Battery Module Housing EMP Welding Gap Control
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Solution Overview
Problem
The existing methods for manufacturing battery module housings using EMP welding face inefficiencies due to the need for separate jigs to set initial gaps, leading to non-welded regions and increased vulnerability to external impacts, which can cause cracks.
Innovation Solution
A battery module housing design featuring a flyer and target structure that allows for EMP welding without a separate jig, utilizing spacers and cover portions to create an initial gap and improve collision efficiency, and a method for manufacturing that includes preparing and positioning the plates to ensure precise alignment and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate positioning and initial gap setting jig is used to perform EMP welding, then the initial gap between preforms can be set constantly, but the device complexity increases and the manufacturing process becomes less efficient
Solution Approach 1:
The battery module housing structure itself provides the positioning and gap-setting function through its own geometric features (corner portions and end portions), eliminating the need for external jigs. The structure serves itself by incorporating built-in positioning mechanisms that define the initial gap during assembly.
Solution Approach 2:
The positioning and gap-setting function is extracted from the separate jig and integrated directly into the battery module housing structure. The corner portions and end portions of the housing itself perform the positioning function that previously required a dedicated positioning device.
2Ease of manufacture
If EMP welding is performed without ensuring sufficient induced current density at opposite ends of preforms, then the welding process is simpler, but non-welded regions occur and structural reliability decreases
Solution Approach 1:
The housing structure has different geometric configurations at different locations: corner portions with larger dimensions are positioned at regions requiring higher induced current density (opposite ends of preforms), while other portions have smaller dimensions. This local variation in geometry ensures sufficient current density where needed while maintaining overall process simplicity.
3Strength
If the mono-frame is fabricated by joining four plates by welding, then the structural strength is improved, but the manufacturing cost and process complexity increase compared to snap-fitting or bolting
Solution Approach 1:
The positioning function and the structural housing components are merged into a single integrated structure. The corner portions and end portions serve dual purposes: they are both structural elements of the housing and positioning features that enable precise assembly without additional 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
This approach eliminates the need for separate jigs, minimizes the occurrence of non-welded regions, enhances the structural robustness, and improves the quality of welding by ensuring consistent induced current density and impact absorption.
Implementation Method 1
an induced current is generated at one preform due to the high current instantaneously flowing through a coil
Implementation Method 2
the shape of the preform is deformed due to Lorentz force causing the preform to collide with another preform at high speed, thereby welding the preforms
Data Source
AI summary
A battery module housing having a rectangular tube structure and method for forming the battery module housing is provided. The battery module housing includes a first side plate and a second side plate, the first and second side plates having target portions at upper and lower ends thereof, respectively, and spacers vertically protruding from the target portions; and a top plate and a bottom plate disposed upper and lower portions of the first and second side plates, respectively, each of the top and bottom plates having flyer portions supported on the spacers of the first and second side plates. The flyer portions of the top and bottom plates are joined to the target portions by means of electromagnetic pulse welding such that outer portions of the flyer portions contact the target portions and inner portions of the flyer portions are separated from the target portions by a gap.