Battery Base Siderail Weld Groove for Flush Sealant Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery assembly technologies face challenges with weld beads protruding significantly above the surface, which can compromise the integrity of the sealant layer and require costly and time-consuming dressing processes.
Innovation Solution
The solution involves forming a weld groove at an angle of approximately 35° between the siderail and the base plate, with a depth of about 2 mm, to minimize the height of the weld bead above the surface. This allows for a sealant layer to be applied without prior dressing of the weld beads, maintaining sufficient sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If weld beads are formed without a weld groove, then the welding process is simpler, but the weld bead protrudes significantly above the surface compromising sealant layer integrity
Solution Approach 1:
A weld groove is formed in advance on the base plate or siderail inner edge before welding. This preliminary preparation of the surface geometry ensures that when the weld bead is deposited, it remains contained within an acceptable height range, preventing excessive protrusion that would compromise the sealant layer integrity.
2Manufacturing precision
If the weld groove angle is increased, then the weld bead height is reduced, but the groove formation becomes more complex
Solution Approach 1:
The weld groove is designed with a specific angle of approximately 35 degrees relative to the interface between the siderail and base plate. This optimized angular parameter, combined with a depth of about 2 mm, effectively controls the weld bead height to remain below 1.5 mm above the surface, achieving precise dimensional control while maintaining manufacturability.
3Reliability
If weld beads are dressed to reduce protrusion, then sealant layer integrity is maintained, but the assembly process becomes more time-consuming and costly
Solution Approach 1:
The weld groove geometry is designed and formed in advance during the manufacturing of base plates or siderails. This preliminary action ensures that subsequent welding produces beads of controlled height without requiring post-weld dressing operations, thereby maintaining sealant layer integrity while preserving assembly productivity.
4Manufacturing precision
If the weld groove depth is increased, then the weld bead height is reduced, but the risk of undercutting increases
Solution Approach 1:
The weld groove is designed with an optimal depth of approximately 2 mm and an angle of about 35 degrees. This carefully balanced parameter combination achieves effective control of weld bead height while maintaining sufficient material volume to prevent undercutting, thus avoiding the harmful effects of excessive groove depth.
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
This approach reduces the height of the weld bead to less than 1.5 mm, enabling the sealant layer to accommodate minor surface variations without compromising seal integrity, thus simplifying the assembly process and reducing costs.
Implementation Method 1
The siderail is attached to the base plate by a weld bead formed along the weld groove
Data Source
AI summary
A battery assembly base portion, comprising a base plate comprising a base plate top surface and side edges, and a siderail comprising a siderail top surface and an inner edge. A weld groove is formed in one of the inner edge of the siderail and a side edge of the base plate. The siderail is attached to the base plate by a weld bead formed along the weld groove such that the base plate top surface and the siderail top surface are flush with one another.