Battery Cell Enclosure Stiffening by Post-Formed Beads and Dimples
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional enclosures for electric vehicle battery cells, made using extrusion or deep drawing methods, lack sufficient stiffness to prevent bulging due to internal pressure, and are limited in their ability to incorporate complex stiffening features.
Innovation Solution
A method for manufacturing enclosures that involves initially forming the enclosure body through extrusion or deep drawing without stiffening portions, and subsequently forming post-formed stiffening portions, such as beads or dimples, on the enclosure body using an expandable physical or hydraulic punch or hydroforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extrusion or deep drawing methods are used to manufacture enclosures, then the manufacturing process is simple and efficient, but the enclosure lacks sufficient stiffness and cannot incorporate complex stiffening features
Solution Approach 1:
The enclosure body is first formed using simple extrusion or deep drawing methods without stiffening portions, then stiffening portions are added in a subsequent post-forming step. This preliminary formation followed by enhancement allows the base structure to be created simply while adding complexity only where needed for stiffness.
Solution Approach 2:
The manufacturing process is segmented into two distinct stages: (1) forming the basic enclosure body without stiffening features, and (2) subsequently forming the stiffening portions. This segmentation allows each stage to be optimized independently - the first for simplicity and efficiency, the second for enhancing mechanical properties.
2Strength
If thicker metal materials are used to increase enclosure stiffness, then structural strength is improved, but weight and material cost increase
Solution Approach 1:
Instead of uniformly thickening the entire enclosure, stiffening portions are strategically added only at specific locations where structural reinforcement is needed. This local enhancement provides the necessary strength while minimizing additional weight compared to uniform thickening.
Solution Approach 2:
The enclosure combines base metal material with added stiffening portions to create a composite structure. This composite approach achieves enhanced mechanical properties through the combination of different structural elements rather than relying solely on increased material thickness.
3Strength
If stiffening portions are formed during initial extrusion or deep drawing, then the enclosure has sufficient stiffness, but the manufacturing process becomes more complex and less versatile
Solution Approach 1:
The enclosure body is first formed using simple extrusion or deep drawing methods without stiffening portions, then stiffening portions are added in a subsequent post-forming step. This preliminary formation followed by enhancement allows the base structure to be created simply while adding complexity only where needed for stiffness.
Solution Approach 2:
The manufacturing process is made dynamic and adaptable by allowing the stiffening portions to be added after the basic form is created. This enables flexibility in designing different stiffening patterns for different applications without changing the fundamental manufacturing process.
4Productivity
If complex stiffening patterns are incorporated into the enclosure design, then nesting efficiency of adjacent enclosures is improved, but the manufacturing process becomes more difficult
Solution Approach 1:
The enclosure body is first formed using simple extrusion or deep drawing methods without stiffening portions, then stiffening portions are added in a subsequent post-forming step. This preliminary formation followed by enhancement allows the base structure to be created simply while adding complexity only where needed for stiffness.
Solution Approach 2:
The manufacturing process is segmented into two distinct stages: (1) forming the basic enclosure body without stiffening features, and (2) subsequently forming the stiffening portions. This segmentation allows each stage to be optimized independently - the first for simplicity and efficiency, the second for enhancing mechanical properties.
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 method enhances the geometric stiffness and strength of the enclosure body, allowing for the use of thinner metal materials while maintaining structural integrity, and enables the formation of complex stiffening patterns that allow for efficient nesting of adjacent enclosures.
Implementation Method 1
forming a plurality of stiffening portions on the enclosure body... using an expandable physical or hydraulic punch or hydroforming
Implementation Method 2
using an expandable physical or hydraulic punch or hydroforming
Data Source
AI summary
An enclosure body and a method for manufacturing an enclosure includes one of extruding and deep drawing an enclosure including a plurality of side walls defining a first cavity. The plurality of side walls are formed without stiffening portions. After extruding and deep drawing of the enclosure, forming a plurality of stiffening portions on the enclosure using an expandable punch, a hydraulic punch, and/or hydroforming.