Battery Carrier Frame with Defined Adhesive Gaps
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Solution Overview
Problem
Existing battery carriers for electric motor vehicles face challenges in manufacturing complexity and achieving tightness, particularly in corner regions, due to the limitations of sheet-metal formed components during forming processes and ensuring tightness.
Innovation Solution
A battery carrier design featuring a trough formed by a base and a peripheral frame from extruded hollow profiles, with protruding webs to create defined gaps for sealants and adhesives, ensuring tightness and modular construction for heat management, using light metal alloys like aluminum for the frame profiles and integrating a cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sheet-metal formed components are used for the battery carrier, then the structural integrity is improved, but the manufacturing complexity and difficulty in achieving tightness in corner regions increases
Solution Approach 1:
The battery carrier is divided into modular components: a base and a peripheral frame made from separate extruded hollow profiles. This segmentation allows each component to be manufactured independently with simpler processes, then assembled together, reducing overall manufacturing complexity while maintaining structural integrity through the modular design.
Solution Approach 2:
The invention uses composite construction by combining extruded hollow profiles (frame) with a base plate, creating a hybrid structure that leverages the advantages of both components. The extruded profiles provide structural strength and rigidity, while the modular assembly approach simplifies manufacturing compared to forming complex sheet-metal components.
2Strength
If sheet-metal formed components are used for the battery carrier, then the structural integrity is improved, but the tightness in corner regions during forming processes deteriorates
Solution Approach 1:
By separating the battery carrier into a base and a peripheral frame made from extruded profiles, the invention avoids the corner region forming issues inherent in monolithic sheet-metal components. The extruded profiles are manufactured separately with precise dimensions, and their assembly to the base ensures consistent tightness without the distortion problems of deep-drawing corner regions.
Solution Approach 2:
The invention changes the manufacturing parameter approach by using extrusion processes for the frame profiles instead of sheet-metal forming. Extrusion allows for precise dimensional control and consistent cross-sectional geometry, eliminating the tightness problems that occur in corner regions during sheet-metal forming operations.
3Ease of manufacture
If a frame from extruded hollow profiles is used, then the manufacturing simplicity is improved, but the definition of gap for sealant and adhesive incorporation deteriorates without protruding webs
Solution Approach 1:
The protruding webs are pre-formed as integral parts of the extruded hollow profiles during the extrusion process. This preliminary action ensures that the gap-defining features are already precisely positioned and dimensioned before assembly, eliminating the need for additional gap-definition steps and ensuring consistent sealant and adhesive incorporation.
Solution Approach 2:
The extruded hollow profiles are designed to include their own gap-defining features (protruding webs) as part of their self-structure. This self-service approach means the profiles inherently provide the necessary gap definition for sealing without requiring separate components or additional manufacturing steps, combining manufacturing simplicity with precise gap control.
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 solution simplifies manufacturing, enhances tightness, and provides effective heat management by using extruded hollow profiles and modular construction, ensuring reliable sealing and efficient heat dissipation while maintaining structural integrity and crash resistance.
Implementation Method 1
a sealant and/or adhesive being incorporated
Implementation Method 2
a cooling system, in particular in the form of a cooling plate, is arranged under the base plate in the installation position
Data Source
AI summary
Battery carrier for an electric motor vehicle, having a trough formed by a base and a peripheral frame coupled to the base, wherein the frame is formed from extruded hollow profiles and a cover is arranged on the frame. In the installation position, the frame has a web protruding in each case in relation to its upper side and/or lower side in such a manner that a defined gap with respect to the base and/or with respect to the cover is produced, with a sealant and/or adhesive being incorporated.