Extruded Hollow Battery Box Plate With Self-Locking Bonded Joints
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Solution Overview
Problem
The existing methods for manufacturing battery shells in electrical automobiles, such as friction stir welding, are time-consuming and inefficient due to the extensive time required for welding seams, which restricts the manufacturing speed of battery shells.
Innovation Solution
A spliced and bonded battery box bottom plate structure using extruded hollow plates with specific protrusions and grooves, including involute surfaces and bonding layers, allows for a self-locking connection that simplifies the assembly process and eliminates the need for heating, reducing production time and device costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir welding is used to join extruded hollow plates, then the seams have sufficient strength, but the manufacturing time increases significantly
Solution Approach 1:
The patent replaces the friction stir welding process with a mechanical self-locking connection system. The protrusion and groove structures with involute surfaces create a mechanical interlock that eliminates the need for thermal welding, thereby reducing manufacturing time while maintaining connection strength through mechanical engagement rather than metallurgical bonding.
Solution Approach 2:
The self-locking connection structure allows the extruded hollow plates to connect automatically through their own geometric features (protrusions and grooves) without requiring external welding equipment or complex fixation processes. The structure serves its own joining function, eliminating the time-consuming welding operation.
2Strength
If friction stir welding is used to join extruded hollow plates, then the seams have sufficient strength, but the device complexity and cost increase
Solution Approach 1:
The patent eliminates the need for friction stir welding equipment by using a purely mechanical self-locking connection. This substitution removes complex welding machinery, heating systems, and control mechanisms from the manufacturing process, thereby reducing device complexity and associated costs while maintaining seam integrity through geometric interlocking.
Solution Approach 2:
The invention extracts and eliminates the welding process entirely from the manufacturing system. By removing the welding operation and replacing it with a mechanical connection feature that is integral to the extruded profile itself, the patent simplifies the overall manufacturing system and reduces equipment requirements.
3Strength
If friction stir welding is used to join extruded hollow plates, then the seams are securely connected, but thermal deformation occurs
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical self-locking connection that operates at ambient temperatures. The protrusion and groove structures with involute surfaces engage mechanically without generating heat, thereby eliminating thermal deformation while maintaining secure seam connection through geometric interlocking and frictional engagement.
4Reliability
If the extruded hollow plates are spliced with multiple weld seams, then the structural integrity is maintained, but the production speed decreases
Solution Approach 1:
The self-locking connection structure enables the extruded hollow plates to join automatically through their own geometric features during the extrusion or assembly process. This self-joining capability eliminates the need for separate welding operations for each seam, thereby maintaining structural integrity through mechanical interlocking while significantly improving production speed by reducing the number and time of joining operations.
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 approach significantly enhances production speed, simplifies the assembly process, reduces thermal deformation risks, and improves the waterproof performance of the battery box bottom plate, leading to a more efficient and cost-effective manufacturing method.
Implementation Method 1
the body includes a protrusion and/or a groove at end portions or at an end portion, the protrusion bends downward, the groove forms an upward hook at an opening thereof
Implementation Method 2
in the rotation and insertion process, a first gap is kept between the first curved surface and the second curved surface, and a second gap is kept between the third curved surface and the fourth curved surface
Implementation Method 3
a spliced and bonded battery box bottom plate structure using extruded hollow plates with specific protrusions and grooves, including involute surfaces and bonding layers
Data Source
AI summary
An extruded hollow plate and an electric vehicle battery casing formed by combining the extruded hollow plates. The extruded hollow plate has a plate-shaped body having a constant cross-section, a cavity is provided inside the plate-shaped body, a protrusion and/or a groove is provided at an end of the body, the protrusion is bent downward, the groove opens upwards as a hook, and the arc surfaces forming the protrusion and the groove each comprise at least two involute surfaces. Compared with the existing battery box manufacturing process of friction stir welding, the combining and bonding connection manner has the significant advantages of rapid production speed, a low device cost, high flatness, etc.