Battery Box Beam Overlap Structure Against Extrusion Cracking
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Solution Overview
Problem
The welding surfaces of existing battery box beams crack and separate due to being parallel to the extrusion force during battery expansion, compromising the anti-expansion and extrusion performance.
Innovation Solution
A battery box beam design with overlapping pressure bearing sections that are perpendicular to the extrusion force, featuring integral bending and sliding connections to enhance resistance and buffer extrusion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the welding surface is arranged parallel to the extrusion force direction, then the manufacturing process is simplified, but the welding surface cracks and separates under extrusion force
Solution Approach 1:
The patent changes the orientation of the welding surface from parallel to perpendicular relative to the extrusion force direction. The first and second pressure bearing sections are arranged perpendicular to the extrusion force, with their welding surfaces oriented perpendicular to the force direction, thereby eliminating cracking while maintaining manufacturing feasibility
Solution Approach 2:
Instead of arranging the welding surface parallel to the extrusion force as in conventional designs, the patent inverts this arrangement by positioning the welding surface perpendicular to the extrusion force direction, which fundamentally resolves the cracking issue while preserving structural integrity
2Strength
If the pressure bearing sections are extended to overlap, then the anti-extrusion performance is enhanced, but the structural complexity increases
Solution Approach 1:
The patent merges the first and second pressure bearing sections by extending them to overlap, creating a combined structural unit that enhances anti-extrusion performance. The overlapping sections work together as an integrated load-bearing system, distributing extrusion forces more effectively across the beam structure
Solution Approach 2:
The pressure bearing sections are pre-designed with extension and overlap capabilities during the beam manufacturing process. The integral bending design incorporates the overlapping configuration into the basic beam structure, allowing the enhanced anti-extrusion performance to be achieved without adding separate components or complex assembly steps
Data Source
AI summary
The present disclosure provides a battery box beam, a battery box, and a battery module, which relates to a technical field of batteries, and aims to improve the technical problem that the connection strength of the rolled battery box beam at the connecting portion is insufficient and separation may occur. The battery box beam includes a body wall; a first beam wall connected to one end of the body wall, and the first beam wall compries a first pressure bearing section disposed opposite to the body wall; and a second beam wall connected to another end of the body wall, the second beam wall includes a second pressure bearing section, and the second pressure bearing section is disposed opposite to the body wall and extends towards and partially overlaps with the first pressure bearing section, thereby meeting the requirements of light-weight and strength of the battery module.