Perforated Battery Pack Box Base Plate for Lightweight Rigidity
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Solution Overview
Problem
Existing battery pack boxes are heavy, difficult to manufacture, and lack sufficient structural support and impact resistance, limiting their energy density and load-bearing capacity.
Innovation Solution
A battery pack box design featuring a base plate composed of a first and second plate with a perforated plate in between, containing holes and optionally reinforced by crossbeams, which are made of aluminum alloy to reduce weight and enhance structural rigidity and support strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base plate is made as an integral stamped and molded metal structure, then the structural strength and support capacity are improved, but the manufacturing complexity and difficulty increase, and group efficiency requirements cannot be met
Solution Approach 1:
The base plate is divided into multiple independent components: a first plate, a second plate, and a perforated plate with supporting beams. These segmented components are connected through welding or bonding, replacing the integral stamped structure. This segmentation simplifies manufacturing processes while maintaining the required support capacity through the distributed beam structure.
2Weight of moving object
If concave parts are added to the inner surface of the base plate to reduce weight, then the energy density is improved, but the structural complexity increases and manufacturing becomes more difficult
Solution Approach 1:
Instead of creating complex concave features on a single base plate, the structure is segmented into multiple plates connected by perpendicular supporting beams. The hollow spaces are formed naturally by the spatial arrangement of these beams between the first and second plates, achieving weight reduction without complicating the manufacturing of individual components.
Solution Approach 2:
The supporting beams extend in the height direction (vertical dimension) rather than creating complex 2D concave patterns on the base plate surface. This dimensional transition simplifies the manufacturing of each plate while achieving weight reduction through the three-dimensional spatial structure.
3Productivity
If the base plate structure is simplified to improve manufacturing efficiency, then the production speed increases, but the load-bearing capacity and impact resistance decrease
Solution Approach 1:
The base plate is segmented into simple flat plates and perpendicular supporting beams, each easy to manufacture. The load-bearing capacity is maintained through the distributed beam structure that provides support across the entire base, with beams positioned to optimize structural strength while simplifying individual component fabrication.
Solution Approach 2:
The base plate structure combines multiple materials or processing methods: the plates may be made of different materials or undergo different surface treatments, and the connections between components use welding or bonding. This composite approach allows each component to be optimized for its specific function while maintaining overall structural integrity and load-bearing capacity.
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
The design reduces weight, improves energy density, and enhances structural rigidity and impact resistance, making it easier to manufacture and assemble while maintaining strong pressure resistance and seismic performance.
Implementation Method 1
the perforated plate is welded and fixed to the first plate and the second plate respectively
Implementation Method 2
materials of the first plate, the second plate and the perforated plate are the same; a material of the perforated plate includes aluminum alloy
Data Source
AI summary
The present application is provided with a battery box and a battery pack. The battery pack box includes a base plate and a frame, the base plate being connected with the frame; where the base plate includes: a first plate; a second plate, disposed opposite to the first plate; and a perforated plate, provided with a plurality of holes spaced; where the perforated plate is located between the first plate and the second plate, and is welded and fixed to the first plate and the second plate respectively. In the present application, the perforated plate can reduce the overall weight of the box and increase the energy density of the battery pack.