Battery Housing Coupling Rods Eliminate Welding Heat

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Solution Overview

Problem

Conventional battery housing manufacturing methods, such as welding, often result in thermal damage to battery cells and peripheral parts due to heat generation, and lack sufficient rigidity, leading to compromised weldability and potential deformation.

Innovation Solution

A battery housing design featuring a plurality of covers coupled together using a coupling rod, with adhesive injection into insert holes and grooves, providing enhanced bonding and rigidity without heat generation during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding methods are used to fabricate the battery housing, then the bonding strength is improved, but the battery cells or peripheral parts may be damaged or deformed due to heat generated during welding

Engineering Contradiction:

Improvebonding strengthVSAvoidthermal damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical coupling system consisting of coupling rods and coupling holes. The covers are joined through mechanical insertion and friction fit rather than thermal bonding, eliminating heat generation while maintaining structural strength. This substitution of thermal field with mechanical field directly resolves the contradiction between bonding strength and thermal damage prevention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The coupling rods serve as intermediary elements that facilitate the connection between covers without direct thermal contact. By introducing these mechanical intermediaries, the bonding function is achieved through physical interlocking rather than thermal fusion, thereby preventing thermal damage to battery cells while maintaining joint strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If the welding region becomes longer, then the bonding coverage is improved, but the weldability is deteriorated due to the deformation of members caused by accumulated heat

Engineering Contradiction:

Improvebonding coverageVSAvoidweldability

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The mechanical coupling system allows for extended bonding coverage through multiple coupling rods distributed across the housing structure. Unlike welding where heat accumulates and deforms members over long regions, the mechanical system distributes connection points without thermal accumulation, maintaining member integrity and weldability even across extended bonding areas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The coupling system divides the bonding function into multiple discrete coupling rods positioned at different locations. This segmentation allows each coupling point to operate independently without thermal interference, enabling extended bonding coverage while preventing the accumulated heat deformation that plagues continuous welding regions.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If conventional welding methods are used, then the manufacturing process is established, but the battery housing lacks sufficient rigidity and may experience deformation

Engineering Contradiction:

Improvemanufacturing processVSAvoidstructural rigidity

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The coupling rods feature rounded ends that fit into corresponding coupling holes, creating a friction-based mechanical lock. This curved geometry provides superior rigidity compared to flat welded joints, as the spherical contact points distribute loads more effectively and prevent deformation while maintaining ease of assembly through simple insertion motions.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The coupling system combines multiple materials including the coupling rods, covers, and adhesive substances to create a composite structure with enhanced rigidity. This multi-material approach provides both the ease of manufacture through modular assembly and the structural stability needed to prevent deformation, overcoming the limitations of single-method welding.

Inventive Principle:

Principle #40Composite materials

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

Prevents damage to battery cells and peripheral parts by eliminating heat-induced issues during bonding and enhances the structural rigidity of the battery housing, ensuring reliable and efficient assembly.

Implementation Method 1

an adhesive may be injected into the first insert hole and the second insert hole so that the coupling rod is coupled to the first cover and the second cover

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11289765B2Battery housing and battery module comprising same

Publication Date: 2022.03.29 LG ENERGY SOLUTION LTD

AI summary

Disclosed is a battery housing. The battery housing includes a plurality of covers coupled to each other to form a space in which the battery is accommodated, the plurality of covers having a first cover and a second cover disposed adjacent to the first cover and coupled to the first cover; and a coupling rod configured to couple the first cover and the second cover.