Battery Case Welding Across Opposite Surfaces for Closed-Loop Sealing
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Solution Overview
Problem
The existing manufacturing methods for battery cases face limitations in achieving airtightness and watertightness due to structural constraints, which restrict the arrangement of internal components and require additional protective measures, making it difficult to form closed-loop welding lines on the same surface.
Innovation Solution
A method involving a two-step welding process where a first welding line is formed on one surface and a second welding line on an opposite surface, connected to form a closed-loop shape, using different welding methods such as MIG or TIG welding for the first line and friction stir welding for the second, allowing for increased structural freedom and improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support panel and frame are welded on the same surface to form a closed-loop welding line, then the airtightness and watertightness performance are secured, but the structural freedom is limited and additional protective members are required
Solution Approach 1:
The patent transitions from forming a closed-loop welding line on a single surface (2D constraint) to forming welding lines that extend to edges and connect through edge welding (3D spatial arrangement). This dimensional change allows the welding lines to form a closed loop in three-dimensional space rather than being constrained to a single surface, thereby achieving both airtightness/watertightness and structural freedom
2Reliability
If the support panel and frame are welded on the same surface, then the airtightness and watertightness performance are secured, but separate protective members and fastening structures are required for electrical components and cooling ports
Solution Approach 1:
The patent merges the functions of the frame, protective members, and fastening structures into an integrated welded structure. The frame itself is designed to provide both structural support and protective enclosure, eliminating the need for separate protective members and fastening structures while maintaining airtightness and watertightness through the welded connections
3Reliability
If a sealer is applied to supplement the closed-loop welding line, then the airtightness and watertightness are improved, but a separate process is added and the efficiency is reduced
Solution Approach 1:
The patent extracts and eliminates the separate sealing process by designing the welding structure itself to provide the closed-loop seal. Through proper arrangement of welding lines on different surfaces and edge welding, the structure achieves inherent airtightness and watertightness without requiring additional sealing operations, thereby maintaining productivity
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 ensures airtightness and watertightness while increasing structural freedom, allowing for more complex battery case designs without protruding electrical components or cooling ports, enhancing collision stability and sealing performance.
Implementation Method 1
a first welding line on a first surface of the first member by welding a portion at which the first member overlaps the second member
Data Source
AI summary
A method of manufacturing a welded structure includes a preparation operation of arranging a first member to overlap a second member; a first welding operation of forming a first welding line on a first surface of the first member by welding a portion at which the first member overlaps the second member, the first surface of the first member being a surface of the first member facing the second member; a second welding operation of forming a second welding line on a second surface of the first member by welding the portion at which the first member overlaps the second member, the second surface of the first member being a surface opposite to the first surface; and connecting the first welding line to the second welding line.