Battery Module Lid Assembly for EMC Sealing Without Screws
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Solution Overview
Problem
Existing battery module connections rely on screw connections, which are costly and complex, and lack electromagnetic compatibility and effective sealing against environmental factors.
Innovation Solution
A battery module design featuring a metallic housing and lid elements connected via spaced plastic deformations, forming an electromagnetically compatible and sealed internal space without the need for screw connections, utilizing a circumferential rib and sealing element for mechanical and electrical contact, and ensuring electromagnetic shielding and fluid-tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to connect housing element and lid element, then mechanical strength and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the screw connections from the assembly, replacing them with plastic deformations that are integrated directly into the lid element. This removal of external fastening components simplifies the overall structure while maintaining connection reliability through the deformations' mechanical interlocking with the housing element.
Solution Approach 2:
The patent merges the electrical contact function and mechanical connection function into a single integrated structure. The plastic deformations serve dual purposes: providing mechanical anchoring between housing and lid while simultaneously establishing electrical contact paths, thereby eliminating the need for separate electrical contacts and reducing overall complexity.
2Reliability
If screw connections are used for electrical contact, then electrical connection reliability is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines mechanical fastening and electrical contact functions into the plastic deformations. The deformations create both structural attachment and continuous electrical pathways between metallic components, eliminating the need for separate electrical contacts and reducing manufacturing steps.
Solution Approach 2:
The plastic deformations serve multiple functions simultaneously: mechanical anchoring, electrical conduction, and structural reinforcement. This multi-functionality reduces the total number of components needed and simplifies both manufacturing and assembly processes while maintaining reliable electrical connections.
3Ease of operation
If housing and lid are connected with gaps, then assembly ease is improved, but electromagnetic compatibility and sealing performance deteriorate
Solution Approach 1:
The patent applies local quality by creating specific plastic deformations at strategic locations where electrical and mechanical contact is needed, while maintaining gaps in other areas for assembly ease. The deformations are localized features that provide electromagnetic continuity without requiring full contact between housing and lid throughout.
Solution Approach 2:
The plastic deformations act as intermediary elements that bridge the gap between housing and lid. These deformations provide both mechanical connection and electrical continuity, serving as mediators that maintain electromagnetic compatibility while allowing the overall structure to remain assembled with minimal contact areas.
4Reliability
If multiple connection points are created, then electrical contact reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the electrical contact function into multiple distributed plastic deformations rather than using a single complex connection structure. Each deformation acts as an independent contact point, and collectively they provide redundant electrical pathways, improving reliability while keeping individual deformation features simple to manufacture.
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 design simplifies handling, reduces costs, and provides reliable electrical and mechanical connections while ensuring electromagnetic compatibility and fluid-tight sealing, preventing corrosion and condensate accumulation.
Implementation Method 1
The lid element (4) and/or the housing element (2) are connected to one another by forming a plurality of plastic deformations (8) of the lid element (4)
Implementation Method 2
an electrical contact is formed between the housing element and the lid element
Implementation Method 3
a sealing element is further arranged between the housing element and the lid element in such a manner that the interior is sealed against an environment in a fluid-tight manner
Data Source
AI summary
A battery module includes a housing element (2) made of a metallic material (3) and a lid element (4) made of a metal material (5), which are connected to one another while forming a common internal space (6) configured to accommodate a plurality of battery cells (7) by the formation of a plurality of plastic deformations (8) of the lid element (4) that are arranged so as to be spaced apart from one another, in such a way that an electrical contact is established between the housing element (2) and the lid element (4).