Battery Casing Bottom Structure With Flat Ribbed Joint Undersurface
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Solution Overview
Problem
Existing battery casing bottom structures with extruded aluminum members for electric vehicles lack sufficient rigidity and a flat undersurface due to protruding joints, which compromises protection against road interference and aerodynamics.
Innovation Solution
A battery casing bottom structure combining extruded members with perpendicular extrusion directions, featuring a notch on one member and a ribbed, hollow second member that covers the notch to create a flat, wide undersurface and enhance rigidity, with the rib positioned above the joint to absorb loads and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two extruded members are joined together to increase rigidity, then the rigidity of the battery casing bottom structure is improved, but the undersurface becomes non-flat due to protruding joints
Solution Approach 1:
The battery casing bottom structure is divided into multiple extruded members (first extruded member and second extruded member) that are joined together. This segmentation allows each member to be optimized independently while achieving overall enhanced rigidity through their combination, resolving the contradiction between individual member simplicity and overall structural strength.
Solution Approach 2:
The invention introduces a vertical dimension solution by positioning the rib on the second extruded member to extend downward and cover the joint area. This dimensional approach allows the rib to mask the protruding joint from the horizontal plane, achieving a flat undersurface appearance while maintaining the joined structure's rigidity benefits.
2Shape
If a flat undersurface is achieved by avoiding protruding joints, then aerodynamics and road interference protection are improved, but the rigidity of the bottom structure is reduced
Solution Approach 1:
The rib is strategically positioned only at the critical joint area where the first and second extruded members connect. This localized reinforcement provides rigidity exactly where needed to support the joined structure, while the rest of the undersurface remains flat for aerodynamic and road interference protection, resolving the contradiction between localized strength and global flatness.
Solution Approach 2:
The rib acts as an intermediary element that mediates between the joined extruded members and the external environment. It covers the joint area to provide structural reinforcement while presenting a flat surface to external forces, effectively bridging the need for both rigidity and aerodynamic flatness.
3Reliability
If extruded members are joined using conventional methods, then the structural integrity is improved, but the joint protrudes downward creating a non-flat surface
Solution Approach 1:
Instead of trying to make the joint itself flat, the invention inverts the approach by adding a covering element (the rib) that extends downward from the second extruded member to mask the joint protrusion. This reverse thinking achieves flatness not by flattening the joint but by covering it, while maintaining structural integrity.
Solution Approach 2:
The rib is nested within the overall structure of the second extruded member, extending downward from its surface. This nesting approach integrates the rib as an integral part of the extruded member rather than a separate attachment, achieving joint coverage while maintaining a unified structural appearance and integrity.
Data Source
AI summary
A battery casing bottom structure is mounted in a lower part of a vehicle and includes a combination of extruded members. The bottom structure includes a first extruded member including a notch that is a cut portion at an end in an extrusion direction on a top face of the first extruded member, and a second extruded member having a hollow shape and including a rib connecting a top face portion and an undersurface portion. The first extruded member and the second extruded member are joined to each other by covering the notch of the first extruded member with an undersurface of the second extruded member from above. The extrusion direction of the first extruded member and an extrusion direction of the second extruded member are perpendicular to each other. The rib is positioned immediately above a portion where the first extruded member and the second extruded member are joined.