Battery Housing Spacer Joint for Flush Plate Support
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Solution Overview
Problem
Existing battery housing designs for motor vehicles face challenges in ensuring the securement and rigidity of battery modules, particularly due to their heavy weight and the need for even weight distribution to maintain vehicle stability and prevent damage from ground contact.
Innovation Solution
A battery housing design that incorporates a spacer with an insertion portion projecting into a cut-out on the base and cover plates, where the end face of the insertion portion is materially connected to the plate, providing a positive fit and secure support without projecting parts outside the plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the spacer has an insertion portion that projects into the cut-out to the maximum extent (end face flush with outer side of plate), then the structural integrity and force distribution are improved, but the risk of accidental melt-through during welding increases
Solution Approach 1:
The patent applies local quality by creating a fillet weld in the corner region where the insertion portion meets the plate. This localized welding approach concentrates the strengthening effect at the critical corner junction while avoiding excessive heat input that could cause melt-through of the plate material. The fillet weld geometry provides gradual stress distribution and enhanced local strength without compromising the plate's integrity.
2Stability of the object's composition
If the spacer is secured on the plate with material connection (welding), then the rigidity and stability are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the welding process into discrete fillet welds at specific corner locations rather than requiring continuous welding around the entire perimeter of the cut-out. This segmentation reduces the total welding time and material consumption while maintaining sufficient rigidity and stability. The corner regions are identified as critical load-bearing points, so welding these locations provides optimal strength-to-manufacturing-complexity ratio.
3Force
If the end face of the insertion portion lies flush with the outer side of the plate, then the positive fit and force distribution are improved, but the precision requirements for assembly increase
Solution Approach 1:
The patent incorporates a fillet weld at the corner region that acts as a cushioning element, accommodating minor misalignments between the insertion portion end face and the plate outer side. This fillet weld creates a gradual transition zone that tolerates small dimensional variations and assembly tolerances, reducing the stringency of precision requirements while maintaining effective force distribution across the joint.
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 the structural integrity and stability of the battery housing by ensuring even force distribution and preventing deformation, while also simplifying assembly and reducing the risk of accidental melt-through during welding.
Implementation Method 1
the center of the weld seam arranged on the end face of the insertion portion of the spacer
Data Source
AI summary
A battery housing for a motor vehicle comprising a base part having a base plate and a cover part having a cover plate. The base part and the cover part delimit a receptacle volume for receiving at least one battery module. The two plates are spaced apart by at least one spacer which is disposed inside the receptacle volume and is supported on the two plates. In the region of at least one support of the spacer, the respective plate has a cut-out. The spacer has an insertion portion which projects into the cut-out and is secured on this plate. The insertion portion projects into the cut-out to the maximum extent that the end face of the insertion portion lies flush with the outer side of the plate.