Challenges in battery assembly:
- Joint strength and leak tightness
- Removable cover for service requirements
- Repeatable fastening/tightening
- Electrical contacting
- One-sided access
- Large series production
Our solution for cover-to-tray joining:
Flow drill fastening meets high standards for joint strength and crash performance. With our K-Flow technology, the battery cover can be mounted to the tray with single-sided access. The joint is leak tight between fastener and sheet as well as between both sheets and it can be combined with a liquid gasket. At the same time, it is detachable to facilitate maintenance and dismantling. The metallic components are in a conductive bond and form a Faraday cage, which prevents electromagnetic interference. With short cycle times and high process reliability, it is suited for large series production.
Two layer stack with clearance hole
By using a clamping part with clearance hole, thicker stack-ups with up to four layers can be joined with flow drill fastening. The upper layer can be aluminum or even high-strength steel (HSS). Since no upcoming material needs to be accommodated by the joining element, a cheaper flat head fastener can be used. However, the position of the robot is very important to exactly meet the clearance hole. If used with adhesive, a stitch bead application is recommended to avoid squeeze out.
This joint variant is commonly used for applications where serviceability is a priority, for example cover to tray joining in battery assembly for electric vehicles. Due to the clearance hole in the cover sheet, the cover can be easily disassembled and reassembled several times and remain leak tight.
Joint properties (for reference only):
- Two layer stack
- Clamping part with pre-hole
- Materials: Aluminum 2.0 mm / Aluminum 4.0 mm
- Fastener: M5x20 internal torx
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