Battery Case Cross Member Core to Minimize Laser Welding Gaps
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Solution Overview
Problem
The thermal deformation of cross members with a closed square cross-sectional shape during laser welding leads to gaps and reduced welding quality when assembling parts to the battery case in electric vehicles.
Innovation Solution
A core assembly system comprising steel core blocks with inclined slip surfaces and magnet members, along with a mounting jig, is used to minimize thermal deformation by inserting into the cross member's closed section and pressing surfaces during laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to bond parts to the cross member, then welding efficiency and automation are improved, but thermal deformation occurs causing gaps and reduced welding quality
Solution Approach 1:
A core insert is introduced as an intermediary component placed inside the closed-section cross member. This core serves as a mediator that absorbs and distributes the thermal stress generated during laser welding, preventing direct thermal deformation of the cross member structure and maintaining welding precision while preserving high welding efficiency
Solution Approach 2:
The core insert is pre-installed inside the cross member before the laser welding process begins. This beforehand cushioning approach prepares the internal structure to withstand and distribute upcoming thermal stresses, preventing gaps and deformation before they occur during welding
2Strength
If the cross member has a closed square cross-sectional shape for structural strength, then mechanical strength is improved, but thermal deformation during laser welding increases causing gaps
Solution Approach 1:
The core insert is nested inside the closed-section cross member, creating a concentric structure. This nesting approach maintains the external closed-square shape for structural strength while introducing an internal element that mitigates thermal deformation effects during laser welding
Solution Approach 2:
The core acts as an internal intermediary that absorbs thermal energy and prevents it from causing deformation of the cross member's closed-section structure, allowing the strong closed shape to be maintained without suffering from thermal deformation issues
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 system prevents gaps and enhances laser welding quality by minimizing thermal deformation, ensuring secure bonding of parts to the cross member.
Implementation Method 1
a plurality of first magnet members (30) installed on one surface of the first core block (10), and a plurality of second magnet members (40) installed on one surface of the second core block (20)
Data Source
AI summary
Disclosed is a core for assembling a cross member of a battery case. A core for assembling a cross member of a battery case is insertable into a closed section in a longitudinal direction of the cross member to laser-weld at least one part to be assembled to the cross member of the battery case with the closed section. The core may include: a first core block made of steel, which includes a first slip surface formed at one side in a width direction to be inclined in a direction toward the other side; a second core block made of the steel, which includes a second slip surface formed to be inclined at the one side in the width direction to slip on the corresponding first slip surface in an upper and lower direction; a plurality of first magnet members installed on one surface of the first core block; and a plurality of second magnet members installed on one surface of the second core block facing the one surface of the first core block.