Battery Housing Flange Forming for U-Shaped Cover Assembly
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Solution Overview
Problem
Existing battery housing assembly processes are inconvenient and inefficient, with low volume utilization and poor assembly efficiency due to the complexity of connecting top covers to the housing.
Innovation Solution
A forming method involving a flat plate with notch grooves that is folded to form a flange, allowing a U-shaped housing configuration, which is then welded and combined with a U-shaped cover plate to create a battery housing structure, enabling direct insertion and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one or two top covers are provided on the housing and connected through assembling operations, then the battery housing structure can be formed, but the connection operation becomes inconvenient and assembly efficiency decreases
Solution Approach 1:
The patent integrates the top cover and housing into a single integrated structure formed from one flat plate. The flat plate is folded to simultaneously create both the housing body and the top cover, eliminating the need for separate assembly operations and improving manufacturing efficiency
Solution Approach 2:
The flat plate is divided into functional regions through folding lines, creating distinct housing and top cover sections that are formed in one piece. The notch grooves further segment the plate to enable proper folding and formation of the three-dimensional structure with integrated components
2Volume of stationary object
If traditional assembly methods are used to connect top cover to housing, then the structure can be assembled, but volume utilization rate of the housing decreases
Solution Approach 1:
By forming both the housing and top cover from a single flat plate through folding, the patent eliminates gaps and interface complexities between separate components. This integration maximizes the usable volume within the housing structure while simplifying the overall assembly
Solution Approach 2:
The flat plate is transformed into a three-dimensional structure through folding along specific lines, creating an integrated housing and top cover configuration that optimizes spatial arrangement and volume utilization without requiring additional assembly components
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 assembly convenience and efficiency, improves safety performance, and ensures effective sealing and positioning during the assembly process.
Implementation Method 1
folding a periphery of the flat plate outward to form a flange... a folding angle is formed between the flange and the flat plate... respectively bending two ends of the flat plate outward along the bending lines
Implementation Method 2
completely closing the gaps by welding to form weld seams
Data Source
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AI summary
The present application relates to the technical field of batteries. Disclosed is a forming method for a battery housing structure. The forming method comprises: providing a surface plate; forming four notch grooves on the surface plate, each notch groove having an outward-opening groove opening, and flanging the periphery of the surface plate outwards to form a turned edging; folding both ends of the surface plate outwards to form two housing side plates, and completely closing the notch grooves by means of welding to form weld seams; forming a U-shaped housing, and enclosing the turned edging to form a U-shaped cavity opening; and a top cover comprising a U-shaped cover plate, placing the cover plate in a housing cavity by means of the cavity opening, closing the cavity opening, and clamping the cover plate between the two housing side plates. By means of the four notch grooves formed on the surface plate, the turned edging is folded and the periphery of the housing is fully covered, the housing and the cover plate are bent and arranged in a U shape, and the cover plate directly seals and covers the cavity opening. Meanwhile, the turned edging plays a role in assembling and positioning, such that the whole assembly and connection are convenient, efficiency is high, and battery safety performance is improved.