Battery Box Connecting Element for Low-Heat Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing battery boxes face challenges such as high production costs and potential warping of the base plate due to excessive heat input during welding, which can lead to premature melting and mechanical instability.
Innovation Solution
The introduction of a connecting element with a joining section designed for laser welding, allowing for a secure and economical connection to the battery box, while minimizing additional material usage and heat input, and incorporating a sheet-like lamella for enhanced mechanical stability and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connecting elements are welded to the base plate using conventional welding methods, then a mechanical connection is achieved, but the base plate warps and melts due to excessive heat input
Solution Approach 1:
The connecting element incorporates a joining section with locally optimized geometry and material properties. This section has reduced thickness and enhanced thermal conductivity compared to the main body, concentrating heat away from the base plate during welding while maintaining connection strength at the interface.
Solution Approach 2:
The patent changes physical parameters of the connecting element, specifically the thickness and thermal conductivity of the joining section. By reducing thickness to 0.5-2mm and selecting materials with high thermal conductivity (≥10 W/m·K), the heat input to the base plate is controlled, preventing warping and melting while achieving sufficient connection strength.
2Strength
If the connecting element has a large height for sufficient screw travel, then mechanical connection stability is improved, but heat input during welding increases causing base plate melting
Solution Approach 1:
The connecting element is segmented into distinct functional sections: a connecting section with sufficient height for screw travel and a joining section with reduced height and optimized thermal properties. This segmentation allows the connecting section to provide mechanical stability while the joining section minimizes heat input during welding.
Solution Approach 2:
Different sections of the connecting element have different geometric and material properties. The joining section has reduced thickness (0.5-2mm) and high thermal conductivity, while the connecting section maintains sufficient height (5-20mm) for mechanical connection. This local differentiation resolves the contradiction between mechanical stability and heat control.
3Strength
If conventional welding methods are used with filler material, then connection is achieved, but manufacturing costs significantly increase
Solution Approach 1:
The invention extracts and eliminates the filler material from the welding process. By designing the joining section with optimized geometry and material composition, self-shielding gas welding or laser welding can be used without additional filler materials, reducing manufacturing complexity and cost while maintaining connection quality.
Solution Approach 2:
The joining section is designed to perform its own joining function without requiring external filler materials. The optimized geometry and material properties of the joining section enable it to receive and distribute welding heat efficiently, allowing the welding process to be self-sufficient and eliminating the need for additional consumables.
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 enables a more efficient, cost-effective, and reliable production process with reduced deformation of the base plate, improving mechanical stability and simplifying the manufacturing process by allowing for precise alignment and welding of connecting elements and separating plates in a single operation.
Implementation Method 1
The connecting element is joined to the base plate in the area of the joining section by welding, in particular by laser welding
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
The invention relates to a connection element (1) for connecting a battery cell (15) of an electric vehicle (16) to a battery box (10), wherein the connection element (1) has at least one connection section (5) for connection to the battery cell (15) and is joined to the battery box (10). The problem addressed by the invention is that of being able at least largely to omit the use of additional material when the connection element is joined to the battery box and making the join to the bottom plate of the battery box better in quality and more cost-effective. The problem is solved by a connection element (1) which has at least one join section (2) for permanent connection to the battery box (10).