Stepped Battery Module Case Structure for Stronger Welded Joints
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Solution Overview
Problem
Welding defects occur during the manufacturing of battery modules, reducing the yield and bonding force of the battery module case.
Innovation Solution
A battery module case design featuring a stepped portion on the bottom plate, with a recessed coupling portion on the end plate, allowing for improved welding and increased bonding force between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional flat bottom plate design is used, then the manufacturing process is simple, but welding defects occur and bonding force is reduced
Solution Approach 1:
The bottom plate is designed with a stepped portion that creates different thickness levels at different locations. The first thickness portion has a greater thickness than the second thickness portion, allowing the welding structure to concentrate bonding force at the thicker first thickness portion while maintaining a thinner second thickness portion for other functions. This local variation in thickness optimizes the welding interface quality and reduces welding defects.
Solution Approach 2:
The invention transitions from a conventional uniform two-dimensional plate design to a three-dimensional stepped structure with varying thickness. The stepped portion creates multiple height levels, adding a vertical dimension to the welding interface. This dimensional change allows for better weld penetration and bonding at the thicker first thickness portion, thereby improving bonding force and reducing welding defects.
2Strength
If the bottom plate thickness is increased uniformly, then bonding force may improve, but manufacturing complexity and material usage increase
Solution Approach 1:
Instead of uniformly increasing the bottom plate thickness, the invention applies increased thickness only at the first thickness portion where welding occurs. The stepped portion creates a localized thickened area that concentrates bonding force, while the rest of the bottom plate maintains a thinner profile. This selective thickening improves bonding force without proportionally increasing overall structural complexity or material usage.
Solution Approach 2:
The invention changes the thickness parameter of the bottom plate from a uniform value to a variable value with two distinct thickness levels. The first thickness portion has a greater thickness optimized for welding, while the second thickness portion has a smaller thickness for other functional requirements. This parameter variation allows optimization of bonding force at critical locations without uniformly increasing the entire structure's complexity.
Data Source
AI summary
Disclosed herein is a battery module. The battery module case can include a stepped structure to increase the bonding forces between components of the case to improve yield of a battery module. The battery module can include a main body with a bottom plate connected to first and second side surfaces at opposite lateral portions. The case can include a first end plate and a second end plate to connect to the main body and cover the front and rear surfaces. A cover plate can enclose the upper surface of the main body. The stepped structure can be along an edge of the bottom plate to connect with the first and second end plate.