Asymmetrical Laser Welding for Battery Module Frame and End Plate
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Solution Overview
Problem
The coupling strength between the module frame and end plate in battery modules is compromised due to the blow hole phenomenon and high surface reflectance, leading to reduced welding reliability.
Innovation Solution
A Snowman wobble pattern welding method is employed, with asymmetrical welding parts and different energy densities applied to components of varying materials, using a circular shape for the module frame and an elliptical shape for the end plate, to enhance coupling strength and prevent blow holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed to couple the module frame and end plate, then coupling strength is improved, but blow hole phenomenon occurs reducing welding reliability
Solution Approach 1:
The patent applies different energy densities to different regions of the welding area. The welding energy density is adjusted based on the local material properties and thickness, with higher energy density applied to areas prone to blow holes and lower energy density to areas that are already sufficiently welded. This localized energy distribution prevents blow hole formation while maintaining overall coupling strength.
Solution Approach 2:
The patent changes the welding parameters, specifically the energy density distribution, to optimize the welding process. By adjusting the energy density parameters across different regions of the welding area, the patent prevents blow hole phenomenon while ensuring adequate coupling strength between the module frame and end plate.
2Strength
If welding is performed on materials with high surface reflectance, then coupling is achieved, but coupling strength decreases due to reflection
Solution Approach 1:
The patent applies higher welding energy density to regions with high surface reflectance to compensate for the reflected energy. By locally increasing the energy input in these areas, the patent ensures that sufficient energy is absorbed to achieve proper welding and coupling strength despite the high reflectance.
Solution Approach 2:
The patent adjusts the welding energy density parameters to account for surface reflectance variations. By increasing the energy density in high-reflectance areas, the patent compensates for energy loss due to reflection and maintains adequate coupling strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method improves coupling strength by adjusting energy densities and preventing blow holes, ensuring reliable welding and reduced distortion, thereby enhancing the structural integrity of battery modules.
Implementation Method 1
A welding process may be performed for the coupling between the module frame and an end plate
Implementation Method 2
a first welding part formed in the first member and a second welding part formed in the second member
Data Source
AI summary
Discussed is a coupling structure including a first member and a second member which are adjacent to each other, the first member and second member are weld-coupled to each other, a welding part of the first member and the second member includes a first welding part formed in the first member and a second welding part formed in the second member with respect to a coupling surface of the first member and the second member, and the first welding part and the second welding part have a mutually asymmetrical shape.