Car Battery Array Load Distribution via Reinforcing Rods
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Solution Overview
Problem
Conventional car battery arrays with multiple high-capacity battery cells are excessively heavy due to the weight of the battery cells being supported by a thick metal frame, leading to a heavy and cumbersome external case.
Innovation Solution
A car battery array design featuring battery blocks mounted on a first load-bearing plate and secured to a second load-bearing plate via reinforcing rods, distributing the load and providing a sturdy box-shaped structure with integrated cooling and exhaust ducts, which also serve as reinforcing elements, thereby reducing overall weight while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery cells are housed in an external case with a thick metal frame plate to support the weight, then structural strength is improved, but the overall weight of the external case increases
Solution Approach 1:
The external case is segmented into multiple functional components: a thin frame plate for basic structure, separate reinforcing rods for structural strengthening, and an upper cover plate for protection. This segmentation allows each component to be optimized independently, with the thin frame plate reducing weight while reinforcing rods provide the necessary strength.
Solution Approach 2:
The reinforcing rods extend vertically between the frame plate and upper cover plate, adding a vertical dimension to load distribution. This three-dimensional reinforcement structure efficiently transfers battery weight to both the frame plate and cover plate, reducing the need for a thick frame plate while maintaining structural strength.
2Power
If many high capacity battery cells are connected in series to raise output voltage, then power supply capability is improved, but the overall weight of the battery array increases
Solution Approach 1:
The upper cover plate serves multiple functions: it protects the battery cells from damage, provides a mounting surface for terminal boxes, and acts as a load-bearing element that supports battery weight through the reinforcing rods. This multi-functionality reduces the need for separate protective structures, reducing overall weight while maintaining power capability.
Solution Approach 2:
The external case uses composite construction combining metal frame plate, metal reinforcing rods, and plastic upper cover plate. This composite approach optimizes the weight-strength ratio by using materials with appropriate properties for each functional requirement, reducing overall weight while maintaining structural integrity for high-power battery arrays.
Data Source
AI summary
A car battery array is provided with battery blocks (2) having a plurality of connected batteries (1), a first load-bearing plate (3) on top of which the battery blocks are mounted, a second load-bearing plate (4) attached on both sides to the first load-bearing plate and covering the tops of the battery blocks, and a reinforcing rod (5) that connects with the second load-bearing plate and the battery blocks to attach the second load-bearing plate to the battery blocks. The battery blocks are disposed in a battery compartment (6) established inside the first and second load-bearing plates, which are joined together on both sides. The battery blocks are mounted on top of the first load-bearing plate and connected to the second load-bearing plate via the reinforcing rod to support the battery block load with the first load-bearing plate and the second load-bearing plate.