Battery Box Welded Joint Structure for Vibration-Resistant Strength
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Solution Overview
Problem
The existing battery module box designs face issues with low connection strength between end plates and side plates, leading to potential disconnection during vehicle vibration and increased weight by thickening the plates, which raises energy consumption.
Innovation Solution
A battery box design featuring multiple bent welding members formed from the end and side plates, which are welded together to enhance connection strength, reducing the likelihood of open welding and improving structural integrity without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If butt-welding is used to connect end plates and side plates, then the connection is formed, but the connection strength is low and laser leakage may occur
Solution Approach 1:
The welding process is segmented into multiple passes (first welding, second welding, third welding) rather than attempting a single strong weld. This segmentation allows each welding pass to perform a specific function: the first weld establishes basic connection, the second weld reinforces strength, and the third weld seals any potential laser leakage paths, thereby resolving the contradiction between connection strength and laser leakage prevention
Solution Approach 2:
The end portions of the side plates are bent into welding members before the welding process begins. This preliminary shaping creates a structured geometry that guides the welding process and ensures proper alignment during multi-pass welding, enabling the subsequent welding passes to effectively build connection strength and prevent laser leakage
2Strength
If the thickness of the board is increased to improve structural strength, then the overall structural strength is ensured, but the weight of the battery pack is greatly increased
Solution Approach 1:
Instead of changing the thickness parameter of the side plates, the invention changes the geometric parameter by bending the end portions into welding members. This parameter transformation allows the structure to achieve enhanced strength through shape modification rather than material quantity increase, thereby improving structural strength without increasing the weight of the battery pack
3Strength
If multiple welding members are formed by bending, then the connection strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The bending and welding operations are merged into an integrated manufacturing process. The side plates are bent into welding members and then welded in a continuous multi-pass sequence, combining what could be separate operations into a unified process flow. This merging reduces the number of discrete steps and tooling changes required, thereby managing manufacturing complexity while achieving enhanced connection strength
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 enhanced connection strength between end and side plates improves the robustness of the battery box, reducing the risk of disconnection and maintaining energy efficiency by avoiding weight increases.
Implementation Method 1
the plurality of welding members are configured to be welded to a corresponding end plate or a corresponding side plate
Data Source
AI summary
A battery box includes at least two end plates, at least two side plates, and a plurality of welding members. One of the at least two end plates is provided between two adjacent side plates of the at least two side plates. The at least two end plates and the at least two side plates are connected to one another to enclose a cavity of the battery box. The plurality of welding members are formed by bending an end portion of an end plate of the at least two end plates multiple times. The end portion of the end plate is configured to implement the connection of at least two side plates and the at least two end plates to one another to enclose the cavity of the battery box. The plurality of welding members are configured to be welded to a corresponding side plate.