Battery Module Top Cover Fitting Ribs Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules face challenges in securing coupling strength and inspecting welding quality between plastic top covers and metal side plates, particularly when welding without a guide jig, which affects the reliability and efficiency of the assembly process.
Innovation Solution
The battery module design incorporates fitting ribs on the top cover and anti-deformation ribs on the side plate, allowing for secure coupling and inspection of welding quality without a guide jig, using a plastic composite top cover and metal side plate, where the fitting ribs are melted to fill gaps during welding, and anti-deformation ribs prevent deformation due to battery swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the top cover is made of plastic composite material to reduce weight, then the weight of the battery module is reduced, but the coupling strength between the top cover and side plate during welding deteriorates
Solution Approach 1:
The side plate is designed with localized reinforcement ribs at the welding positions with the top cover. These ribs concentrate structural strength at the critical coupling points while maintaining the overall lightweight plastic construction of the top cover, thus resolving the contradiction between weight reduction and coupling strength
Solution Approach 2:
The module case utilizes composite construction combining plastic top cover with metal side plate. The metal side plate provides superior welding compatibility and structural strength, while the plastic top cover contributes to weight reduction. This composite approach allows both materials to contribute their advantageous properties
2Strength
If the top cover and side plate are welded to ensure coupling strength, then the coupling strength is improved, but the ability to inspect welding quality deteriorates
Solution Approach 1:
The welding process utilizes visual indication methods where the welding quality is reflected through observable changes in appearance, color, or surface characteristics at the welding position, allowing easy inspection without complex equipment
Solution Approach 2:
A guide jig is introduced as an intermediary tool during the welding process. This jig not only ensures proper positioning and coupling strength but also serves as a reference for inspecting welding quality, making the inspection process simpler and more reliable
3Manufacturing precision
If a guide jig is used during welding to ensure positioning accuracy, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The guide jig is integrated with the module case structure itself rather than being a separate complex fixture. The side plate's geometric features and reinforcement ribs serve as built-in positioning elements, combining the guiding function with the structural components already present in the design
Solution Approach 2:
The module case structure provides self-positioning capabilities through its geometric design. The side plate and top cover have complementary features that automatically align during assembly, reducing or eliminating the need for external guide jigs and simplifying the welding process
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 enhances coupling strength and allows for easy inspection of welding quality, enabling reliable assembly without a guide jig, thus improving manufacturing efficiency and ensuring robust battery packs.
Implementation Method 1
the fitting ribs are melted to fill gaps during welding
Implementation Method 2
when the top cover and the side plate are welded
Data Source
AI summary
A battery module, which includes at least one battery cell and a module case for packaging the at least one battery cell, wherein the module case includes: a top cover configured to cover an upper side of the at least one battery cell; and a side plate configured to cover all of opposing side surfaces of the top cover and opposing side surfaces of the at least one battery cell and configured to be coupled to the top cover by fitting.