EV Battery Case Cooling Plate Injection Bonding Without Deformation
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Solution Overview
Problem
The existing method of bonding an electric vehicle battery case frame to a cooling plate using friction stir welding (FSW) results in product deformation and high investment costs due to the high pressure and rotation involved, leading to incorrect dimensions and increased production costs.
Innovation Solution
A cooling plate injection bonding method that includes preparing fixing holes in the battery case and cooling plate, temporarily assembling them in an injection mold, forming an injection molding space, and injecting a material to bond the components, thereby eliminating the need for welding and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir welding (FSW) is used to bond the battery case frame and cooling plate, then bonding strength is improved, but product deformation occurs and manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical friction stir welding process with an injection molding process. The battery case frame and cooling plate are bonded by injecting molten material into a mold cavity formed by these components, transforming a mechanical welding process into a thermal-forming bonding process that avoids deformation while maintaining bonding strength
Solution Approach 2:
The patent changes the bonding process parameters from high-pressure mechanical stirring (FSW) to controlled injection of molten material at specific temperatures and pressures. By controlling injection parameters such as material temperature, injection pressure, and cooling time, the process achieves bonding without the deformation caused by FSW's high mechanical stress
2Strength
If friction stir welding (FSW) is used to bond the battery case frame and cooling plate, then bonding strength is improved, but equipment investment cost increases
Solution Approach 1:
The patent makes the injection mold serve multiple functions: it acts as both the bonding tool and the final shaping tool for the battery case. The mold cavity defines both the bonding interface and the final product geometry, eliminating the need for separate welding equipment and subsequent finishing operations, thereby reducing equipment investment
Solution Approach 2:
The patent merges the bonding process with the molding process into a single integrated operation. The battery case frame and cooling plate are positioned in the mold cavity, and injection of molten material simultaneously bonds these components while forming the final battery case structure, combining what would traditionally be separate welding and forming operations into one process
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 method improves process efficiency, reduces production costs, and enhances product quality by stabilizing the bonding process without deformation, using a structure that integrates the cooling plate with the battery case frame.
Implementation Method 1
an injection operation of filling the injection molding space of the injection mold and the injection part fixing holes with a preset injection material
Data Source
AI summary
Disclosed is a method of bonding a battery case frame and a cooling plate in a process of producing an electric vehicle battery case, including a cooling plate preparation operation of preparing the electric vehicle battery case and the cooling plate and forming injection part fixing holes in the battery case and the cooling plate, a mold seating operation of temporarily assembling the electric vehicle battery case and the cooling plate, seating the temporarily assembled electric vehicle battery case and cooling plate in an injection mold, and forming an injection molding space communicating with the injection part fixing holes and having a predetermined volume, an injection operation of filling the injection molding space of the injection mold and the injection part fixing holes with a preset injection material, and a bonding completion operation of separating the electric vehicle battery case from the injection mold.