One-Piece Battery Box Fixing Structure Without Welding
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Solution Overview
Problem
Existing battery box structures in electric vehicles suffer from low structural strength, vulnerability to damage from welding, and lengthy production cycles due to welding operations, which compromise stability and ease of mounting.
Innovation Solution
A one-piece fixing structure integrally formed with the battery box, featuring multiple connection points and a U- or C-shaped design with threaded and unthreaded holes, hangers, and bolted connectors for enhanced stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding operations are used to assemble the battery box structure, then the structural strength can be improved, but the production cycle becomes lengthy and the box body is vulnerable to welding damage
Solution Approach 1:
The patent integrates the fixing structure and box body into a single integrated component formed by one-piece molding. This merging eliminates the need for separate welding operations to assemble multiple parts, thereby reducing production cycle time while maintaining structural strength through the integrated design.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical joining system) with a one-piece molding process that creates integral structures. This substitution eliminates welding-related damage to the box body and reduces production time by removing the welding step entirely.
2Strength
If welding operations are used to assemble the battery box structure, then the structural strength can be improved, but the box body is vulnerable to welding damage
Solution Approach 1:
The patent replaces the welding process with a one-piece molding process that creates integral structures without thermal or mechanical damage to the box body. The molding process forms the fixing structure and box body as a single unit, eliminating all welding-related harmful effects.
Solution Approach 2:
By merging the fixing structure and box body into a single integrated component, the patent eliminates the welding interface that would be a source of damage. The integral design ensures structural strength without exposing the box body to welding heat or stress.
3Strength
If welding operations are used to assemble the battery box structure, then the structural strength can be improved, but the production cycle becomes lengthy
Solution Approach 1:
The patent combines the fixing structure and box body into a single molded part, eliminating multiple assembly steps including welding. This integration dramatically reduces production cycle time while the molded design maintains structural strength through optimized geometry and material distribution.
Solution Approach 2:
The one-piece molding process performs all structural forming operations in advance during a single manufacturing step, rather than requiring sequential assembly operations afterward. This preliminary action approach eliminates the time-consuming welding and assembly steps that extend the production cycle.
4Ease of manufacture
If traditional multi-part structures are used for the battery box, then ease of manufacture is improved, but structural strength is reduced
Solution Approach 1:
The patent merges multiple components into a single integrated structure that is formed by one-piece molding. This approach maintains ease of manufacture through a single molding operation while achieving superior structural strength by eliminating weak interfaces between separate parts.
Solution Approach 2:
The patent changes the manufacturing parameter from multi-step assembly to single-step molding. This parameter change enables the production of complex integrated structures with high strength while maintaining manufacturing efficiency through the simplicity of a single molding process.
Data Source
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AI summary
A fixing structure (300) for a battery pack is provided. The battery pack includes a box body (100). The fixing structure (300) is disposed on an outer surface of the box body (100) and includes a first connecting body (301), a second connecting body (302), and a transition body (303). The first connecting body (301) has one end connected with the box body (100). The second connecting body (302) has one end connected with the box body (100). The second connecting body (302) is spaced apart from the first connecting body (301). The transition body (303) has two ends connected with one end of the first connecting body (301) away from the box body (100) and one end of the second connecting body (302) away from the box body (100) respectively.