Welded Battery Module Case Design for Structural Integrity
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Solution Overview
Problem
Existing battery modules face challenges in achieving stable strength and rigidity, high sealability, and improved productivity, particularly in large-scale applications such as automobiles, where they need to withstand external impacts and prevent foreign substance penetration while minimizing components for increased efficiency.
Innovation Solution
A battery module design featuring a cell assembly with a cooling plate, covered by multiple welded plates including a front, rear, left, and right side covers, and an upper plate, utilizing friction stir welding for assembly, which eliminates the need for cartridges and cooling fins, enhancing structural integrity and sealing without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (cartridges, cooling fins, multiple sealing parts) are used to ensure mechanical strength and sealing, then reliability and sealability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (cartridges, cooling fins, sealing parts) into an integrated case structure. The case serves multiple functions simultaneously: it provides mechanical protection, thermal management through integrated cooling channels, and sealing through welded joints. This merging reduces the number of discrete parts while maintaining or improving reliability and sealability.
Solution Approach 2:
The case is designed as a multi-functional component that performs mechanical support, thermal dissipation, and sealing functions. The integrated design allows a single component to fulfill multiple roles that previously required separate parts, thereby reducing device complexity while maintaining reliability.
2Reliability
If multiple separate components (cartridges, cooling fins, sealing parts) are used to ensure mechanical strength and sealing, then reliability and sealability are improved, but manufacturing cost and weight increase
Solution Approach 1:
The patent integrates multiple components into a unified case structure, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation lowers manufacturing costs through reduced material usage, simplified production processes, and decreased assembly operations while maintaining mechanical strength through the integrated welded structure.
3Reliability
If traditional sealing methods with multiple parts are used, then sealability is improved, but assembly time and productivity are reduced
Solution Approach 1:
The patent employs welded joints to integrate the case components, replacing traditional multi-step sealing assemblies. Welding creates permanent, sealed connections in a single operation, eliminating the need for multiple separate sealing components and their associated assembly steps. This significantly reduces assembly time and improves productivity while maintaining high sealability.
4Strength
If rigid structural components are added to withstand external impacts, then mechanical strength is improved, but weight and device complexity increase
Solution Approach 1:
The patent integrates structural support and impact resistance functions into the case itself, eliminating the need for separate reinforcement components. The case is designed with sufficient wall thickness and structural geometry to withstand external impacts, thereby providing mechanical strength without adding extra weight from additional rigid components.
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
The solution provides a battery module with enhanced scalability, reduced component count, improved assembly efficiency, and increased thermal conductivity, ensuring stability and sealing performance even under pressure, thus reducing manufacturing costs and weight while maintaining high rigidity.
Implementation Method 1
a cooling plate having a plate shape and placed below the cell assembly to receive the cell assembly thereon
Implementation Method 2
at least two of the cooling plate, the front cover, the rear cover, the left side cover, the right side cover, and the upper plate may be welded together by a friction stir welding method
Data Source
AI summary
The present disclosure relates to a battery module having stable strength and rigidity, high sealability and assemblability, and improved productivity. The battery module of the present disclosure includes: a cell assembly; a cooling plate; a front cover having a lower portion welded to the cooling plate; a rear cover having a lower portion welded to the cooling plate; a left side cover having a lower end portion welded to the cooling plate and a rear end portion welded to the rear cover; a right side cover having a lower end portion welded to the cooling plate, a front end portion welded to the front cover, and a rear end portion welded to the rear cover; and an upper plate having a left end portion welded to the left side cover and a right end portion welded to the right side cover.