Battery Box Thermal Management Structure for Gap-Free Sealing
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Solution Overview
Problem
Existing battery technologies face challenges in improving the performance and energy density of battery boxes due to issues with thermal management, weight, and sealing processes, which affect the overall reliability and efficiency of electric vehicle batteries.
Innovation Solution
A battery box design incorporating a thermal management component with a protruding edge and recess configuration, connected by a welding process that avoids additional sealing gaps, utilizing friction stir welding to ensure reliable connections and minimize deformation, and incorporating thin-walled flow channel cavities and integrated mounting structures for enhanced stability and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thermal management component is integrated into the battery box to save internal space and increase energy density, then the energy density is improved, but the manufacturing complexity and sealing reliability deteriorate due to additional welding joints and potential gaps
Solution Approach 1:
The patent integrates the thermal management component with the battery box by making the thermal management component's edge form an integral part of the box structure. Specifically, the first edge of the thermal management component forms a protrusion that connects to other structural members, eliminating the need for separate connecting plates and welding joints. This merging approach maintains structural integrity and sealing reliability while achieving space savings and increased energy density.
2Reliability
If additional connecting plates and welding processes are used to connect thermal management components, then the connection reliability is improved, but the manufacturing complexity and weight increase
Solution Approach 1:
The patent eliminates separate connecting plates by integrating the connection function directly into the thermal management component's structure. The first edge of the thermal management component forms a protrusion that serves as both a structural element and a connection interface, reducing the number of parts and manufacturing steps while maintaining connection reliability.
Solution Approach 2:
The first edge of the thermal management component serves multiple functions: it provides structural support, forms a connection interface with other box members, and eliminates the need for separate sealing components. This multi-functionality reduces manufacturing complexity while maintaining reliability.
3Reliability
If arc welding is used to seal gaps between thermal management components and box members, then the sealing reliability is improved, but the box deformation and weight increase
Solution Approach 1:
The patent eliminates the need for arc welding by integrating the thermal management component's edge into the box structure. The protrusion formed by the first edge creates a gap-free connection with other structural members, removing the source of leakage without requiring additional sealing processes that cause deformation and weight increase.
Solution Approach 2:
The patent converts the potential harm of gaps and leakage into a benefit by designing the first edge to form a protrusion that naturally prevents gap formation. This design eliminates the need for harmful arc welding processes while maintaining sealing reliability.
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 solution results in a battery box with higher reliability, reduced weight, increased energy density, and improved thermal management, while avoiding deformation and additional weight from sealing processes, thus enhancing the overall performance and safety of electric vehicle batteries.
Implementation Method 1
a thermal management component configured to accommodate a fluid to adjust the temperature of the battery
Implementation Method 2
the connecting plate is welded to the second edge and the protrusion by a friction stir welding process
Data Source
AI summary
Provided are a box of a battery, a battery, an electrical apparatus, and a method and apparatus for preparing a battery. The box and the battery in which it is located have better performance. The box of the battery includes: a thermal management component configured to accommodate a fluid to adjust the temperature of the battery, an end region of a first edge of the thermal management component being provided with a protrusion which protrudes outwardly in a first direction (x), the first direction (x) being parallel to the first edge of the thermal management component, and the protrusion and a second edge of the thermal management component forming a recess; and a connecting plate accommodated in the recess and connected to the second edge and the protrusion.