EV Battery Module Case Press-Fit Assembly Without Laser Welding
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Solution Overview
Problem
Conventional battery module cases for electric vehicles face manufacturing defects leading to battery damage and increased volume due to extrusion molding, and high costs and defects from laser welding, resulting in degraded product quality and productivity.
Innovation Solution
A battery module case with a case portion formed through extrusion molding and a cover portion through die casting, featuring press-fit protrusions and bifacial-close contacting grooves for secure press-fitting without welding, enhancing coupling force and preventing thermal deformation-induced detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding method is used to couple the body and cap, then coupling strength is improved, but manufacturing cost increases and defect rate increases due to melting error
Solution Approach 1:
The patent replaces the laser welding method with a mechanical press-fit coupling system. The press-fit protrusion and corresponding groove create a mechanical interlock between the body and cap, eliminating the need for thermal welding processes. This substitution resolves the contradiction by providing adequate coupling strength through mechanical means while avoiding the high costs and defect rates associated with laser welding of aluminum materials with different melting characteristics.
2Ease of manufacture
If mechanical coupling method such as bolt fastening is used, then manufacturing cost is reduced, but overall volume of battery module increases due to additional components
Solution Approach 1:
The patent merges the coupling function directly into the structural components of the battery module. The press-fit protrusion is integrated into the cap as a single-piece component, and the corresponding groove is formed in the body. This integration eliminates the need for separate bolt fastening components while maintaining mechanical coupling, thereby reducing the overall volume of the battery module while keeping manufacturing costs low.
3Productivity
If extrusion molding is used to form the body, then manufacturing efficiency is improved, but sharp protrusions may form causing battery damage
Solution Approach 1:
The patent applies preliminary anti-action by designing the press-fit protrusion with a rounded tip geometry that prevents it from acting as a sharp edge. The extrusion molding process forms this rounded press-fit protrusion as an integral part of the cap structure, which then contacts the battery surface during assembly. This preliminary design feature counteracts the potential harmful effect of sharp protrusions that would otherwise be created by the extrusion process, protecting the battery from damage while maintaining manufacturing efficiency.
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 solution prevents welding defects, improves product quality and productivity by eliminating the need for expensive laser welding, and enhances coupling force and space utilization through secure press-fitting and elastic constraints.
Implementation Method 1
a catching and constraining protrusion and a catching and constraining groove which are provided on one side and the other side, opposing each other, among the press-fit protrusion and the bifacial-close contacting groove are mutually elastically caught and coupled
Implementation Method 2
press-fit protrusion and bifacial-close contacting groove are mutually press-fitted
Implementation Method 3
case portion formed of an aluminum material through extrusion molding
Implementation Method 4
one or more cover portions formed of an aluminum material through die casting
Data Source
AI summary
The present invention provides a battery module case for an electric vehicle, wherein an electric vehicle battery provided to be utilized in an electric vehicle is accommodated inside the battery module case to improve assemblability. The battery module case for an electric vehicle is characterized by comprising: a case part which is formed by extrusion-molding an aluminum material, has a cavity formed in an inner profile corresponding to the outer profile of the battery for an electric vehicle, and is open in at least one end in the longitudinal direction, wherein a press-fit protrusion is formed along the edge of the open end; and at least one cover part which is formed by die-casting an aluminum material and provided so as to be coupled to the open end of the case part, and in which an extension portion is integrally formed to extend and protrude toward the case part from the edge thereof, at a position corresponding to the press-fit protrusion, so as to be press-fit on the edge of the press-fit protrusion, and both-side contacting grooves surrounding and closely contacting both sides of the press-fit protrusion are recessed in an end section of the extension portion.