Welding Bush Design for Battery Module Structural Integrity
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Solution Overview
Problem
Existing rechargeable battery modules face challenges in efficiently supporting and securing unit cells while maintaining a lightweight and robust structure, particularly in limited spaces, due to structural limitations in welding bushes that connect end plates and side plates.
Innovation Solution
The rechargeable battery module incorporates a welding bush design with a cylinder member and cap member, where the cap member increases the surface area to which loads are applied, and is formed from materials like stainless steel and steel with lower strength, respectively, to enhance structural integrity and reduce weight, while maintaining efficient unit cell placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding bushes are used to connect end plates and side plates, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The welding bush comprises a cylinder member nested within a cap member, where the cap member is inserted into the cylinder member. This nested structure allows two functional components to be combined in a compact arrangement, providing both structural integrity through the welding connection and simplified assembly by integrating multiple functions into a single bush component.
2Strength
If cap member is added to increase surface area, then load distribution is improved, but weight increases
Solution Approach 1:
The cap member is strategically added only at specific locations where load application occurs, increasing the surface area precisely where needed for load distribution. The cylinder member provides the essential welding function, while the cap member locally enhances load-bearing capacity without adding unnecessary weight throughout the entire structure.
3Volume of moving object
If welding bush structure is optimized, then space efficiency is improved, but manufacturing difficulty increases
Solution Approach 1:
The welding bush is segmented into two distinct members: a cylinder member for welding connections and a cap member for load distribution. This segmentation allows each component to be manufactured separately using optimized processes for its specific function, then assembled together. The modular approach enables compact design while maintaining ease of manufacture through specialized production of individual 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
This design allows for a rechargeable battery module with maximized efficiency and output, as it effectively secures unit cells without increasing the occupied space, while minimizing weight and preventing damage from structural stress.
Implementation Method 1
the cap member increasing a corresponding surface area to which the load is applied
Implementation Method 2
welding bushes being connected to the end plate and the side plates, and combined with the support member by a penetrating fastening member
Data Source
AI summary
A rechargeable battery module may include: a plurality of unit cells arranged in a first direction and electrically coupled via a bus bar, including a pair of outermost unit cells at opposite ends of the first direction; an end plate supporting the outermost unit cells; side plates at opposite ends of a second direction to support side surfaces of the unit cells; a support member supporting the unit cells at a lower end of a third direction; and welding bushes extended in the third direction at opposite ends of the end plate in the second direction and opposite ends of the side plates in the first direction. Each welding bush may include a cylinder member to which the end plate and one of the side plates are welded, and a cap member combined with at least one of opposite ends of the cylinder member.