Battery Case Rib-Aligned Joint Layout to Prevent Plate Deflection
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Solution Overview
Problem
The deflection of a plate member in a battery case due to the absence of ribs at the corners, which reduces the joining strength between the plate member and the longitudinal and lateral frames in a battery unit disposed below a vehicle's floor panel.
Innovation Solution
The plate member is joined to the longitudinal and lateral frames along a joint line that overlaps with the longitudinal and lateral ribs, ensuring continuous support and preventing deflection by using friction stir welding or series welding with overlapping electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the plate member is joined to the longitudinal frames and lateral frames at ribless portions, then the joining process can be simplified, but the plate member deflects and joining strength is reduced
Solution Approach 1:
The patent applies preliminary action by positioning the joint line to overlap with the longitudinal ribs and lateral ribs before the joining process. This pre-planned alignment ensures that the plate member is joined at locations where ribs provide structural support, preventing deflection during the joining process while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies local quality by making the joint line's position relative to the ribs a variable parameter. The joint line can be adjusted to overlap with ribs at specific locations, creating localized areas of enhanced support exactly where needed, rather than requiring uniform rib structure throughout the entire frame.
2Ease of manufacture
If the joint line does not overlap with the longitudinal ribs and lateral ribs, then the manufacturing process is simpler, but the plate member deflects during joining
Solution Approach 1:
The design preliminarily positions the joint line to overlap with the ribs before manufacturing, ensuring that structural support is already in place to prevent deflection during the joining process, thereby maintaining both manufacturing simplicity and plate stability.
Solution Approach 2:
The ribs act as an intermediary element between the plate member and the joining process. By positioning the joint line to overlap with the ribs, the ribs serve as a mediating support structure that prevents plate deflection during joining, allowing the process to remain simple while ensuring stability.
3Productivity
If pressure joining is applied to the plate member at ribless portions, then the joining process can be completed, but the plate member deflection reduces joining strength
Solution Approach 1:
The patent applies local quality by making the joint line's position relative to the ribs a variable parameter. The joint line can be adjusted to overlap with ribs at specific locations, creating localized areas of enhanced support exactly where needed, rather than requiring uniform rib structure throughout the entire frame.
Solution Approach 2:
The patent applies parameter changes by adjusting the position of the joint line relative to the ribs. This parameter adjustment ensures that pressure joining is applied at locations where ribs provide structural support, preventing deflection and maintaining high joining strength while completing the joining process efficiently.
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 solution effectively suppresses deflection of the plate member, maintaining strong joint integrity between the frames and plate, enhancing the battery unit's structural stability.
Implementation Method 1
Specific examples of the pressure joining may include friction stir welding and series welding.
Implementation Method 2
Pressure joining may be used for joining the plate member 160 to the longitudinal frames 140 and the lateral frames 150. In pressure joining, the plate member 160 may be pressed against and joined to the longitudinal frames 140 and the lateral frames 150.
Data Source
AI summary
A battery unit including a battery cell housed in a battery case, wherein the battery case includes longitudinal frames extending in a front-rear direction, lateral frames extending in a left-right direction, and a base plate on the frames, the longitudinal and lateral frames are assembled into a quadrangular frame shape and surround the battery cell, the frames include ribs that couple an upper and lower end of a hollow cross section and extend in the front-rear or left-right direction, the longitudinal rib and the lateral rib come into contact with each other, the base plate covers the longitudinal and lateral frames on a top or bottom, and the base plate is joined to the longitudinal and lateral frames along a joint line that extends along the longitudinal and lateral ribs such that the joint line overlaps with the longitudinal and lateral ribs.