Battery Module Case Welding Guide Groove for Precise Bonding
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Solution Overview
Problem
The challenge in manufacturing battery modules is the difficulty in detecting contact surfaces during welding, leading to heat transfer to unintended points, potential damage, and gaps between components, which reduces durability.
Innovation Solution
The battery module design includes a module case with specific bonding portions and guide grooves to facilitate accurate welding, reducing heat transfer and gaps, and incorporates step structures in components to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the module cover and accommodation portion are formed of the same material, then manufacturing cost is reduced, but the contact surface (welded portion) cannot be easily detected
Solution Approach 1:
The patent applies color contrast by forming the guide groove on the sidewall cover, creating a visible boundary that contrasts with the surrounding surface. This allows the contact surface and welding position to be easily detected even when the module cover and accommodation portion are made of the same material, thus maintaining manufacturing cost savings while solving the detection problem.
2Device complexity
If welding is performed without clear detection of contact surfaces, then manufacturing process is simplified, but heat may be transferred to unintended points causing damage
Solution Approach 1:
The guide groove is formed in advance on the sidewall cover before the welding process. This preliminary action creates a pre-marked guide region that clearly indicates where the contact surface is located, allowing the welding process to be performed accurately without complex detection systems, thus preventing heat transfer to unintended points while maintaining process simplicity.
3Ease of manufacture
If gaps are formed between components of the module case, then assembly is easier, but the module case has reduced durability
Solution Approach 1:
The bonding portion acts as an intermediary element that fills and bonds the gap between the sidewall cover and the sidewall. This intermediary structure allows the components to be easily assembled with a small gap while ensuring strong bonding and maintaining the durability of the module case, thus resolving the contradiction between assembly ease and durability.
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 design improves manufacturing convenience, prevents damage during welding, and enhances the durability of the battery module by ensuring precise bonding and minimizing gaps between components.
Implementation Method 1
a first bonding portion connecting the second surface of the sidewall cover and the sidewall to each other
Data Source
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AI summary
A battery module includes a cell assembly including a plurality of battery cells, and a module case accommodating the cell assembly. The module case includes an accommodation portion including a main plate supporting the cell assembly and a sidewall extending from the main plate, a module cover including an upper plate covering the cell assembly, the upper plate having a first surface oriented in a first direction, a sidewall cover extending from the upper plate, the sidewall cover covering a portion of the sidewall, the sidewall cover having a second surface oriented in a second direction opposite to the first direction, and a guide groove formed in the second surface, and a first bonding portion connecting the second surface of the sidewall cover and the sidewall to each other.