Battery Housing Weld Joint Structure for Higher Energy Density
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Solution Overview
Problem
Current battery technologies face limitations in achieving high energy density, which is crucial for improving battery quality and meeting market demands for power, despite advancements in electrochemical energy storage devices.
Innovation Solution
The design of a battery housing that includes a lower and upper housing with flanges and concave structures, where the flanges are welded to form a melt that is contained within the concave structures, reducing the overall volume and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery housing uses traditional welding without concave structures, then the welding process is simple, but the melt occupies excessive space reducing energy density
Solution Approach 1:
The patent applies local quality by creating concave structures at specific locations (joint areas) of the battery housing where welding occurs. These localized concave regions concentrate the melt in specific areas rather than allowing it to spread uniformly, thereby containing the melt volume in strategic locations that minimize overall space occupation while maintaining welding integrity.
Solution Approach 2:
The patent utilizes the depth dimension by forming concave structures that extend inward from the surface of the battery housing. This dimensional approach allows the melt to be contained in the vertical depth of the concave regions rather than occupying horizontal space, effectively using the Z-axis to resolve the volume conflict and improve energy density.
2Quantity of substance
If the battery housing thickness is reduced to improve energy density, then the energy density increases, but the structural strength decreases
Solution Approach 1:
The patent segments the battery housing structure by introducing reinforcing ribs that divide and support different regions of the housing. These ribs create a segmented framework that distributes mechanical loads across multiple support points, allowing the overall housing thickness to be reduced while maintaining structural integrity through the distributed reinforcement network.
Solution Approach 2:
The patent employs composite material strategies by combining the housing material with strategically placed reinforcing elements and concave structures. This composite approach creates a multi-functional structure where the base material provides containment while the added features (ribs, concave regions) provide reinforcement, achieving high strength-to-volume ratio suitable for thin-walled high-density battery housings.
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
This configuration allows for a reduction in the occupied space within the battery housing, thereby improving the energy density of the battery without affecting its dimensions, and provides structural reinforcement to prevent deformation during welding.
Implementation Method 1
the first flange is in contact with the second flange by welding to obtain melt
Implementation Method 2
by welding to obtain melt, and the melt is disposed in the second concave structure
Data Source
AI summary
A battery housing includes an upper housing and a lower housing. The lower housing includes a bottom portion and first side walls, the first side walls extend upward from edges of the bottom portion, the bottom portion and the first side walls enclose a cavity, and at least one of the first side walls having a first flange on an end of the first side wall away from the bottom portion. The upper housing is located above the lower housing, the upper housing includes a top portion and a second flange, a second concave structure is disposed at a joint between the second flange and the top portion, the first flange is in contact with the second flange by welding to obtain melt, and the melt is disposed in the second concave structure.