Battery Module Boss Hot-Melt Fixation to Prevent Weld Spatter
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Solution Overview
Problem
Existing battery modules face issues with spattering during welding of the metal lower case with other components, weight concerns due to metal usage, and ineffective electrical insulation, which affects the stability and quality of the battery module, particularly when connecting the lower case to a heat conducting plate.
Innovation Solution
A battery module design featuring a lower case with a boss that fits into a receiving hole on the heat conducting plate, allowing for a stable and spatter-free connection, where the lower case is made of insulating material and the heat conducting plate is made of metal, enabling improved insulation and reduced weight, with the boss being hot-melted for a strong fixed connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal lower case is used for structural strength, then the connection strength between lower case and heat conducting plate is improved, but spattering occurs during welding and weight increases
Solution Approach 1:
The boss structure acts as an intermediary connection element between the lower case and heat conducting plate. Instead of directly welding the metal lower case to the heat conducting plate (which causes spattering), the boss provides a dedicated connection interface that eliminates spattering while maintaining connection strength through its integrated design and hot-melt fixation.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical system) with a hot-melt fixation process. The boss is fixed in the receiving hole through hot-melt, substituting the welding operation that causes spattering with a cleaner fixation method that achieves the same connection purpose without harmful spatter.
2Strength
If a metal lower case is used for structural strength, then the connection strength between lower case and heat conducting plate is improved, but the weight of the battery module increases
Solution Approach 1:
The lower case is constructed using composite materials, specifically an insulating material base combined with the boss structure. This composite approach maintains the necessary connection strength through the boss integration while reducing overall weight compared to a fully metal construction, achieving a balance between strength and weight reduction.
Solution Approach 2:
Instead of making the entire lower case from heavy metal material, the patent applies metal-like strength locally only where needed through the boss structure. The main body of the lower case uses lighter insulating material, while the boss provides localized strength for connection purposes, optimizing the weight-strength ratio.
3Weight of moving object
If insulating material is used for the lower case to reduce weight and prevent spattering, then weight is reduced and spattering is prevented, but electrical insulation effectiveness decreases
Solution Approach 1:
The lower case uses insulating material with differentiated local properties: the main body provides lightweight structure and general insulation, while the boss structure provides localized electrical insulation specifically at the connection point with the heat conducting plate. This local quality differentiation ensures insulation effectiveness is maintained where electrically critical.
Solution Approach 2:
The boss structure serves as an intermediary that bridges the insulating lower case and the metal heat conducting plate while maintaining electrical insulation. The boss is designed to provide both mechanical connection and electrical insulation, preventing direct electrical contact between the metal components while enabling structural connection.
4Object-generated harmful factors
If the lower case is made of insulating material to prevent spattering and reduce weight, then spattering is prevented and weight is reduced, but the connection stability between lower case and heat conducting plate deteriorates
Solution Approach 1:
The boss structure is pre-formed as an integral part of the insulating lower case before assembly. This preliminary formation ensures the boss is already positioned and shaped correctly to provide stable connection, eliminating the need for post-assembly adjustments and ensuring connection stability is built into the structure from the beginning.
Solution Approach 2:
The boss undergoes parameter changes through hot-melt fixation, where thermal energy is applied to melt and fix the boss in the receiving hole. This parameter change (from solid to melted state and back) creates a strong, stable bond between the insulating lower case and the metal heat conducting plate, ensuring connection stability despite the insulating material used.
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 prevents spattering, enhances the connection strength between the lower case and heat conducting plate, improves insulation, reduces weight, and maintains effective heat dissipation, thereby improving the overall quality and reliability of the battery module.
Implementation Method 1
the boss is hot-melted and fixed in the receiving hole
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present disclosure relates to the technical field of energy storage devices, and particularly, to a battery module. The battery module includes a lower case, a plurality of battery cells sequentially stacked and received in the lower case; and a heat conducting plate. A boss is formed on the lower case. The heat conducting plate is provided with a receiving hole. The boss fits in the receiving hole, and the boss is hot-melted and fixed in the receiving hole. In the present disclosure, through the fitting of the boss and the receiving hole and the subsequent hot-melting, the hot-melted boss forms a fixed connection with the receiving hole, which solves the spattering problem caused by welding in the related art and improves the connection strength between the lower case and the heat conducting plate.