Ultrasonic Welding Battery Pack Side Walls
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Solution Overview
Problem
Conventional battery packs with small-thickness cases face challenges in manufacturing due to reduced welding strength and increased poor welding rates, requiring additional labels for increased coupling force and foreign matter prevention, while maintaining structural stability against impacts.
Innovation Solution
The battery pack design incorporates side walls on the upper and lower cases with a predetermined thickness for ultrasonic welding, eliminating the need for additional labels by increasing the coupling force and interface area, thus simplifying manufacturing and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of cases is reduced to meet miniaturization demands, then the battery pack size is reduced, but the welding strength and coupling force are reduced
Solution Approach 1:
The patent transitions from welding at the end surfaces of the cases to welding at the side walls, effectively changing the welding dimension from horizontal (end-to-end) to vertical (side-to-side). This dimensional change allows the welding area to extend along the length of the side walls rather than being confined to small end surfaces, thereby maintaining welding strength while reducing case thickness.
Solution Approach 2:
The patent changes the welding parameters by selecting side wall locations for ultrasonic welding instead of end surface locations. This parameter change in welding position enables the welding area to be distributed along the side walls, increasing the effective welding area and coupling force even when the overall case thickness is reduced for miniaturization.
2Strength
If additional labels are added to increase coupling force and prevent foreign matters, then the coupling force is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the additional label component from the battery pack structure. By designing the cases with sufficient side wall thickness and performing ultrasonic welding at these side walls, the patent achieves adequate coupling force without requiring extra protective labels, thereby simplifying the overall structure and reducing manufacturing complexity.
Solution Approach 2:
The case side walls themselves serve the dual function of providing structural support and serving as the welding interface. The side walls are designed with appropriate thickness to directly withstand the welding process and provide the necessary coupling force, eliminating the need for separate protective labels and simplifying the structure.
3Ease of manufacture
If ultrasonic welding is performed at end surfaces, then the manufacturing process is simple, but the interface area is small and coupling force is insufficient
Solution Approach 1:
The patent changes the welding interface from the end surfaces to the side walls of the cases. This dimensional transition allows the welding interface to extend along the length of the side walls, significantly increasing the welding interface area while maintaining the simplicity of the ultrasonic welding process.
4Length of moving object
If the case thickness is reduced, then the battery pack becomes thinner, but the structural stability against impacts is reduced
Solution Approach 1:
The patent compensates for reduced case thickness by changing the welding configuration from end surfaces to side walls. The extended welding area along the side walls provides enhanced structural stability and impact resistance, offsetting the reduced thickness of the cases while maintaining overall structural integrity.
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 achieves a strong coupling force and increased structural stability against impacts without the need for additional labels, allowing for smaller thicknesses and reduced manufacturing costs.
Implementation Method 1
ultrasonic welding is performed at side walls extending from an upper case and a lower case
Implementation Method 2
the coupling force due to the ultrasonic welding is very large
Data Source
AI summary
Disclosed herein is a battery pack wherein ultrasonic welding is performed at side walls extending from an upper case and a lower case, each of the side walls having a predetermined thickness, and a film-shaped label is formed at the upper surface and/or the lower surface of the case, whereby the coupling force due to the ultrasonic welding is very large although the thickness is very small, the structural stability against being dropped or external impacts is high, and interface area of the coupling regions is large, with the result that the attachment of any label for increasing the coupling force and preventing the introduction of foreign matters is not necessary.