Double-Bottom Vehicular Battery Case for One-Sided Laser Joining
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Solution Overview
Problem
The existing manufacturing process for vehicular battery cases is complex and costly due to the need for multiple steps and orientation changes, particularly in joining the bottom plate members to the side frames, which increases the number of steps and manufacturing costs.
Innovation Solution
A vehicular battery case design featuring a double-bottom structure with a plate-shaped inner and outer bottom plate portion, a lower frame, and a frame body with specific joint surfaces, allowing for laser joining from a single direction, reducing the number of manufacturing steps and orientation changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bottom plate member is joined to the side frames using rivets or caulking from both upper and lower sides, then the joining strength is improved, but the number of manufacturing steps and device complexity increase
Solution Approach 1:
The patent inverts the conventional joining approach by performing all laser welding operations from the lower side only, rather than requiring operations from both upper and lower sides. The frame body and lower frame are designed with specific geometric features that enable laser beams to access welding positions from below, eliminating the need for part reorientation and reducing manufacturing steps while maintaining joining strength
Solution Approach 2:
The patent replaces mechanical joining methods (rivets, caulking) with laser welding. This substitution eliminates the need for multiple joining operations from different sides, as laser welding can be performed continuously from a single side, reducing the number of manufacturing steps and device complexity while providing sufficient joining strength
2Stability of the object's composition
If the first plate and second plate are joined to side frames from opposite sides, then the structural integrity is improved, but the manufacturing time and productivity decrease
Solution Approach 1:
The patent inverts the conventional approach by designing the frame body and lower frame with geometric features that allow laser beams to access all welding positions from the lower side only. This eliminates the need to reorient parts during manufacturing, enabling continuous welding operations from a single side and significantly improving productivity while maintaining structural integrity through proper joint design
Solution Approach 2:
The patent incorporates preliminary design features in the frame body and lower frame geometry that enable one-sided laser welding. By pre-configuring the structure with appropriate angles and access paths, the design allows laser beams to reach all welding positions from below without requiring subsequent reorientation of components during the welding process
3Manufacturing precision
If multiple orientation changes are performed during manufacturing, then the joining completeness is improved, but the manufacturing cost and time increase
Solution Approach 1:
The patent eliminates the need for orientation changes by inverting the welding approach to perform all operations from the lower side. The frame body and lower frame are designed with specific geometric configurations that provide laser beam access to all welding positions from below, ensuring complete joining without requiring time-consuming reorientation steps
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 simplifies the manufacturing process by enabling one-directional attachment of components, reducing manufacturing costs and enhancing the structural integrity of the battery case.
Implementation Method 1
a laser joining method includes a step of joining the outer peripheral portion of the inner bottom plate portion to the first joint surface of the frame body by applying a laser from a lower side
Implementation Method 2
a step of joining the lower frame to the inner bottom plate portion by applying a laser from a lower side to the first flange portion of the lower frame arranged on a lower side of the inner bottom plate portion
Implementation Method 3
a step of joining the outer bottom plate portion to the frame body by applying a laser from a lower side to the outer peripheral portion of the outer bottom plate portion arranged in such a way as to overlap the second joint surface from a lower side
Data Source
AI summary
A vehicular battery case includes inner and outer bottom plate portions, a lower frame, and a frame body. The outer bottom plate portion is on a lower side of the inner bottom plate portion. The lower frame is between the inner and outer bottom plate portions. The frame body stands upward from outer peripheral portions of the inner and outer bottom plate portions. The frame body includes a lower portion including a first joint surface joined to the inner bottom plate portion and a second joint surface on an outer side of the first joint surface and joined to the outer bottom plate portion. The lower frame includes an upper end portion including a first flange portion including an upper surface facing a lower surface of the inner bottom plate portion. The first flange portion is joined to the lower surface of the inner bottom plate portion.