Battery Pack Ultrasonic Welding Sealing Design
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Solution Overview
Problem
Conventional battery packs for hybrid and electric vehicles are costly due to the complexity of multiple components and process steps required for assembly, and they face challenges in preventing electrolyte leakage and external moisture ingress.
Innovation Solution
A battery pack design featuring a plastic lower housing with receiving parts and an ultrasonically welded upper cap, which includes barriers and grooves for electrode tab connection, sealing members to prevent electrolyte leakage, and a simplified structure that reduces the number of components by directly inserting electrode assemblies into the housing and integrating the upper housing with the lower housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components and process steps are used for assembly, then the battery pack structure is more robust, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple components into integrated structures. The upper cap integrates the sealing function, electrode tab connection structure, and upper housing support into a single component. The lower housing integrates the receiving parts and barriers into one piece, eliminating the need for separate assembly steps and reducing overall component count while maintaining structural integrity.
Solution Approach 2:
The upper cap serves multiple functions simultaneously: it seals the receiving parts, provides connection structures for electrode tabs, supports the upper housing, and includes protrusions that engage with grooves for structural reinforcement. This multi-functionality reduces the number of separate components needed.
2Ease of manufacture
If conventional assembly methods are used, then the battery pack can be manufactured, but the manufacturing cost is high due to multiple components and process steps
Solution Approach 1:
The patent reduces component count by merging functions into fewer parts. The upper cap combines sealing, connection, and support functions, while the lower housing integrates receiving parts and barriers. This reduction in component count directly lowers manufacturing costs and simplifies the bill of materials.
3Reliability
If the upper cap and lower housing are welded together, then the sealing performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical sealing methods (such as gaskets or threaded connections) with ultrasonic welding, which uses vibration and friction to create a permanent bond between the upper cap and lower housing. This provides superior sealing performance while the welding process itself is relatively simple and can be automated.
4Reliability
If barriers and grooves are added to the lower housing, then the electrode tab connection is improved, but the manufacturing complexity of the housing increases
Solution Approach 1:
The lower housing is segmented into distinct functional zones: receiving parts for battery cells, barriers to separate and organize electrode tabs, and grooves for tab insertion. This segmentation provides clear structural organization that improves electrode tab connection while the features are integrated into a single molded housing piece, avoiding the need for separate assembly 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 design enhances safety by preventing electrolyte leakage and external moisture ingress while reducing component count and assembly complexity, thereby lowering costs and improving the overall efficiency of the battery pack.
Implementation Method 1
The upper cap and the lower housing may be welded to each other by ultrasonic welding to be integrally coupled with each other
Data Source
AI summary
A battery pack includes a plurality of electrode assemblies, a lower housing including a plurality of receiving parts that receive the plurality of electrode assemblies, an upper cap coupled to a top portion of the lower housing, the upper cap sealing the plurality of receiving parts, and an upper housing combined with the lower housing.