Weld joint geometry and control

Abstract

An apparatus is described. The apparatus includes a first part, a second part, and a third part. The second part has a first interlocking region, and the third part has a second interlocking region. The first interlocking region is mated to the second interlocking region to couple the second part the third part. The apparatus also includes a weld joint that couples the first part, the second part and the third part together.

Description

[0001] WELD JOINT GEOMETRY AND CONTROL

[0002] TECHNICAL FIELD

[0003] This disclosure relates joint welding and in particular to a method and system for polymer joint welding and associated geometries for the welds.

[0004] BACKGROUND

[0005] Welding such as plastic welding by heating of parts is typically used to join a pair of straight walls, such as walls made out of a polymer, e.g., plastic. An example of such a welding process is shown in FIG. 1, where a first part and a second part are welded via a weld joint. The IR weld joint is formed by heating up the joining ends of the parts to melt the ends, and then the parts are pushed together to form a hermetically sealed joint which can also withstand various loading conditions while maintaining the union. While such a process may be suitable for joining two parts, the operation becomes much more complex and time consuming when more than two part need to be joined together. For example, welding a third part to two already joined parts can result in unintended and undesirable separation of the originally joined two parts. Also, adding the third part during the IR weld joining operation when welding all three parts at one time can, as shown in FIG. 2, result in excess melted material that is under pressure flowing into the gap between the original two parts, which reduces the overlap area of the joint, separates the two lower parts and thereby reduces the strength of the weld.

[0006] FIG. 3 shows an example of a three part IR weld in which the first, second, and third parts are made of polyamide 12 (PA 12) (which may be referred to as Nylon 12) material in which the part edges are straight and the IR weld is made using known techniques. FIG. 4 shows an example of a three part IR weld in which the first, second, and third parts are made of a glass fiber reinforced polyamide 6 (PA6 GF20) material in which the part edges are straight, and the IR weld is made using known techniques. As can be seen in both FIGS. 3 and 4, the welding of these different materials using known techniques results in separation, e.g., a gap, between the second part and third part. FIG. 5 is a graph showing weld joint strength of IR welds among samples of PA 12 material. FIG. 6 is a graph showing weld joint strength of IR welds among samples of PA6 GF20 material. As can be seen, the yield stress among samples is not consistent. Thus, the strength of welds using these materials and known techniques is not likely to be consistent when deployed in the field on fabricated products. SUMMARY

[0007] This disclosure provides methods and arrangements for using welding, such as IR welding, heat platens (referred to herein as heat platen welding for ease of understanding) or other welding techniques where parts (such as polymer parts) are heated to the melting point temperature at the joining interfaces, and pressed together to create fused joints parts that join more than two parts together, e.g., an upper wall and a pair of lower walls that are lined up with a predetermined gap (e.g., a minimum gap) in between. The method and arrangements allow the aforementioned joining of the three parts in one operation, while utilizing a predetermined available space, as well as maintaining the joint strength, e.g., at or above a predetermined threshold. Furthermore, separation of the lower two parts during the welding process is avoided.

[0008] In brief, aspects of the disclosure may provide one or more of the following benefits:

[0009] 1. Simplifying the joining operation of the parts compared to joining one part at a time, which thereby improve process efficiency as compared with other arrangements;

[0010] 2. Utilizing the available space needed to make the joint; and

[0011] 3. Improving the overall strength of the assembly of parts compared to two separate joints to join the three parts, which may require additional structural support to achieve equivalent strength.

[0012] According to one aspect, an apparatus is described. The apparatus includes a first part, a second part, and a third part. The second part has a first interlocking region, and the third part has a second interlocking region. The first interlocking region is mated to the second interlocking region to couple the second part the third part. The apparatus also includes a weld joint that couples the first part, the second part and the third part together.

[0013] According to another aspect, an apparatus is described. The apparatus includes a first part, a second part, a third part, and a weld. The second part has a first geometry, and the third part has a second geometry. The first geometry and the second geometry are arranged to create a flow zone when the second part is adjacent and in contact with the third part. The weld joint couples the first part, the second part and the third part together, where the weld joint includes weld joint material. The flow zone is arranged to allow weld joint material to flow into the flow zone when the weld joint is formed.

[0014] According to one aspect, a battery case is described. The battery case includes a cover, a housing, a cell carrier, and a weld joint. The housing has a first interlocking region, and the cell carrier has a second interlocking region. The first interlocking region is mated to the second interlocking region to couple the cell carrier to the housing. The weld joint couples the cover, the housing, and the cell carrier together.

[0015] According to another aspect, a battery case is described. The battery case includes a top cover, a cell carrier, a housing, and a weld joint. The cell carrier has a first geometry, and the housing has a second geometry. The first geometry and the second geometry are arranged to create a flow zone when the cell carrier is adjacent and in contact with the housing. The weld joint couples the top cover, the cell carrier and the housing together. The weld joint includes weld joint material, and the flow zone is arranged to allow the weld joint material to flow into the flow zone when the weld joint is formed.

[0016] According to one aspect, a battery case is described. The battery includes a cover, a housing, a cell carrier, and a well joint. The housing has a first interlocking region, and the cell carrier has a second interlocking region. The first interlocking region is mated to the second interlocking region to couple the cell carrier to the housing. The weld joint couples the cover, the housing, and the cell carrier together.

[0017] According to another aspect, a battery case is described. The battery cases includes a top cover, a cell carrier, a housing, and a weld joint. The cell carrier has a first geometry. The housing has a second geometry. The first geometry and the second geometry are arranged to create a flow zone when the cell carrier is adjacent and in contact with the housing. The weld joint couples the top cover, the cell carrier and the housing together. The weld joint includes weld joint material, and the flow zone is arranged to allow the weld joint material to flow into the flow zone when the weld joint is formed.

[0018] According to one aspect, a method for joining at least a first part, a second part, and a third part. The first part has a first part weld region, the second part has a first interlocking region and a second part weld region, and the third part has a second interlocking region and a third part weld region. The method includes coupling the second part to the third part at their respective first interlocking region and second interlocking region, placing the first part on the second part and the third part, and welding the first part to the second part and the third part at the first part weld region, the second part weld region and the third part weld region.

[0019] According to another aspect, a method for joining at least a first part having a first part weld region, a second part having a first geometry and a third part having a second geometry is described. The method includes placing the second part adjacent and in contact with third part. The first geometry and the second geometry create a flow zone when the second part is adjacent and in contact with the third part. The method also includes welding the first part, the second part and the third part together. The welding produces weld joint material, the flow zone arranged to allow the weld joint material to flow into the flow zone when the welding is performed.

[0020] According to one aspect, an apparatus is described. The apparatus includes a first part, a second part, a third part, and a weld joint. The second part has a first interlocking region and a first geometry, and the third part has a second interlocking region and a second geometry. The first interlocking region is mated to the second interlocking region to couple the second part the third part and to create a flow zone. The weld joint couples the first part, the second part and the third part together. The weld joint includes weld joint material, and the flow zone is arranged to allow the weld joint material to flow into a flow zone when the weld joint is formed.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0023] FIG. 1 is a diagram showing an example weld of two parts;

[0024] FIG. 2 is a diagram showing an example weld of three parts where the bottom walls separate during welding;

[0025] FIG. 3 is an illustration showing an example three part weld using PA 12 (Nylon) material;

[0026] FIG. 4 is an illustration showing an example three part weld using PA6 GF20 (polyamide 6) material;

[0027] FIG. 5 is a graph showing weld joint strength of welds among samples of PA 12 material;

[0028] FIG. 6 is a graph showing weld joint strength of welds among samples of PA6 GF20 material;

[0029] FIG. 7 is a block diagram showing a view of an example weld joint geometry suitable for a three part weld in accordance with the principles of the present disclosure;

[0030] FIG. 8 is a block diagram showing another view of the example weld joint geometry suitable for a three part weld in accordance with the principles of the present disclosure;

[0031] FIG. 9 is a block diagram showing a view of another example weld joint geometry in accordance with the principles of the present disclosure; FIG. 10 is a block diagram showing another view of the other example weld joint geometry in accordance with the principles of the present disclosure;

[0032] FIG. 11 is a block diagram showing a view of an example weld geometry in accordance with the principles of the present disclosure;

[0033] FIG. 12 is a block diagram showing another view of the example weld geometry in accordance with the principles of the present disclosure;

[0034] FIG. 13 is a block diagram showing a view of another example weld geometry in accordance with the principles of the present disclosure;

[0035] FIG. 14 is a block diagram showing another view of the other example weld geometry in accordance with the principles of the present disclosure;

[0036] FIG. 15 is a block diagram showing a view of an example weld geometry in accordance with the principles of the present disclosure;

[0037] FIG. 16 is a block diagram showing another view of the example weld geometry in accordance with the principles of the present disclosure;

[0038] FIG. 17 is a block diagram showing another embodiment of a three part weld in accordance with the principles of the present disclosure;

[0039] FIG. 18 is a block diagram showing another embodiment of a three part weld in accordance with the principles of the present disclosure;

[0040] FIG. 19 is a block diagram showing another embodiment of a three part weld in accordance with the principles of the present disclosure;

[0041] FIG. 20 shows an example three part assembly including a weld joint in accordance with the principles of the present disclosure;

[0042] FIG. 21 is an exploded view of an example battery case that can be assembled with joint welds in accordance with the principles of the present disclosure;

[0043] FIG. 22 is a top view of the battery case of FIG. 21 ;

[0044] FIG. 23 is a diagram an exploded section side view of the battery case of FIG. 21;

[0045] FIG. 24 is a diagram of an embodiment of an exploded view of the parts of FIG. 21;

[0046] FIG. 25 is a diagram of an example embodiment of an exploded section side view of a battery case showing the weld joint in relation to a housing, a steel plate, a cell carrier and a top cover;

[0047] FIG. 26 is a diagram of another example embodiment of an exploded section side view of a battery case showing the weld joint in relation to the housing, the steel plate, the cell carrier and the top cover; FIG. 27 is a flowchart of an example method in accordance with the principles of the present disclosure; and

[0048] FIG. 28 is a flowchart of another example method in accordance with the principles of the present disclosure.

[0049] DETAILED DESCRIPTION

[0050] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to a weld joint geometry that welds more than two parts together. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0051] As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and / or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0052] In some embodiments, the term “weld” or “welding” is used and may refer to joining two or more parts together. For example, welding may refer to using heating and / or melting of parts (e.g., plastic parts) to join the parts or couple the parts to each other. The welding may include infrared (IR) welding. However, the embodiments of the present disclosure are not limited to IR welding, and any other type of welding such as hot air and hot plate welding may be used.

[0053] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0054] In embodiments described herein, the joining term, “in communication with” and the like, may be used to indicate electrical or data communication, which may be accomplished by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling or optical signaling, for example. One having ordinary skill in the art will appreciate that multiple components may interoperate, and modifications and variations are possible of achieving the electrical and data communication.

[0055] Referring again to the drawing figures where like reference designators refer to like elements, there is shown in FIGS. 7 and 8 two views (e.g., top view and side view, respectively) of an example weld geometry suitable for use in a three part weld in which the weld is accomplished without gaps or separation among the parts. As used herein, the term “weld” can be any suitable weld for joining polymer parts, including but not limited to IR welding, heat platen welding and the like. Heat platen welding refers to welding using hot melt plate(s), which heat up the part surface via. physical contact. IR welding refers to the use of infrared energy to melt the part surfaces.

[0056] As shown in FIG. 7, parts 2 and 3 may include one or more interlock elements 4A and one or more interlock elements 4B, respectively. Interlock elements 4A, 4B may be complimentary dovetail joints (or other interlocking patterns) that can hold parts 2 and 3 together during the welding operation with part 1 (not shown). The interlocking pattern region is shown as region 10 in FIGS. 7 and 8. Each one of parts 2 and 3 may have its own corresponding interlocking region 10 (or portion thereof) which may be arranged to mate to the complementary interlocking region 10 (or portion thereof) of the other part 2, 3. In some embodiments, the portion of interlocking region 10 on any one of parts 2, 3 may be referred to interlocking region 10 of that part 2, 3. Although FIG. 7 shows a dovetail joint, it is understood that other interlocking arrangements in which two parts can be slid together and interlocked can be used. For example, the weld geometry of FIGS. 9 and 10, uses an overhang, i.e., interlocking tooth, geometry in which part 2 and part 3 are interlocked together via interlock elements 4A, 4B before the weld with part 1 (not shown). In some embodiments, part 1 may be referred to a first part, part 2 may be referred to as a second part, and part 3 may be referred to as a third part. When the three part weld is made, the downward pressure on parts 2 and 3 placed on these parts by part 1 keeps parts 2 and 3 together and from separating. In some embodiments, the interlocking geometry of FIGS. 9 and 10 is less complex than that of the geometry shown in FIGS. 7 and 8.

[0057] Weld geometries, regions and zones are not limited to arrangements where parts 2 and 3 interlock in some fashion. It is also contemplated that parts 2 and / or 3 and / or 1 can have geometries that allow the weld material to flow in a manner that does not force parts 2 and 3 apart. FIGS. 11 and 12 show such different views (e.g., top view and side view, respectively) of an example arrangement. As shown in FIGS. 11 and 12, parts 2 and 3 have respective geometries that are notched at their upper areas (adjacent to where part 1 (not shown) is to be welded). More specifically, one or more notches 5 form a flow zone 11 in the form of a channel (e.g., a trough) where the melted weld material can flow without forcing parts 2 and 3 apart. Although FIGS. 11 and 12 show a channel with orthogonally arranged walls 6A and wall 6B (bottom), it is understood that other shapes can be used. For example, the lower comers of the notches in parts 2 and 3 can be rounded to form a trough-like rounded channel.

[0058] Although FIGS. 11 and 12 show flow zone 11 formed as a contiguous channel across the entireties of the upper surfaces of parts 2 and 3, the channel need not be contiguous. FIGS. 13 and 14 show different views (e.g., top view and side view, respectively) of another example weld geometry in which the geometries of parts 2 and 3 are arranged such that flow zone 11 is formed as a series of discontiguous notches 5 (e.g., channels) thus creating a series of pockets into which the melted weld material can flow without causing parts 2 and 3 to separate. The bridged areas 7 (where parts 2 and 3 directly contact) provide the discontinuities in the channel forming flow zone 11 but add joint strength as compared to the embodiment of FIG. 9. The size of the pockets, e.g., length and interval, can be arranged to balance gap control between parts 2 and 3 with joint strength.

[0059] FIGS. 15 and 16 show different views (e.g., top view and side view, respectively) of another example weld geometry that can be used to support three part welds. In the embodiment of FIGS. 15 and 16, the geometries of parts 2 and 3 are such that flow zone 11 is formed as a triangular notch 5 (e.g., a V-notch, a triangular trough, etc.) between parts 2 and 3. The notch 5 can be formed by eliminating the upper comers of parts 2 and 3 at their junction point. This size of flow zone 11 can be arranged so that the melted weld material occupies the flow zone 11 but does not create unnecessary unused flow zone 11 channel volume. The weld geometry of FIGS. 15 and 16 allows for a greater surface area contact at the sidewall junction 8 of parts 2 and 3, as compared with the flow zone 11 channel of FIGS. 11 and 12. This is due to the inward and downward nature of the flow zone 11 walls as compared with the orthogonal arrangement in FIGS. 11 and 12. In one embodiment, e.g., an embodiment in which parts 2 and 3 are battery housing parts, flow zone 11 can, for example, be 1.0mm deep. However, the depth of the flow zone 11 is not limited as such and can be any other depth value.

[0060] FIG. 17 is a diagram of another example weld geometry that can be used to support three part welds. The geometries of parts 2 and 3 in FIG. 17 may be the same as those in FIGS. 15 and 16. In the embodiment of FIG. 17, the geometry of the surface 9A of part 1 that mates with surface 9B and 9C of parts 2 and 3 is arranged with a triangular notch 5 (e.g., V-shaped trough) corresponding to flow zone 11. Each one of surfaces 9A, 9B, 9C may be referred to as a weld region. The arrangement provides additional room for the melted weld material to flow into as compared with the geometry of FIG. 11 , but still maintains the surface area point of contact between parts 2 and 3 as is shown in FIGS. 15 and 16.

[0061] FIG. 18 is a diagram of still another example weld geometry that can be used to support three part welds. As shown in FIG. 18, part 1 has a concave and / or slanted shape on the surface 9 A where part 1 will be welded to surfaces 9B, 9C of parts 2 and 3, respectively. In complimentary fashion, the sides of parts 2 and 3 that will be welded to part 1 have a convex / slanted shape. The use of the downward and outward slanted welding side (or concave shape) of part 1 forces parts 2 and 3 together during the weld operation when the downward force is applied to part 1. Of note, the convex / concave / slanted shape geometry can optionally be combined with other geometries (e.g., those shown in FIGS. 7-17), such as to improve overall control to minimize the wall separation and achieve process consistency and joint strength as compared with straight edged mating surfaces. In other words, although FIG. 18 shows flow zone 11 as having a particular geometry, other geometries, e.g., flow zone 11 shapes, interlocking arrangements, etc., can be used.

[0062] FIG. 19 is a yet another example weld geometry that can be used to support three part welds. The arrangement of the parts in FIG. 19 is similar to that in FIG. 18 with the exception that the geometries of parts 1 , 2 and 3 do not include any accommodation for flow zone 11.

[0063] FIG. 20 shows an example embodiment of a three part assembly including parts 1 , 2, and 3 after welding. Once welding is performed, part 1 is joint to parts 2 and 3 via weld joint 12. FIG. 20 also shows an example interlocking region 10 and example flow zone 11. Of note, although FIG. 20 includes both interlocking region 10 and flow zone 20, implementations do not require both. It is contemplated that embodiments can include one or both of interlocking regions 10 and flow zone 20. The welded parts 1, 2, 3 may correspond to parts 1, 2, 3 of any of FIGS. 7-19.

[0064] FIG. 21 shows an exploded view of a battery (without the actual battery cells, conductors, etc.) case 14 that can be assembled with joint welds in accordance with the principles of the present disclosure, e.g., IR welding, heat platen welding, or other polymer welding technique. Battery case 14 can include housing 16, plate 18, cell carrier 20 and cover 22. As is shown in this example embodiment, cell carrier 20 which can be used to house the actual battery cells (not shown) can be placed into plate 18 (e.g., optional steel / metal plate) which in turn can be placed inside housing 16. Cover 22 can be sealed to housing 16 and cell carrier 20 using a weld as discussed herein. In such an arrangement, the inner mating area at the top periphery of housing 16 and the outer mating area at the top periphery of cell carrier 20 can include the interlocking region 10, e.g., dovetail joint, discussed above with respect to FIGS. 7 and 8 or the interlocking teeth arrangement discussed above with respect to FIGS. 9 and 10. FIG. 22 is a view (e.g., top view) of the battery case 14 of FIG. 21, shown with housing 16, plate 18 (not visible in FIG. 22), cell carrier 20 assembled, but without cover 22. Interlocking region 10 and flow zone 11 are shown in FIG. 22 only along a portion of the periphery 24 for ease of understanding, but it is understood that interlocking region 10 and / or flow zone 11 can be formed along the entire periphery 24 of the mating surface of housing 16 and cell carrier 20, a longer portion of the periphery 24 than is shown or along multiple discontiguous portions of the periphery 24. It is also understood that flow zone 11 can be used with or without interlocking region 10.

[0065] FIG. 23 is a diagram of an example of an exploded section side view of battery case 14 showing weld joint 26 in relation to housing 16, plate 18, cell carrier 20 and cover 22. As is shown, the use of interlocking region 10 allows keeping the edge between housing 16 and cell carrier 20 straight and without separation. Interlocking region 10 as shown may include features such as interlocking elements 4A, 4B, of any of the embodiments described herein and / or shown in any one of FIGS. 7-10 (and / or any other figures). In some embodiments, housing 16 includes housing weld region 16a along the top periphery of the housing 16, cell carrier 20 includes cell carrier weld region 20a along the top periphery of the cell carrier 20, and cover 22 includes cover weld region 22a along the bottom periphery of the cover 22. FIG. 24 is a diagram of an embodiment of an exploded view of the parts of FIG. 23. As is seen the outer edge of the periphery of cell carrier 20 includes the interlocking features for mating with the inner periphery of the housing 16. Although not shown this way in FIG. 24, the interlocking features can be any of the features described herein, e.g., a dovetail joint.

[0066] In some embodiments, cover 22 may refer to a first part 1, housing 16 may refer to a second part 2, and carrier 20 may refer to a third part 3. In some other embodiments, housing 16 includes interlocking region 32 which may be arranged to interlock, mate, or couple to interlocking region 34 of carrier 20. The interlocking regions 32, 34 may include or refer to interlocking region 10 and / or interlocking elements 4A, 4B as described herein.

[0067] FIGS. 25 and 26 are diagrams of example embodiments of exploded section side view of battery case 14 showing weld joint 26 in relation to housing 16, plate 18, cell carrier 20 and cover 22. As is shown, the use of interlocking region 10 allows keeping the edge between housing 16 and cell carrier 20 straight and without separation. The embodiment of FIG. 25 includes a slotted gap 28 formed by the cover 22, cell carrier 20 and housing 16. The embodiment of FIG. 26 includes a rhombus-like shaped gap 30, e.g., to form flow zone 11 such as is shown in FIGS. 17 and 18, formed by the cover 22, cell carrier 20 and housing 16. Gaps 28 and 30 can be used, for example, to provide an area for the melted joint material to flow when the weld is made. In some embodiments, at least a portion of flow zone 11 is filled with the melted joint material (e.g., which may solidify) to form the weld described herein.

[0068] In some embodiments, a method for joining at least a first part, e.g., cover 22, having a first part weld region, e.g., top cover weld region 22a, a second part, e.g., housing 16, having a first interlocking region 32 and a second part weld region, e.g., housing weld region 16a, and a third part, e.g., cell carrier 20, having a second interlocking region 34 and a third part weld region, e.g., cell carrier weld region 20a, is provided. The method includes coupling the second part to the third part at their respective first interlocking region 32 and second interlocking region 34, placing the first part on the second and third parts, and welding the first part to the second part and the third part at the first weld region, the second weld region and the third weld region.

[0069] In some embodiments, a method for joining at least a first part, e.g., cover 22, having a weld region, a second part, e.g., housing 16, having a first geometry and a third part, e.g., cell carrier 20, having a second geometry, is provided. The method includes placing the second part adjacent and in contact with third part. The first geometry and the second geometry are arranged to create a flow zone when the second part is adjacent and in contact with the third part, and welding the first part, the second part and the third part together, the flow zone arranged to allow weld joint material to flow into the flow zone when the welding is performed.

[0070] FIG. 27 shows an example method for joining at least a first part 1, a second part 2, and a third part 3. The first part 1 has a first part weld region (or surface 9A), the second part 2 has a first interlocking region 10 and a second part weld region (or surface 9B), and the third part 3 has a second interlocking region 10 and a third part weld region (or surface 9C). The method includes coupling (Block S100) the second part 2 to the third part 3 at their respective first interlocking region 10 and second interlocking region 10, placing (Block S102) the first part 1 on the second part 2 and the third part 3, and welding (Block S104) the first part 1 to the second part 2 and the third part 3 at the first part weld region (or surface 9A), the second part weld region (or surface 9B)and the third part weld region (or surface 9C).

[0071] In some embodiments of the method, part 1, part 2, and part 3 may refer to any parts, such as battery parts or components, of any of the embodiments of the present disclosure. In a nonlimiting example, part 1 may refer to cover 22, part 2 may refer to cell carrier 20 or housing 16, and part 3 may refer to housing 16 or cell carrier 20. Further, the first part weld region may refer to cover weld region 22a, the second part weld region may refer to cell carrier weld region 20a or housing weld region 16a, and the third part weld region may refer to housing weld region 16a or cell carrier weld region 20a.

[0072] In some embodiments, the welding creates a weld joint 12, 26.

[0073] In some other embodiments, the first interlocking region 10 may refer to interlocking region 34 or interlocking region 32, and the second interlocking region 10 may refer to interlocking region 32 or interlocking region 34.

[0074] FIG. 28 shows an example method for joining at least a first part 1 having a first part weld region (or surface 9A), a second part 2 having a first geometry and a third part 3 having a second geometry is described. The method includes placing (Block S200) the second part 2 adjacent and in contact with third part 3. The first geometry and the second geometry create a flow zone 11 when the second part 2 is adjacent and in contact with the third part 3. The method also includes welding (Block S202) the first part 1, the second part 2 and the third part 3 together. The welding produces weld joint material, and the flow zone 11 is arranged to allow the weld joint material to flow into the flow zone 11 when the welding is performed. In some embodiments of the method, part 1, part 2, and part 3 may refer to any parts, such as battery parts or components, of any of the embodiments of the present disclosure.

[0075] In some embodiments, the welding creates a weld joint 12, 26. In some other embodiments, weld joint 12, 26 may include an infrared weld joint, a heat platen weld joint, a hot plate weld joint, and / or a hot air weld joint. That is, weld joint 12, 26 is not limited to any specific welding process and may be formed, for example, using an infrared welding process, a heat platen welding process, a hot plate welding process, a hot air welding process or any other welding or joining process. In one or more embodiments, the methods corresponding to FIGS. 27 and 28 may be performed to join or weld one or more parts or battery components described herein.

[0076] It will be appreciated by persons skilled in the art that the present embodiments are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings and following claims.

Claims

What is claimed is:

1. An apparatus comprising: a first part (1); a second part (2) having a first interlocking region (10); a third part (3) having a second interlocking region (10), the first interlocking region (10) being mated to the second interlocking region (10) to couple the second part(2) to the third part (3); and a weld joint (12) coupling the first part (1), the second part (2) and the third part(3) together.

2. The apparatus of Claim 1, wherein the first interlocking region (1) includes one or more first interlocking elements (4A), the second interlocking region includes one or more second interlocking elements (4B), the one or more first interlocking elements (4A) being mated to the one or more second interlocking elements (4B) to couple the second part (2) to the third part (3).

3. The apparatus of any of Claims 1 and 2, wherein the weld joint (12) is one of an infrared weld joint, a heat platen weld joint, a hot plate weld joint, and a hot air weld joint.

4. An apparatus comprising: a first part (1); a second part (2) having a first geometry; a third part (3) having a second geometry, the first geometry and the second geometry arranged to create a flow zone (11) when the second part (2) is adjacent and in contact with the third part (3); and a weld joint (12) coupling the first part (1), the second part (2) and the third part (2) together, the weld joint (12) including weld joint material, the flow zone (11) arranged to allow weld joint material to flow into the flow zone (11) when the weld joint (12) is formed.

5. The apparatus of Claim 4, wherein the first part (1) has a concave shaped surface (9A) and the second part (2) and third part (3) each have a convex shaped surface(9B, 9C), the concave shaped surface (9 A) being welded to the convex shaped surfaces (9B, 9C) of the second part (2) and third part (3) via the weld joint (12).

6. The apparatus of any of Claims 4 and 5, wherein the weld joint (12) is one of an infrared weld joint, a heat platen weld joint, a hot plate weld joint, and a hot air weld joint.

7. A battery case (14) comprising: a cover (22); a housing (16) having a first interlocking region (16a); a cell carrier (20) having a second interlocking region (20a), the first interlocking region (16a) being mated to the second interlocking region (20a) to couple the cell carrier (20) to the housing (16); and a weld joint (26) coupling the cover (22), the housing (16), and the cell carrier (20) together.

8. The battery case (14) of Claim 7, wherein the first interlocking region (16a) and the second interlocking region (20a) include one or more dovetail joints.

9. The battery case (14) of any one of Claims 7 and 8, wherein the first interlocking region (16a) is formed on an inner periphery of the housing (16), and the second interlocking region (20a) is formed on an outer periphery of the cell carrier (20).

10. The battery case (14) of any of Claims 7-9, wherein the weld joint (26) is one of an infrared weld joint, a heat platen weld joint, a hot plate weld joint, and a hot air weld joint.

11. A battery case (14) comprising: a top cover (22); a cell carrier (20) having a first geometry; a housing (16) having a second geometry, the first geometry and the second geometry arranged to create a flow zone when the cell carrier (20) is adjacent and in contact with the housing (16); anda weld joint (26) coupling the top cover (22), the cell carrier (20) and the housing (16) together, the weld joint (26) including weld joint material, the flow zone arranged to allow the weld joint material to flow into the flow zone when the weld joint (26) is formed.

12. A method for joining at least a first part (1) having a first part weld region (9 A), a second part (2) having a first interlocking region (10) and a second part weld region (9B), and a third part (3) having a second interlocking (10) region and a third part weld region (9C), the method comprising: coupling (S100) the second part (2) to the third part (3) at their respective first interlocking region (10) and second interlocking region (10); placing (S102) the first part (1) on the second part (2) and the third part (3); and welding (S104) the first part (1) to the second part (2) and the third part (3) at the first part weld region (9A), the second part weld region (9B) and the third part weld region (9C).

13. A method for joining at least a first part (1) having a first part weld region (9 A), a second part (2) having a first geometry and a third part (3) having a second geometry, the method comprising: placing (S200) the second part (2) adjacent and in contact with third part (3), the first geometry and the second geometry creating a flow zone (11) when the second part (2) is adjacent and in contact with the third part (3); and welding (S202) the first part (1), the second part (2) and the third (3) part together, the welding producing weld joint material, the flow zone (11) arranged to allow the weld joint material to flow into the flow zone (11) when the welding is performed.

14. An apparatus comprising: a first part (1); a second part (2) having a first interlocking region (10) and a first geometry; a third part (3) having a second interlocking region (10) and a second geometry, the first interlocking region (10) being mated to the second interlocking region (2) to couple the second part the third part (3) and to create a flow zone (11); and a weld joint (12) coupling the first part (1), the second part (2) and the third part (3) together, the weld joint (12) including weld joint material, the flow zone (11) arrangedto allow the weld joint material to flow into the flow zone (11) when the weld joint (12) is formed.

15. The apparatus of Claim 14, wherein the weld joint (12) is an infrared weld joint.

16. The apparatus of Claim 14, wherein the weld joint (12) is a heat platen weld joint.

17. The apparatus of Claim 14, wherein the weld joint (12) is a hot plate weld joint.

18. The apparatus of Claim 14, wherein the weld joint (12) is a hot air weld joint.

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