Battery Module End Plate Rib for Welding Alignment and Protection
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Solution Overview
Problem
The existing battery module manufacturing process faces challenges in efficiently assembling the module frame and end plate for welding, leading to potential damage from laser welding and weld spatters to internal components.
Innovation Solution
Incorporating a rib structure on the end plate that protrudes towards the module frame, with a chamfer for improved assembly efficiency and a rib groove locking mechanism to prevent misalignment and protect internal components during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed to bond the module frame and end plate, then bonding strength is improved, but internal components may be damaged by laser or weld spatters
Solution Approach 1:
A rib structure is introduced as an intermediary element between the end plate and module frame. This rib serves as a physical barrier that blocks laser beams and weld spatters from reaching internal battery components during the welding process, while still allowing the end plate to be bonded to the module frame through the rib structure
Solution Approach 2:
The end plate is segmented by adding a rib structure that divides the plate into regions. This segmentation creates a protective protrusion that extends toward the module frame, forming a shield that prevents harmful welding byproducts from contacting internal components while maintaining the structural integrity of the end plate
2Manufacturing precision
If the module frame and end plate are fixed for welding alignment, then bonding precision is improved, but assembly efficiency deteriorates due to complex fixation requirements
Solution Approach 1:
The rib structure is designed with a chamfer at its tip that performs a preliminary action of engaging with the module frame before the actual welding process. This chamfered rib automatically guides and positions the end plate relative to the module frame, establishing preliminary alignment that simplifies subsequent welding operations without requiring complex external fixation devices
Solution Approach 2:
The rib structure with chamfer serves as a self-aligning feature that automatically positions the end plate correctly on the module frame during assembly. The chamfered surface of the rib engages with the module frame to self-correct misalignments and establish proper positioning without requiring additional external alignment tools or complex fixation mechanisms
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
Enhances the temporary assembly efficiency of the module frame and end plate, preventing laser and weld spatter damage to internal components while ensuring precise alignment and reducing the risk of distortion during the welding process.
Implementation Method 1
either the laser itself passing therethrough during a welding process or weld spatters may cause damage to the internal components
Implementation Method 2
for the welding, it is necessary to fix the module frame 20 and the end plate 30 so that the bonding surfaces of the module frame 20 and the end plate 30 are located so as to correspond to each other
Data Source
AI summary
A battery module includes a battery cell stack, in which a plurality of battery cells are stacked, a module frame configured to accommodate the battery cell stack, and of which a front surface and a rear surface facing each other are opened, and an end plate configured to cover each of the front surface and the rear surface of the module frame, wherein the module frame includes a first bonding surface formed at edges constituting each of the front surface and the rear surface, and wherein the end plate include a second bonding surface bonded to the first bonding surface, and a rib located toward the center of the end plate than the second bonding surface and protruding toward the module frame.