Semi-Enclosed Battery Module Structure for Weld Crack Resistance
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Solution Overview
Problem
Traditional battery modules face inefficiencies in assembly, risk of weld cracking due to high swelling forces, and reduced structural strength from multiple welds, which can lead to module failure.
Innovation Solution
A battery module design featuring a semi-enclosure structure with two enclosing plates and fasteners, reducing the number of junctions and enhancing structural strength by distributing fasteners to resist swelling and deformation, while facilitating easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If butt welding is used to connect end plates and side plates, then the enclosure structure is formed, but the assembling efficiency is low due to process operations and weld cracking occurs under swelling force
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system using bolts or rivets. This substitution eliminates the complex welding operations and associated defects while maintaining structural integrity. The fasteners provide reliable mechanical connection without the harmful effects of welding under swelling forces.
2Ease of manufacture
If multiple welds are used to connect plates, then the enclosure structure is formed, but the structural strength is reduced as weld strength is only 70% of parent metal
Solution Approach 1:
The patent replaces multiple weak weld joints with fewer, stronger mechanical fasteners. Each fastener provides a connection strength comparable to or exceeding the parent metal, eliminating the 70% strength limitation of welded joints. The mechanical fastening system achieves the same enclosure formation with superior structural integrity.
3Ease of manufacture
If welding is used to connect plates, then the enclosure structure is formed, but weld cracking occurs under swelling force of 30 KN or more
Solution Approach 1:
The patent replaces welding with mechanical fasteners that can better withstand swelling forces. The fasteners distribute the 30 KN or more swelling force across multiple connection points, preventing the stress concentration that leads to weld cracking. This mechanical connection system maintains reliability under high swelling conditions.
4Strength
If fasteners are distributed to resist swelling, then structural strength is increased, but the number of connecting holes increases
Solution Approach 1:
The patent divides the connection system into multiple discrete fastener locations distributed across the plate surfaces. This segmentation allows the swelling force to be distributed across many small connection points rather than concentrated at few large joints, increasing overall structural strength while managing the complexity through standardized fastener placement.
Data Source
AI summary
This application provides a battery module, including a plurality of batteries, a first enclosing plate, and a second enclosing plate. The first enclosing plate includes a first side plate, a first front plate containing a first connecting hole, and a first rear plate containing a third connecting hole. The second enclosing plate includes a second side plate, a second front plate containing a second connecting hole, and a second rear plate containing a fourth connecting hole. The first connecting hole and the second connecting hole are fixedly connected to the first front plate and the second front plate by the fasteners. The third connecting hole and the fourth connecting hole are fixedly connected to the first rear plate and the second rear plate by the fasteners. Both the first enclosing plate and the second enclosing plate form a semi-enclosure structure, and tightly enclose the plurality of batteries.