Battery Cell Cooling Container Tongue-Groove Weld for Leak-Tight Joints
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Solution Overview
Problem
Existing liquid containers for battery cell temperature control require high and long energy inputs for ultrasonic welding, which can lead to incomplete connections and potential damage, compromising liquid tightness and mechanical stability.
Innovation Solution
The design features a tongue with a width exceeding the groove's width, with lateral surfaces forming welding surfaces seated against the groove walls, allowing for a low-energy ultrasonic welding process that creates a double shear joint for enhanced stability and liquid tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high and long energy input is used for ultrasonic welding, then a firm connection between main bodies is achieved, but damage to the main body at the probe-main body contact surface occurs
Solution Approach 1:
The welding process is segmented into two distinct phases: a first ultrasonic welding phase that creates an initial connection, and a second ultrasonic welding phase that reinforces the connection. This segmentation allows the welding process to be divided into manageable energy input stages, preventing excessive energy concentration at any single point and thus avoiding damage to the main body while ensuring a firm connection.
Solution Approach 2:
The ultrasonic welding is performed in two periodic phases with different energy inputs. The first phase uses a certain energy input to establish the initial weld, and the second phase applies a different energy input to complete the connection. This periodic action pattern allows for controlled energy distribution over time, achieving strong connections without causing damage from continuous high energy input.
2Object-affected harmful factors
If low energy input is used for ultrasonic welding, then damage to the main body is avoided, but the connection between main bodies becomes incomplete and liquid tightness cannot be guaranteed
Solution Approach 1:
The welding process is divided into two sequential phases where the first phase creates an initial connection and the second phase completes the weld. This segmentation ensures that even though each individual phase uses limited energy input that prevents damage, the cumulative effect of both phases achieves complete welding and guarantees liquid tightness.
Solution Approach 2:
The first ultrasonic welding phase performs a preliminary welding action that creates an initial connection between the main bodies. This preliminary action prepares the joint for the second phase, ensuring that when the second welding phase occurs, the materials are already partially bonded, which facilitates achieving complete liquid-tight connection with lower overall energy input.
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 enables a quick and stable connection with low energy input, ensuring liquid tightness even under excess pressure, and improves mechanical stability through a redundant double shear joint.
Implementation Method 1
By inducing ultrasonic waves, frictional heat is generated at this welding line, which leads to the melting of the groove and the tongue
Implementation Method 2
By inducing ultrasonic waves, frictional heat is generated at this welding line
Implementation Method 3
During ultrasonic melting, a shear flow occurs between the groove wall and the lateral surface of the tongue, which promotes a material mixing of the melt of the different main bodies
Data Source
AI summary
A liquid container for controlling the temperature of battery cells (1) comprises two main bodies (2a, 2b), which, when assembled, delimit a flow channel (3). For ultrasonic welding, one main body (2a) has an at least partially peripherally extending groove (7) and one main body (2b) has an at least partially peripherally extending tongue (8) for insertion into the groove (7). A stable and fluid-tight connection between the main bodies (2a, 2b) is possible. Before the ultrasonic welding the width (11) of the tongue (8) exceeds the width (12) of the groove (7) and the lateral surfaces (13) of the tongue (8) form peripherally extending welding surfaces that are seated against the groove walls (14).