Battery Housing Beam Joint Structure for Cell Expansion Loads
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Solution Overview
Problem
The existing battery housing technologies face challenges in enhancing the safety and impact resistance performance while maintaining ease of mounting and low costs, particularly due to the expansion forces generated by battery cells, which can lead to reduced connection strength and cracking in the welding area.
Innovation Solution
The proposed solution involves a battery housing design with a frame beam and cross beam configuration, where the cross beam is embedded in engaging grooves on the frame beam, featuring a protruding structure that increases the force-receiving area and improves connection strength, ensuring the housing can withstand expansion forces without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connection between frame beam and cross beam is simplified, then the ease of manufacture is improved, but the connection strength is reduced and the housing may crack under expansion force
Solution Approach 1:
The connection structure is segmented into three distinct components: the frame beam with engaging groove, the cross beam with protruding structure, and the welding connection. This segmentation allows each component to be manufactured separately and then assembled, improving ease of manufacture while maintaining connection strength through the distributed engagement design
Solution Approach 2:
The protruding structure of the cross beam is nested into the engaging groove of the frame beam, creating a interlocking configuration. This nesting design allows the cross beam to be embedded within the frame beam structure, providing mechanical interlocking that enhances connection strength while maintaining a compact and manufacturable design
2Ease of manufacture
If the welding area is reduced to lower cost, then the manufacturing cost is reduced, but the connection strength is reduced and cracking occurs under expansion force
Solution Approach 1:
The engaging groove and protruding structure are pre-formed on the frame beam and cross beam respectively, before the welding process. This preliminary mechanical interlocking ensures that the components are properly positioned and pre-stressed, allowing for reduced welding area while maintaining connection reliability under expansion forces
Solution Approach 2:
The connection system combines mechanical engagement (physical interlocking of groove and protrusion) with welding (metallurgical bond). This composite connection approach distributes the load between two different mechanisms, allowing reduced welding volume while maintaining overall connection strength and reliability, thereby lowering manufacturing cost without sacrificing safety
3Strength
If the force receiving area between frame beam and cross beam is increased, then the strength is improved, but the device complexity increases
Solution Approach 1:
The engaging groove and protruding structure are designed to concentrate the force-receiving function at specific localized areas where the groove and protrusion interface. This local quality enhancement provides high strength at critical points without requiring the entire structure to be more complex, thereby improving housing strength while maintaining overall structural simplicity
Data Source
AI summary
A housing of a battery includes a frame beam and a cross beam, the frame beam including a first surface and an engaging groove with an opening on the first surface. The cross beam includes a main body and end portions located at two ends of the main body in a length direction of the cross beam, the end portion including a protruding structure and a connecting surface located on a peripheral side of the protruding structure, the cross beam being engaged with the frame beam through the protruding structure and the engaging groove, and the cross beam being fixedly connected with the frame beam through the first surface and the connecting surface.