Composite Battery Bottom Guard With Honeycomb Impact Resistance
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Solution Overview
Problem
The existing steel guard plates or composite steel guard plates used in battery packs are heavy, rigidly poor, and prone to deformation during bottoming scraping or bottoming out, leading to potential damage or fire, compromising the safety of the battery.
Innovation Solution
A composite bottom guard comprising a five-layer structure of stacked first, second, third plates, and metal and honeycomb plates, with the metal plate improving structural strength and the honeycomb plate providing cushioning to absorb extrusion and collision energy, reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steel guard plate or composite steel guard plate is used for battery bottom guard, then processing and welding performance is improved, but weight increases and rigidity deteriorates
Solution Approach 1:
The patent applies composite materials by combining aluminum alloy (lightweight, good corrosion resistance) with reinforcing structures (rigid plates, honeycomb structures, or truss structures) to create a bottom guard that achieves both light weight and high rigidity. This resolves the contradiction by replacing traditional steel materials with a composite structure that integrates multiple material advantages.
2Reliability
If steel guard plate or composite steel guard plate is used for battery bottom guard, then protective role is provided, but rigidity is poor and deformation occurs during bottoming scraping or bottoming out
Solution Approach 1:
The patent segments the bottom guard into multiple functional components: an aluminum alloy base plate providing lightweight protection, and separate reinforcing structures (rigid plates, honeycomb structures, or truss structures) that provide enhanced rigidity. This segmentation allows each component to perform its specific function optimally, resolving the contradiction between protective role and rigidity.
Solution Approach 2:
By creating a composite structure that combines aluminum alloy with rigid reinforcing elements, the patent achieves both the protective role (through the aluminum alloy base) and high rigidity (through the reinforcing structures), preventing deformation during bottoming scraping or bottoming out events.
3Ease of manufacture
If steel guard plate or composite steel guard plate is used, then processing performance is improved, but weight increases
Solution Approach 1:
The patent uses aluminum alloy as the base material, which inherently has lower density and weight compared to steel, while maintaining good processing performance. The addition of reinforcing structures is done through methods that complement aluminum alloy's processing characteristics, thus achieving weight reduction without sacrificing ease of manufacture.
4Strength
If traditional steel guard plate is used, then structural strength is provided, but rigidity is poor leading to extrusion and deformation
Solution Approach 1:
The patent divides the bottom guard into functional segments: the aluminum alloy plate providing structural strength and basic protection, and separate rigid reinforcing structures (plates, honeycomb structures, or truss structures) specifically designed to enhance rigidity and prevent deformation. This segmentation allows optimization of each component for its specific purpose.
Solution Approach 2:
The patent enhances rigidity by adding three-dimensional reinforcing structures (such as honeycomb structures or truss structures) to the two-dimensional aluminum alloy plate, creating a multi-dimensional composite structure that provides superior rigidity and resistance to extrusion while maintaining lightweight characteristics.
Data Source
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AI summary
The present disclosure provides a composite bottom guard, a battery, and an electrical device. The composite bottom guard includes a first plate, a second plate, and a metal plate. The first plate and the second plate enclose to define a first holding cavity, and the metal plate is filled in the first holding cavity; or, the composite bottom guard further includes a third plate and a honeycomb plate, the third plate and the second plate enclose to define a second holding cavity, one of the metal plate and the honeycomb plate is filled in the first holding cavity, and the other of the metal plate and the honeycomb plate is filled in the second containment cavity.