Battery Module Asymmetric Weld Structure for Spatter Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods of manufacturing battery modules face issues with spatter introduction during welding, which can damage internal components and misaligned welding lines exacerbate the problem.
Innovation Solution
The battery module design incorporates asymmetric welding portions on the first and second members, and a tilted laser welding process is used to couple these members, minimizing spatter introduction by adjusting the angle of the welding irradiation beam relative to the coupling surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is performed to couple the U-shaped frame and upper plate, then welding strength is improved, but spatter is introduced into the battery module damaging internal components
Solution Approach 1:
The patent applies asymmetry by designing the welding portions with different shapes on the first and second members. Specifically, one welding portion has a wider width than the other, creating an asymmetric configuration that directs spatter away from the battery module interior while maintaining effective welding coupling between the frame members
Solution Approach 2:
The patent converts the harmful spatter generated during laser welding into a beneficial directional flow by strategically designing the asymmetric welding portions. The spatter that would normally damage internal components is redirected through the asymmetric geometry to flow outward away from the battery module, transforming a harmful effect into an acceptable byproduct
2Productivity
If the welding line is misaligned during welding, then welding speed is improved, but spatter is significantly increased entering the battery module
Solution Approach 1:
The asymmetric welding portion design accommodates welding line misalignment by creating a geometry where one welding portion is wider than the other. This asymmetry provides a tolerance buffer that allows for faster, less precise welding operations while still directing spatter away from the module interior through the broader welding surface configuration
3Manufacturing precision
If the U-shaped frame and upper plate are fixed to closely contact for welding, then welding quality is improved, but manufacturing complexity increases
Solution Approach 1:
The asymmetric welding portions simplify the fixing process by creating an inherent alignment feature where the different widths guide the relative positioning of the frame members. This reduces the complexity of precise fixing while maintaining good welding quality, as the asymmetric geometry naturally facilitates proper alignment during assembly
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 prevents spatter from entering the battery module, reducing defects and ensuring strong tensile strength, thereby protecting the internal components.
Implementation Method 1
laser welding process is used to couple these members, minimizing spatter introduction by adjusting the angle of the welding irradiation beam relative to the coupling surface
Data Source
AI summary
A battery module includes a first member and a second member that are coupled in directions that cross each other, wherein the first member and the second member are weld-coupled; a welding portion of the first member and the second member includes a first welding portion formed on the first member and a second welding portion formed on the second member, based on a coupling surface of the first member and the second member; and the first welding portion and the second welding portion have shapes that are asymmetric to each other.