Composite Battery Enclosure With Chassis-Integrated Crash Load Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery enclosures in vehicles are structurally separate from the vehicle system, leading to increased mass and reduced performance due to the need for significant reinforcement, which results in higher manufacturing costs and lower fuel economy.
Innovation Solution
A composite battery enclosure system that integrates with the vehicle chassis, featuring a base member, cover member, and lattice support structure, utilizing raised and depending surface features, and continuous fiber reinforcement to provide structural integrity and protection while minimizing redundant mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional separate battery enclosure design is used, then structural protection is provided, but vehicle mass increases and performance decreases
Solution Approach 1:
The battery enclosure is integrated with the vehicle chassis to form a unified structural system. The enclosure serves dual purposes: protecting batteries and contributing to overall vehicle structural integrity, thereby eliminating redundant mass while maintaining protection capabilities.
Solution Approach 2:
The battery enclosure structure performs multiple functions simultaneously: it provides crash protection for batteries, serves as part of the vehicle's load-bearing chassis structure, and contributes to overall vehicle rigidity. This multi-functionality reduces the need for separate reinforcement elements.
2Reliability
If significant reinforcement is added to battery enclosure, then crash protection is improved, but manufacturing cost increases
Solution Approach 1:
The enclosure structure is merged with the vehicle chassis, allowing shared manufacturing processes and material selection. This integration reduces total material requirements and simplifies the manufacturing workflow, lowering costs while maintaining crash protection through the unified structural design.
3Ease of operation
If battery enclosure is structurally separate from vehicle system, then installation is simplified, but redundant mass is created
Solution Approach 1:
The battery enclosure and vehicle chassis are designed as integrated components that are manufactured and installed together as a single structural assembly. This eliminates the need for separate mounting operations while removing redundant mass, as the enclosure becomes an inherent part of the chassis structure rather than an add-on component.
Data Source
AI summary
A battery enclosure for a vehicle chassis having a base member with raised surface features on the upper surface outlining individual cells, each cell configured to receive at least one battery; a cover member having a plurality of depending surface features on the lower surface which are aligned with the surface features of the base member. The cover member includes a channel formed in the upper surface thereof, aligned with and extending along a length of the depending surface feature disposed on the bottom surface. A lattice support structure is also included which has a plurality of support members extending axially and transversely, wherein the lattice support structure is configured to be at least partially disposed within the channel of the cover member and mounted to the vehicle chassis. The lattice support member providing increased rigidity and a load distribution path for externally applied forces (e.g. crash events) to prevent or inhibit enclosure breakage or puncture.