Battery Module Case Welding Alignment With Guide Groove Bonding
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Solution Overview
Problem
The existing battery modules face issues with manufacturing convenience due to difficulties in detecting contact surfaces during welding, leading to potential damage and gaps between components, which reduces durability.
Innovation Solution
The battery module design includes a module case with specific bonding portions and guide grooves that facilitate accurate welding, reducing the risk of damage and gaps by enhancing positional accuracy and durability through inclined bonding surfaces and contrasting brightness cues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the module cover and accommodation portion are formed of the same material, then manufacturing cost is reduced, but the contact surface between components cannot be easily detected during welding
Solution Approach 1:
The patent applies a coating layer with different color or reflectivity to the accommodation portion compared to the module cover. This creates visual contrast that enables easy detection of the contact surface during welding operations, while the underlying materials can still be the same for cost efficiency.
2Device complexity
If welding is performed without proper detection cues, then manufacturing process is simplified, but heat may be transferred to unintended points causing damage
Solution Approach 1:
The visual contrast created by different coatings or materials on the module cover and accommodation portion provides clear detection cues for the welding system. This allows precise identification of the contact surface without adding complex detection equipment or procedures, preventing heat transfer to unintended areas.
3Productivity
If components are welded without precise positioning, then manufacturing is faster, but gaps form between components reducing durability
Solution Approach 1:
The patent incorporates positioning protrusions and recesses, as well as guide grooves, that are pre-formed on the components before welding. These features automatically align the module cover and accommodation portion during assembly, ensuring precise contact surface positioning before the welding process begins, thereby preventing gaps while maintaining fast welding speeds.
Data Source
AI summary
A battery module includes a cell assembly including a plurality of battery cells, and a module case accommodating the cell assembly. The module case includes an accommodation portion including a main plate supporting the cell assembly and a sidewall extending from the main plate, a module cover including an upper plate covering the cell assembly, the upper plate having a first surface oriented in a first direction, a sidewall cover extending from the upper plate, the sidewall cover covering a portion of the sidewall, the sidewall cover having a second surface oriented in a second direction opposite to the first direction, and a guide groove formed in the second surface, and a first bonding portion connecting the second surface of the sidewall cover and the sidewall to each other.