Aluminum Battery Box Bottom for Lightweight Intrusion Resistance
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Solution Overview
Problem
Existing battery boxes for electric or hybrid motor vehicles face challenges in achieving a balance between light weight, crash resistance, tight sealing, corrosion resistance, temperature control, and the ability to accommodate a maximum number of electrical energy storage cell elements.
Innovation Solution
A bottom part for the battery box made from an aluminum alloy sheet with a thickness between 2 and 6 mm, comprising 2.5 to 4.0 wt.% Mg, 0.1 to 0.8 wt.% Mn, 0.4 wt.% or less Si, 0.5 wt.% or less Fe, 0.5 wt.% or less Cu, 0.1 wt.% or less Cr, 0.1 wt.% or less Zn, 0.1 wt.% or less Ti, with the rest being aluminum and unavoidable impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the sheet thickness is reduced to minimize weight, then the weight of the battery box is improved, but the intrusion resistance and mechanical strength deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the aluminum alloy (Mg: 2.5-4.0%, Mn: 0.1-0.8%, Si: ≤0.4%, Fe: ≤0.5%, Cu: ≤0.5%) to achieve optimal mechanical properties at reduced thickness. This compositional parameter optimization allows the material to maintain high strength-to-weight ratio, enabling weight reduction while preserving intrusion resistance through enhanced material properties rather than increased thickness
Solution Approach 2:
The patent utilizes composite material principles by creating a multi-element aluminum alloy system that combines Mg, Mn, Si, Fe, Cu, and other elements in specific proportions. This composite alloy structure synergistically enhances both strength and corrosion resistance, allowing the bottom part to achieve required mechanical performance at reduced thickness, thereby resolving the contradiction between weight minimization and strength maintenance
2Weight of moving object
If the sheet thickness is reduced to minimize weight, then the weight of the battery box is improved, but the corrosion resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the aluminum alloy (Mg: 2.5-4.0%, Mn: 0.1-0.8%, Si: ≤0.4%, Fe: ≤0.5%, Cu: ≤0.5%) to achieve optimal mechanical properties at reduced thickness. This compositional parameter optimization allows the material to maintain high strength-to-weight ratio, enabling weight reduction while preserving intrusion resistance through enhanced material properties rather than increased thickness
Solution Approach 2:
The patent utilizes composite material principles by creating a multi-element aluminum alloy system that combines Mg, Mn, Si, Fe, Cu, and other elements in specific proportions. This composite alloy structure synergistically enhances both strength and corrosion resistance, allowing the bottom part to achieve required mechanical performance at reduced thickness, thereby resolving the contradiction between weight minimization and strength maintenance
Data Source
AI summary
The present invention is directed to a bottom part of a battery box for electric or hybrid motor vehicles made from an aluminium alloy sheet having a thickness between 2 and 6 mm, wherein said aluminum alloy comprises 2.5 to 4.0 wt. % of Mg, 0.1 to 0.8 wt. % of Mn, 0.4 wt. % or less of Si, 0.5 wt. % or less of Fe, 0.5 wt. % or less of Cu, 0.1 wt. % or less of Cr, 0.1 wt. % or less of Zn, 0.1 wt. % or less of Ti, rest aluminium and unavoidable impurities up to 0.05 wt. % each and 0.15 wt. % total. Another object of the invention is a method to make a bottom part of battery box according to the invention comprising casting said aluminium alloy into a rolling ingot; homogenizing and/or reheating said rolling ingot; hot rolling and optionally cold rolling said rolling ingot to obtain a sheet with a thickness between 2 mm and 6 mm. The bottom part of battery box of the invention is simultaneously light, resistant against intrusion, sufficiently formable and leak tight, corrosion resistant, able to accommodate temperature variations and sufficiently stiff and strong.