In another aspect, the tray is composed of a thermoplastic composite laminate including a thermoplastic composite layer and at least one of: a thermal runaway propagation (TRP) protection layer, a TRP shield material, and an electromagnetic interference (EMI) shielding layer.

[0018] In one aspect, the present invention discloses a one-step induction welding assembly configuration for a battery casing, comprising a tray made of a thermoplastic composite material, wherein the tray is part of the battery casing. The one-step induction welding assembly configuration includes a crossbar made of one of the following: a thermoplastic composite material and a metal, wherein the crossbar is joined to the tray at a joint interface and is part of the battery casing. The one-step induction welding assembly configuration includes a plurality of induction coils energized to generate an electromagnetic field, which generates heat and joins the tray and crossbar together at the joint interface. The one-step induction welding assembly configuration includes an electrically insulating material layer disposed directly below the plurality of induction coils and a mold that applies a clamping force to the crossbar of the battery casing, wherein the plurality of induction coils apply a force directly opposite to the clamping force to hold the tray and crossbar in place.

[0019] On the other hand, the cross rail includes a flange.

[0020] On another front, the one-step induction welding assembly configuration includes a conductive plate disposed between a tray of the battery casing and a layer of electrical insulation material.

[0021] In one aspect, the present invention discloses a one-step induction welding assembly configuration for a battery casing, comprising a first component and a second component positioned coplanarly relative to each other, wherein the first component and the second component are joined together at an interlocking interface. The one-step induction welding assembly configuration includes an induction coil energized to generate an electromagnetic field, which generates heat and joins the first component and the second component together at the interlocking interface. The one-step induction welding assembly configuration includes an insulating clamp made of an electrically insulating material, wherein the insulating clamp applies a clamping force to the interlocking interface between the first component and the second component, and a base plate fixing device made of an electrically insulating material, wherein the induction coil is recessed within the base plate fixing device, and the base plate fixing device remains stationary when the insulating clamp applies a clamping force to the first component and the second component.

[0022] On the other hand, the one-step induction welding assembly configuration includes a conductive plate made of a conductive material and including a planar profile defining an upper surface and a lower surface, wherein the upper surface of the conductive plate contacts a first component and a second component.

[0023] In another aspect, the conductive plate includes a length and a width that extend beyond the total length and total width of the interlocking interface that joins the first and second components together.

[0024] On one hand, the conductive plate is composed of at least one of the following materials used to provide EMI shielding: metal film, metal sheet and metal mesh material, and wherein the conductive plate is joined to the first component and the second component during one-step induction welding.

[0025] Further applications will become apparent from the description provided herein. It should be understood that these descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of the invention. Attached Figure Description

[0026] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way.

[0027] Figure 1 This is a schematic diagram of a vehicle including the disclosed battery casing according to an exemplary embodiment;

[0028] Figure 2A This is an exploded perspective view of one embodiment of a battery casing including a tray and a cooling plate according to an exemplary embodiment;

[0029] Figure 2B According to exemplary embodiments, such as Figure 2A The diagram shows a perspective view of the battery casing, in which the tray and cooling plate are joined together.

[0030] Figure 3 This is according to an exemplary embodiment. Figure 2A and Figure 2B A perspective view of the tray containing the battery casing shown;

[0031] Figure 4 According to exemplary embodiments, such as Figure 3 A schematic diagram of the thermoplastic composite laminate of the tray shown;

[0032] Figure 5 This illustrates a method for using, according to an exemplary embodiment, to... Figure 2A , Figure 2B and Figure 3 A schematic diagram of an exemplary one-step induction welding assembly configuration in which the tray of the battery casing is joined to the cooling plate.

[0033] Figure 6 This is a side view of an embodiment of an induction coil as an electromagnetic coil, according to an exemplary embodiment;

[0034] Figure 7 According to exemplary embodiments, such as Figure 1 An elevation perspective view of another embodiment of the battery casing shown;

[0035] Figure 8 This illustrates an exemplary embodiment, such as Figure 7A schematic diagram of another embodiment of a one-step induction welding assembly configuration for a battery casing is shown;

[0036] Figure 9 This is a top view illustrating a schematic diagram of another embodiment of an exemplary one-step induction welding assembly configuration for joining two coplanar components together at an interlocking interface, wherein the insulating clamps and constraint plates have been omitted.

[0037] Figure 10 According to exemplary embodiments, such as Figure 9 The diagram shows a top view of a one-step induction welding assembly configuration, including insulating clamps and constraint plates.

[0038] Figure 11 An example of an embodiment of the process is shown. Figure 10 One-step induction welding assembly configuration cut from section AA in the middle;

[0039] Figure 12 An example of an embodiment of the process is shown. Figure 10 A one-step induction welding assembly configuration with section BB cut out in the middle; and

[0040] Figure 13 An exemplary embodiment is shown. Figure 11 Details of region CC in the text. Detailed Implementation

[0041] The following description is merely exemplary in nature and is not intended to limit the invention, application, or use.

[0042] Reference Figure 1 This diagram illustrates a vehicle 10 including an exemplary battery housing 12 for powering one or more electric motors 14. It should be understood that while vehicle 10 is shown as a passenger car, it can be any other type of vehicle, such as, but not limited to, a truck, SUV, van, or motorhome. The battery housing 12 contains a battery pack 16. The battery pack 16 includes a plurality of battery modules 18 electrically connected to each other. Although in Figure 1 The vehicle 10 is described and shown, but it should be understood that the battery housing 12 is not limited to vehicles and can also be used in other applications. In fact, the battery housing 12 can be used in a variety of other electric vehicles and stationary applications.

[0043] Figure 2A yes Figure 1 An exploded perspective view of one embodiment of the battery casing 12 is shown, and Figure 2B yes Figure 2A The assembly diagram of the battery casing 12 is shown. (Refer to...) Figure 1 , Figure 2A and Figure 2BAs shown, the battery casing 12 includes a tray 30 and a cooling plate 32. The tray 30 is shaped to accommodate the battery pack 16. The tray 30 includes a base 34 and multiple sides 36, wherein the sides 36 of the tray 30 surround the battery pack 16. See details. Figure 2B Cooling plate 32 through Figure 5 The one-step induction welding assembly configuration 100 shown is connected to the base 34 of the tray 30, as described below. (Refer to...) Figure 2A and Figure 2B As shown, the cooling plate 32 defines an upper surface 38 and a lower surface 40, wherein the battery pack 16 ( Figure 1 The tray 30 is positioned against the upper surface 38 of the cooling plate 32. In the exemplary embodiment shown, both the base 34 of the tray 30 and the cooling plate 32 have rectangular outlines. However, it should be understood that FIG2 is merely exemplary in nature, and the base 34 of the tray 30 and the cooling plate 32 may also have other outlines, such as square outlines.

[0044] Figure 3 This is a cross-sectional view of the tray 30 of the battery casing 12. A plurality of cooling features 42 extend along at least a portion of the base 34 of the tray 30, wherein the cooling features 42 are configured to dissipate heat from the battery pack 16 supported by the cooling plate 32. Figure 1 As shown) sucked away (as shown) Figure 2A and Figure 2B (As shown). In the illustrated embodiment, cooling feature 42 includes a plurality of cooling channels 44. The plurality of cooling channels 44 are formed within a wall 46 positioned along the base 34 of the tray 30, wherein each cooling channel 44 is shaped to receive a cooling medium. (See reference...) Figure 2A and Figure 3 The raised surface 48 is positioned between the cooling channels 44 arranged along the base 34 of the tray 30. The raised surface 48 positioned between the plurality of cooling channels 44 is described below. Figure 5 The weld joint produced during the one-step induction welding assembly configuration 100 shown is connected to the bottom surface 40 of the cooling plate 32.

[0045] In one embodiment, the tray 30 of the battery casing 12 is made of a thermoplastic composite material comprising a fiber-reinforced material and a matrix material. In one embodiment, the fiber-reinforced material of the thermoplastic composite is a conductive material, including continuous carbon fibers, discontinuous carbon fibers, or both continuous and discontinuous carbon fibers. Other examples of conductive materials that can be used as fiber-reinforced materials include, but are not limited to, metal-coated glass fibers (e.g., copper or nickel-coated glass fibers) and conductive natural fibers. It should be understood that the tray 30 or the cooling plate 32, or both the tray 30 and the cooling plate 32, are made of conductive materials to enable induction welding. Therefore, in another embodiment, the cooling plate 32 is made of a conductive material such as metal, and the tray 30 may include conductive or non-conductive fiber-reinforced materials. When the cooling plate 32 is made of metal, the cooling plate 32 includes an electrically insulating layer to provide a connection with the battery pack 16 (e.g., ...). Figure 1 Electrical insulation (as shown). In one embodiment, the matrix material of the thermoplastic composite material includes one or more of the following: polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), perfluoroalkoxy polymer (PFA), polytetrafluoroethylene (PTFE), polyaryletherketone (PAEK), polyethylene (PE), polybutylene terephthalate (PBT), polypropylene (PP), polyamide (PA), and polyacrylonitrile (PAN).

[0046] In a non-limiting embodiment, the battery casing tray 30 is made of a thermoplastic composite laminate 50, such as... Figure 4 As shown. (Refer to...) Figure 4 The thermoplastic composite laminate 50 includes a thermal runaway propagation (TRP) protection layer 52, a thermoplastic composite layer 54, and an electromagnetic interference (EMI) shielding layer 56. The TRP protection layer 52 of the thermoplastic composite laminate 50 is made of a material that passively prevents the thermal runaway propagation of the battery pack 16 (Figure 2 and...). Figure 3 Examples of materials that provide thermal resistance include, for instance, fabrics impregnated or entirely composed of materials that provide thermal resistance, such as aluminum tetrahydrate, ammonium polyphosphate, ammonium sulfate, melamine cyanurate, sodium silicate, metal hydroxides, metal oxides (e.g., titanium dioxide), clay, calcium silicate, kaolin, and hydrated silica, as well as compounds based on phosphorus, nitrogen, antimony, boron, zinc, or halogens (e.g., bromine and chlorine). In some examples, the TRP protective layer 52 is composed of mineral or ceramic materials embedded in the resin or constructed as a rigid plate, such as a mica sheet. The TRP protective layer 52 may also be composed of an expanded material system comprising materials that generate insulating carbon (including an acid source, a carbon source, and a foaming agent). Although Figure 4A thermoplastic composite laminate 50 including a TRP protective layer 52 is shown, but in an alternative, the TRP protective material may be part of the thermoplastic composite laminate 50. The EMI shielding layer 56 is made of a material that shields the battery pack 16 from electromagnetic interference, such as a metal film, metal sheet, or metal mesh. In one embodiment, the thermoplastic composite laminate 50 may be formed by processes such as, but not limited to, compression molding, injection molding, extrusion, or pultrusion.

[0047] Thermoplastic composite layer 54 is defined facing the battery pack 16 ( Figure 1 The first inner surface 58 of the tray 30 and the second outer surface 60 facing the external environment 62 are located within the tray 30. A TRP protective layer 52 of the thermoplastic composite laminate 50 is disposed along the inner surface 58 of the thermoplastic composite layer 54, and an EMI shielding layer 56 is disposed along the outer surface 60 of the thermoplastic composite layer 54. It should be understood that both the TRP protective layer 52 and the EMI shielding layer 56 are optional layers and may be omitted in some embodiments. In embodiments, the TRP protective layer 52 and the EMI shielding layer 56 may be... Figure 5 The one-step induction welding assembly configuration 100 shown is incorporated into the thermoplastic composite layer 54.

[0048] Reference Figure 2A and Figure 2B As shown, the cooling plate 32 may be made of a thermoplastic composite material or metal. When the cooling plate 32 is made of a thermoplastic composite material, in one embodiment, the fiber reinforcement material of the thermoplastic composite material may include continuous carbon fibers, discontinuous carbon fibers, or both continuous and discontinuous carbon fibers. In another embodiment, the thermoplastic composite material may include one or more thermally conductive materials, such as, but not limited to, metal powders, carbon fillers, alumina, boron nitride, silicon carbide, aluminum nitride, boron phosphate, thermally conductive silicone compounds, and thermally conductive polymers. In one embodiment, the upper surface 38 of the cooling plate 32 includes glass fibers to provide electrical insulation. In one embodiment, the matrix material of the thermoplastic composite material includes one or more of the following: PEEK, PEKK, PAEK, PPS, PEI, PFA, PTFE, and PAN. In another embodiment, the cooling plate 32 is made of metal, such as, but not limited to, aluminum and steel. In embodiments where the cooling plate 32 is made of metal, the upper surface 38 of the cooling plate 32 is coated with an electrically insulating layer. It should be understood that when the cooling plate 32 is made of metal and coated with an electrically insulating material, or when the cooling plate 32 is made of a thermoplastic composite material, the thermal resistance of the cooling plate 32 at 65°C does not exceed 3.0 × 10⁻⁶. - 3 m 2 KW -1 .

[0049] In one embodiment, if the cooling plate 32 is made of metal or a thermoplastic composite material different from the thermoplastic composite material of the tray 30, the lower surface 40 of the cooling plate 32, the raised surface 48 disposed between the cooling channels 44 along the base 34 of the tray 30, or both, may undergo one or more surface modification treatments. In one embodiment, the surface modification treatment is a mechanical abrasion technique or a laser texturing technique, which increases the average surface roughness (Ra) value of the lower surface 40 of the cooling plate 32 and / or the raised surface 48 of the tray 30, thereby enhancing the surface roughness. Figure 5 The one-step induction welding assembly configuration 100 shown illustrates the bonding between the tray 30 and the lower surface 40 of the cooling plate 32. Therefore, it should be understood that the lower surface 40 of the cooling plate 32 has a higher average surface roughness value compared to the upper surface 38 of the cooling plate 32 (i.e., the rest of the cooling plate). Similarly, the raised surface 48 of the tray 30 has a higher average surface roughness value compared to the average surface roughness value of the rest of the tray 30.

[0050] In another embodiment, the surface modification treatment technique is plasma treatment, flame treatment, or laser cleaning treatment, which increases the surface energy of the lower surface 40 of the cooling plate 32 compared to the rest of the cooling plate 32 and / or the raised surface 48 of the tray 30 compared to the rest of the tray 30, thereby increasing the surface energy in the following ways: Figure 5 The one-step induction welding assembly configuration 100 shown enhances the bond between the tray 30 and the lower surface 40 of the cooling plate 32.

[0051] Figure 5 This shows the method for placing tray 30 with Figure 2A , Figure 2B and Figure 3 A schematic diagram of an exemplary one-step induction welding assembly configuration 100 for joining the cooling plate 32 of the battery casing 12. Specifically, refer to... Figure 3 and Figure 5 The cooling plate 32 is positioned relative to the tray 30 such that a raised surface 48 positioned between cooling channels 44 located along the base 34 of the tray 30 contacts the lower surface 40 of the cooling plate 32 at the mating interface 64. Figure 5 As shown, a plurality of induction coils 66 are positioned facing the upper surface 38 of the cooling plate 32, wherein the plurality of induction coils 66 include internal cooling features (not shown). In one example, the internal cooling features employ a coolant, such as water, flowing through each induction coil 66. The plurality of induction coils 66 are energized by a radio frequency current generated by an energy source (not shown) to generate an electromagnetic field, which generates heat and bonds the tray 30 and the cooling plate 32 together at the bonding interface 64.

[0052] Figure 6This is a schematic side view of an embodiment of an exemplary induction coil 66 as an electromagnetic coil. It should be understood that the induction coil 66 is shaped to correspond to the geometry of the surfaces joined together. In the illustrated embodiment, the induction coil 66 includes two legs 68 oriented parallel to each other.

[0053] Back Figure 5 Multiple induction coils 66 are made of a conductive material such as copper. An electrical insulating material 70 is disposed between each induction coil 66. The electrical insulating material 70 can be made of an electrical insulating material, such as glass-reinforced fiber epoxy resin laminate G-10 or glass-reinforced polyester such as GPO3. Figure 5 As shown, the conductive plate 72 is disposed between the cooling plate 32 and the electrical insulating material layer 76 of the battery casing 12, wherein the electrical insulating material layer 76 is positioned directly below the plurality of induction coils 66.

[0054] The conductive plate 72 includes an upper surface 80 and a lower surface 82. The upper surface 80 of the conductive plate 72 contacts the lower surface 86 of the electrically insulating material layer 76, and the lower surface 82 of the conductive plate 72 contacts the upper surface 38 of the cooling plate 32. In one embodiment, when the cooling plate 32 is made of a thermoplastic composite material, the conductive plate 72 is included as part of a one-step induction welding assembly 100 for securing the tray 30 to the cooling plate 32. That is, when the cooling plate 32 is made of metal, the conductive plate 72 is omitted from the one-step induction welding assembly, and the lower surface 86 of the electrically insulating material layer 76 directly contacts the upper surface 38 of the cooling plate 32. However, in some embodiments, when the cooling plate 32 is made of a thermoplastic material, the tray 30 may be secured to the cooling plate 32 without the conductive plate 72. The conductive plate 72 is made of a conductive material, such as, but not limited to, steel or aluminum. It should be understood that the specific conductive material constituting the conductive plate 72 depends on factors such as, but not limited to, thermal conductivity and electrical conductivity. It should also be understood that the size of the conductive plate 72 depends on the specific application.

[0055] The one-step induction welding assembly configuration 100 also includes applying a clamping force F to the tray 30. c Mold 88. In such Figure 5 In the example shown, the clamping force F c Oriented upward toward the tray 30. The mold 88 includes individual blocks 90, each block 90 applying a clamping force F to a raised surface 48 positioned between cooling channels 44 located along the base 34 of the tray 30. c When the tray 30 and the cooling plate 32 are joined together at the joint interface 64, multiple induction coils 66 apply a clamping force F. c Directly opposite force F o This is to keep the tray 30 and cooling plate 32 in place.

[0056] Figure 7 yes Figure 1 An elevation perspective view of another embodiment of the battery casing 12 shown. (Refer to...) Figure 1 and Figure 7 The battery casing 12 includes a tray 130 and a plurality of cross rails 132. The tray 130 is shaped to receive a battery pack 16, wherein the cross rails 132 are positioned between battery modules 18. The tray 130 includes a base 134 and a plurality of sides 136, wherein the sides 136 of the tray 130 surround the battery pack 16. The plurality of cross rails are all... Figure 8 The one-step induction welding assembly configuration 200 shown is connected to the base 134 of the tray 130, as described below.

[0057] The tray 130 of the battery casing 12 is made of a thermoplastic composite material comprising fiber reinforcement and a matrix material. In one embodiment, the fiber reinforcement of the thermoplastic composite material comprises continuous carbon fibers, discontinuous carbon fibers, or both continuous and discontinuous carbon fibers. In one embodiment, the matrix material of the thermoplastic composite material comprises one or more of the following: PEEK, PEKK, PAEK, PPS, PEI, PFA, PTFE, PA, PP, PE, PBT, and PAN. In a non-limiting embodiment, the tray 130 of the battery casing 12 is made of... Figure 4 The thermoplastic composite laminate shown is composed of [material name missing].

[0058] The multiple cross rails 132 may be made of thermoplastic composite material or metal. It should be understood that the multiple cross rails 132 include multiple internal cooling channels (not shown in the figure), which connect to the battery pack 16 (…). Figure 1 The battery module 18 (shown in the diagram) absorbs heat. When the plurality of cross rails 132 are made of a thermoplastic composite material, the fiber reinforcement material of the thermoplastic composite material may include continuous carbon fibers, discontinuous carbon fibers, or both continuous and discontinuous carbon fibers. In one embodiment, the matrix material of the thermoplastic composite material includes one or more of the following: PEEK, PEKK, PAEK, PPS, PEI, PFA, PTFE, PA, PP, PE, PBT, and PAN. In another embodiment, the plurality of cross rails 132 are made of metal, such as, but not limited to, aluminum and steel.

[0059] Reference Figure 7 and Figure 8 Each of the plurality of transverse rails 132 includes a flange 140, the flange 140 being through Figure 8 The one-step induction welding assembly configuration 200 shown is attached to the bottom surface 138 of the base 134 of the tray 130. Specifically, as Figure 8As shown, the flange 140 of each cross rail 132 defines a lower surface 146, wherein the lower surface 146 of the flange 140 of the cross rail 132 is engaged to the bottom surface 138 of the tray 130 at the engagement interface 164.

[0060] In one embodiment, if the crossrail 132 is made of metal or a different thermoplastic composite material compared to the thermoplastic composite material of the tray 130, the lower surface 146 of each crossrail 132, the bottom surface 138 of the base 134 of the tray 130, or both, may undergo one or more surface modification treatments. In one embodiment, the surface modification treatment is a mechanical abrasion technique or a laser texturing technique, which increases the average surface roughness (Ra) value of the lower surface 146 of each crossrail 132 and / or the bottom surface 138 of the tray 130, thereby enhancing the surface roughness. Figure 8 The one-step induction welding assembly configuration 100 shown depicts the bonding between the bottom surface 138 of the tray 130 and the lower surface 146 of the cross rail 132. Therefore, it should be understood that when bonding with the remaining outer surfaces 150 of each cross rail 132... Figure 8 Compared to the average surface roughness value of the tray 130, the lower surface 146 of each cross rail 132 has a higher average surface roughness value. Similarly, the bottom surface 138 of the base 134 of the tray 130 has a higher average surface roughness value when compared to the rest of the tray 130.

[0061] In another embodiment, the surface modification treatment technique is plasma treatment, flame treatment, or laser cleaning treatment, which increases the surface energy of the lower surface 146 of each rail 132 and / or the bottom surface 138 of the tray 130, thereby enhancing the surface energy of the rails. Figure 8 The one-step induction welding assembly configuration shown illustrates the connection between the bottom surface 138 of the tray 130 and the lower surface 146 of the cross rail 132.

[0062] Figure 8 This shows the method for placing tray 130 with Figure 7 This is a schematic diagram of an exemplary one-step induction welding assembly configuration 200 where one of the plurality of cross rails 132 of the battery housing 12 is joined. A plurality of induction coils 166 are located on the same side as the outer surface 148 of the tray 130. The plurality of induction coils 166 are energized by radio frequency current to generate an electromagnetic field, which generates heat and joins the tray 130 and the cross rails 132 together at the joining interface 164.

[0063] An electrical insulating layer 176 is located directly beneath the plurality of induction coils 166. For example... Figure 8As shown, a conductive plate 172 is disposed between the base 134 of the tray 130 of the battery casing 12 and the electrically insulating material layer 176. The conductive plate 172 includes an upper surface 180 and a lower surface 182. The upper surface 180 of the conductive plate 172 contacts the outer surface 148 of the base 134 of the tray 130, and the lower surface 182 of the conductive plate 172 contacts the upper surface 186 of the electrically insulating material layer 176. Figure 5 Similarly, in the illustrated embodiments, when the cross rail 132 is made of a thermoplastic composite material, the conductive plate 172 is included as part of the one-step induction welding assembly configuration 200 for securing the tray 130 to the cross rail 132. That is, when the cross rail 132 is made of metal, the conductive plate 172 is omitted from the one-step induction welding assembly configuration, and the upper surface 186 of the electrically insulating material layer 76 directly contacts the outer surface 148 of the base 134 of the tray 130. However, in some embodiments, when the cross rail 132 is made of a thermoplastic material, the tray 130 can be secured to the cross rail 132 without the conductive plate 172.

[0064] The one-step induction welding assembly configuration 200 also includes applying a clamping force F to the flange 140 of the cross rail 132. c Mold 188. In such Figure 8 In the example shown, the clamping force F c Oriented downward toward the transverse rail 132, and the mold 188 includes individual blocks 190, each block 190 applying a clamping force F to the left and right sides 192 of the flange 140. c When the tray 130 and the cross rail 132 are engaged at the engagement interface 164, multiple induction coils 166 apply a clamping force F. c Directly opposite force F o This is to keep the tray 130 and the cross rail 132 in place.

[0065] Reference Figure 5 and Figure 8 It should be understood that Figure 5 The one-step induction welding assembly configuration 100 shown is... Figure 8 The one-step induction welding assembly configuration 200 shown connects trays 30 and 130 to the cooling component, wherein the cooling component is... Figure 5 The cooling plate 32 shown or Figure 8 The horizontal rail 132 is shown. It should be understood that the cooling components may be made of metal or thermoplastic composite materials.

[0066] Figure 9This is a top view of another embodiment of a one-step welded assembly configuration 300 for joining the first component 302 and the second component 304 together. It should be understood that the first component 302 and the second component 304 are positioned coplanarly relative to each other, wherein components 302 and 304 each comprise approximately the same thickness. Figure 9 As shown, the first component 302 and the second component 304 are joined together at the interlocking engagement interface 306, wherein the mating edge 308 of the first component 302 and the mating edge 309 of the second component 304 include complementary interlocking profiles corresponding to each other.

[0067] In such Figure 9 In the exemplary embodiment shown, the interlocking engagement interface 306 includes a trapezoidal profile; however, it should be understood that the interlocking engagement interface 306 is not limited to the trapezoidal profile shown. In practice, the interlocking engagement interface 306 can be any other type of joint including an interlocking profile, such as, but not limited to, a dovetail profile. The first component 302 and the second component 304 can be, for example, as... Figure 1 The base of the tray of a portion of the battery casing 12 shown.

[0068] Both the first component 302 and the second component 304 are made of a thermoplastic composite material. In one embodiment, the thermoplastic composite material includes a fiber reinforcement material and a matrix material. In one embodiment, the fiber reinforcement material of the thermoplastic composite material is conductive. For example, the thermoplastic composite material may include continuous carbon fibers, discontinuous carbon fibers, both continuous and discontinuous carbon fibers, or metal-coated glass fibers to facilitate induction heating. In another embodiment, the fiber reinforcement material is made of a non-conductive material (e.g., glass fibers). In yet another embodiment, the thermoplastic composite material does not include a fiber reinforcement material.

[0069] It should be understood that, Figure 9 This is a diagram of a one-step welding assembly configuration 300, in which the insulating clamp 310 and the constraint plate 312 ( Figure 10 (As shown) has been omitted to expose the interlocking interface 306 between the first component 302 and the second component 304. Figure 10 This is a top view of the one-step welding assembly structure 300. Figure 11 It is along Figure 10 It was cut from section AA in the middle. Figure 12 It is along Figure 10 The section BB in the middle is cut off. Figure 13 yes Figure 11 Details of region CC in the text.

[0070] Reference Figure 9 , Figure 10 and Figure 13The one-step welding assembly configuration 300 includes an insulating clamp 310, a constraint plate 312, a first component 302 and a second component 304, a conductive plate 314, an insulating sheet 316, and an induction coil 318 embedded in a base plate fixing device 320. In the embodiment shown, the first component 302 and the second component 304 are held in the appropriate position between the constraint plate 312 and the conductive plate 314, and a clamping force F is applied to the first component 302 and the second component 304 by the insulating clamp 310. c ( Figure 10 In one embodiment, the conductive plate 314 may be omitted, and the first component 302 and the second component 304 are held in the proper position between the constraint plate 312 and the insulating sheet 316.

[0071] The insulating clamp 310 is made of an electrically insulating material, such as, but not limited to, glass-reinforced epoxy resin G-10. (See reference...) Figure 9 , Figure 10 , Figure 12 and Figure 13 The insulating clamp 310 includes an elongated rectangular profile defining an upper surface 322 and a lower surface 324, wherein the lower surface 324 of the insulating clamp 310 contacts the upper surface 326 of the constraint plate 312. See details. Figure 9 and Figure 10 The insulating clamp 310 is positioned to align with the interlocking engagement interface 306 between the first component 302 and the second component 304 and applies a clamping force F thereon. c (like Figure 9 (As shown). Specifically, the insulating clamp 310 is positioned against the upper surface 326 of the constraint plate 312, such that the insulating clamp 310 extends along the total width W2 of the interlocking interface 306.

[0072] The constraint plate 312 includes a planar profile comprising an upper surface 326 and a lower surface 328. The lower surface 328 of the constraint plate 312 represents a clamping force F for applying clamping force F to the first component 302 and the second component 304. c The horizontal surface. The constraint plate 312 is made of an insulating material, such as glass fiber reinforced epoxy resin G-10. In embodiments, the constraint plate 312 may also be made of a metal such as aluminum or steel.

[0073] Reference Figure 13 The conductive plate 314 includes a planar profile defining an upper surface 330 and a lower surface 332, wherein the upper surface of the conductive plate 314 contacts the first component 302 and the second component 304. The conductive plate 314 is made of a conductive material that is heated during induction welding, such as, but not limited to, steel or aluminum. It should be understood that heating of the conductive plate 314 facilitates the bonding of the first component 302 and the second component 304 together at the bonding interface 306. Figure 9In one embodiment, the conductive plate 314 is made of at least one of the following materials used to provide EMI shielding: a metal film, a metal sheet, or a metal mesh material, and the conductive plate 314 is joined to the first component 302 and the second component 304 during a one-step induction welding process. In embodiments where the first component 302 and the second component 304 are made of a thermoplastic material including conductive fiber reinforcement, the conductive plate 314 is optional and may be omitted. However, if the first component 302 and the second component 304 are made of a thermoplastic material including non-conductive fiber reinforcement or no fiber reinforcement at all, the conductive plate 314 is required.

[0074] It should be understood that the specific conductive material constituting the conductive plate 314 depends on factors such as, but not limited to, thermal conductivity and electrical conductivity. See details [link to relevant documentation]. Figure 9 It should be understood that, in one embodiment, the conductive plate 314 includes a length L1 and a width W1 that extend beyond the total length L2 and total width W2 of the interlocking engagement interface 306 that joins the first component 302 and the first component 304 together.

[0075] Specific reference Figure 13 The insulating sheet 316 includes a planar profile defining an upper surface 334 and a lower surface 336, wherein the upper surface 334 of the insulating sheet 316 contacts the lower surface 332 of the conductive plate 314, and the lower surface 336 of the insulating sheet 316 abuts against the base plate fixing device 320. If the conductive plate 314 is omitted, the upper surface 334 of the insulating sheet 316 contacts the first component 302 and the second component 304. The insulating sheet 316 is made of an electrically insulating material. The insulating sheet 316 is provided to electrically isolate the induction coil 318 from the first component 302, the second component 304, and the conductive plate 314.

[0076] The induction coil 318 is recessed within the base plate fixing device 320. The base plate fixing device 320 includes a defining upper surface 338 (e.g., Figure 9 and Figure 10 The planar profile of the lower surface 340 (as shown) is such that, when viewed along the upper surface 338 of the base plate fixing device 320, the outer surface 344 of the induction coil 318 is exposed. The base plate fixing device 320 is made of an electrically insulating material, such as glass-reinforced epoxy resin G-10. It should be understood that when the insulating clamp 310 applies a clamping force F to the first component 302 and the second component 304... c ( Figure 10 When the base plate fixing device 320 remains stationary.

[0077] In such Figure 9 , Figure 10 and Figure 13In the illustrated embodiment, the induction coil 318 includes two legs 346 oriented parallel to each other. When energized by a radio frequency current generated by an energy source (not shown), the induction coil 318 generates an electromagnetic field that produces heat and joins the first component 302 and the second component 304 together at the interlocking interface 306, while an insulating clamping force F is applied to the first component 302 and the second component 304 by the insulating clamp 310. c ( Figure 10 ).

[0078] Referring generally to the accompanying drawings, embodiments of the disclosed one-step induction welding assembly configuration offer various technical effects and benefits. Specifically, the one-step induction welding assembly configuration provides a method for joining thermoplastic components, or thermoplastic components that are part of a battery casing, and metal components as part of a one-step process. The disclosed method also describes surface treatments that enhance the bonding between components, eliminating the need for an adhesive layer between the components. Eliminating adhesive between components reduces assembly packaging space and improves the ability to recover and recycle materials from the battery casing.

[0079] The description of this invention is merely exemplary in nature, and variations that do not depart from the spirit of the invention are intended to fall within its scope. These variations should not be considered as departing from the spirit and scope of the invention.

Claims

1. A one-step induction welding assembly configuration for a battery casing, the one-step induction welding assembly configuration comprising: A tray, the tray being made of a thermoplastic composite material, wherein the tray is part of the battery casing; A cooling plate, the cooling plate being composed of one of the following: a thermoplastic composite material and a metal, wherein the cooling plate is joined to the tray at a joint interface, and wherein the cooling plate is part of the battery casing; Multiple induction coils are energized to generate an electromagnetic field, which generates heat and bonds the tray and the cooling plate together at the bonding interface. An electrically insulating material layer is disposed directly beneath the plurality of induction coils; and A mold applies a clamping force to a tray of the battery casing, wherein the plurality of induction coils apply a force directly opposite to the clamping force to hold the tray and the cooling plate in place.

2. The one-step induction welding assembly configuration according to claim 1, wherein, The cooling plate is made of the thermoplastic composite material.

3. The one-step induction welding assembly configuration according to claim 2, comprising a conductive plate, the conductive plate comprising an upper surface and a lower surface, wherein, The upper surface of the conductive plate contacts the lower surface of the electrically insulating material layer, and the lower surface of the conductive plate contacts the upper surface of the cooling plate.

4. The one-step induction welding assembly configuration according to claim 1, wherein, The thermal resistance of the cooling plate does not exceed 3.0 × 10⁻⁶ at 65°C. -3 m 2 KW -1 .

5. The one-step induction welding assembly configuration according to claim 1, wherein, The cooling plate is made of metal.

6. The one-step induction welding assembly configuration according to claim 5, wherein, The lower surface of the electrical insulating material layer contacts the upper surface of the cooling plate.

7. The one-step induction welding assembly configuration according to claim 1, wherein, The tray includes a base, and wherein a plurality of cooling features extend along at least a portion of the base.

8. The one-step induction welding assembly configuration according to claim 7, wherein, The plurality of cooling features include a plurality of cooling channels, wherein each cooling channel is shaped to receive a cooling medium.

9. The one-step induction welding assembly configuration according to claim 8, wherein, The raised surface is positioned between multiple cooling channels arranged along the base of the tray.

10. The one-step induction welding assembly configuration according to claim 9, wherein, A raised surface positioned between a plurality of cooling channels located along the base of the tray contacts the lower surface of the cooling plate at the joint interface.

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