Battery Shell Brazing Groove for Reliable Thin-Wall Sealing
Solution Overview
Problem
Existing battery shell manufacturing processes face challenges in achieving precise sealing and high processing efficiency due to complex structures and thin housing, leading to poor soldering quality and increased failure risks.
Innovation Solution
The battery shell design incorporates a first groove on the cover plate or housing to accommodate solder, forming a brazing seam that seals the inner cavity and fixes the cover plate to the housing, with a lower melting point solder used to simplify the soldering process and reduce residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering is used to seal the battery shell, then sealing performance can be achieved, but the complex structure and thin housing lead to poor soldering quality, soldering holes, and high failure risk
Solution Approach 1:
The patent changes the material parameter by using brazing alloy instead of traditional solder, which has different melting characteristics and flow properties. This parameter change allows the sealing material to better adapt to the thin housing structure, filling gaps effectively without causing soldering holes or poor fusion, thereby resolving the contradiction between achieving reliable sealing and maintaining ease of manufacture.
Solution Approach 2:
The patent introduces a groove structure as an intermediary element that accommodates the brazing alloy. This groove acts as a mediator between the cover plate and housing, controlling the flow and distribution of the sealing material. By providing this intermediate structure, the patent enables reliable sealing while simplifying the manufacturing process, as the groove guides the brazing alloy to exactly where it is needed without requiring complex soldering techniques.
2Reliability
If the housing and cover plate are melted and solidified to eliminate gaps, then sealing can be achieved, but residual stress and cracks are easily caused, increasing failure risk
Solution Approach 1:
The patent changes the thermal parameter by using brazing alloy with a lower melting point than the housing and cover plate materials. This allows the sealing material to melt and fill gaps at a temperature that does not cause excessive thermal stress or deformation to the main structural components. The controlled solidification process in the groove minimizes residual stress and prevents cracks, thereby maintaining structural integrity while achieving reliable sealing.
3Manufacturing precision
If high processing precision is required to meet sealing requirements, then gap control between cover plate and housing is improved, but manufacturing complexity and processing costs increase
Solution Approach 1:
The patent introduces the groove structure as an intermediary that decouples the sealing function from the main structural components. Instead of requiring high precision in the cover plate and housing assembly, the groove provides a dedicated space for the brazing alloy to fill and create the seal. This intermediary structure absorbs dimensional variations and simplifies the manufacturing process, allowing for easier assembly while maintaining reliable sealing performance.
Solution Approach 2:
The patent segments the sealing function from the structural function by creating a separate groove structure. The groove is a distinct element that houses the brazing alloy, separating the sealing requirement from the main housing and cover plate assembly. This segmentation allows each component to be manufactured independently with relaxed tolerances, reducing overall manufacturing complexity while ensuring proper sealing through the dedicated groove structure.
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 simplifies the soldering process, improves manufacturing efficiency, reduces residual stress and failure risks, and ensures reliable sealing and protection of the battery core.
Implementation Method 1
the solder is molten through heating after the cover plate and the housing are assembled, to form the brazing seam structure and fill a gap between the cover plate and the housing
Implementation Method 2
a brazing seam is provided between the cover plate and the housing, the brazing seam is configured to fix the housing and the cover plate to cause the cover plate to seal the inner cavity
Data Source
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AI summary
The present disclosure relates to a battery shell, a battery, a battery pack, and a power consuming system. The battery and a battery pack shell form the battery pack to supply power to the power consuming system, and the battery shell of the battery includes a housing and a cover plate. The housing includes an inner cavity, the inner cavity has an opening, the cover plate is fixed to the housing, and the cover plate covers the opening of the inner cavity. A first groove is provided on at least one of a surface of the cover plate facing the housing and a surface of the housing facing the cover plate, a brazing seam is provided between the cover plate and the housing, and the brazing seam is configured to connect the housing to the cover plate fixedly to seal the inner cavity. The first groove is adapted to accommodate solder for forming the brazing seam. The battery shell of the present disclosure is formed through brazing, thereby reducing soldering difficulty, reducing manufacturing costs, and reducing residual stress and a failure risk after soldering.