Battery Pack Housing Assembly for Uniform Weld Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack assembly methods often result in incomplete contact between the upper and lower housing surfaces, leading to inconsistent welding quality and potential defects.
Innovation Solution
A battery pack design that incorporates first and second supports on the outer surfaces of the housing units, which are pressed together by dedicated pressing modules to ensure full contact and uniform welding of the contact surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If only the upper housing is pressed by a jig during assembly, then the assembly process is simple, but the contact surface between upper and lower housing cannot achieve full contact, resulting in poor welding quality
Solution Approach 1:
The pressing function is segmented into two independent pressing modules: a first pressing module for pressing the upper housing and a second pressing module for pressing the lower housing. This segmentation allows each module to independently apply pressure to ensure full contact of the contact surfaces, thereby improving welding quality without excessive complexity
Solution Approach 2:
The first and second supports are provided in advance on the outer surfaces of the upper and lower housings, respectively. These supports prepare the housing structures to receive pressing forces from the pressing modules, ensuring that the contact surfaces are properly positioned and can achieve full contact during the welding process
2Reliability
If only the upper housing is pressed by a jig, then the pressing force can be applied, but the pressing force varies depending on operator skill, leading to inconsistent welding quality
Solution Approach 1:
The assembly system performs the pressing function automatically through the first and second pressing modules, eliminating the need for operator judgment and manual adjustment. The system self-regulates the pressing force applied to each housing, ensuring consistent welding quality regardless of operator skill level
Solution Approach 2:
The manual mechanical pressing operation performed by operators is replaced with automated pressing modules that can precisely control and consistently apply the required pressing forces. This substitution eliminates operator variability and ensures reliable, consistent welding results
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
The solution ensures consistent and uniform welding of the housing unit contact surfaces, preventing defects and maintaining the quality of the battery pack, regardless of operator variability.
Implementation Method 1
the first housing and the second housing are coupled by welding in a state in which the first contact surface and the second contact surface are in contact with each other and pressed against each other
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is a battery pack including a housing unit configured to receive a battery cell therein, the housing unit comprising a first housing including a first contact surface and a second housing including a second contact surface opposite the first contact surface, wherein the first housing and the second housing are coupled by welding in a state in which the first contact surface and the second contact surface are in contact with each other and pressed against each other, a first support is provided on an outer surface of the first housing, the first support contacting a first pressing module that presses the first housing toward the second housing, and a second support is provided on an outer surface of the second housing, the second support contacting a second pressing module that presses the second housing toward the first housing.