Integrated Battery Enclosure Tub for Leak-Resistant EV Assembly
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Solution Overview
Problem
Existing battery enclosures for electric vehicles require complex fabrication, high material usage, and are prone to sealing failures and fractures, leading to increased labor, time, and cost.
Innovation Solution
A single-piece, integrally formed tub design with a cross member and mounting bracket, manufactured via stamping and roll forming processes, which reduces complexity and weight while enhancing structural integrity and sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multi-piece construction is used for the battery enclosure, then the enclosure can be assembled from separate components, but the assembly process requires complex sealing procedures and is prone to leaking and fracture
Solution Approach 1:
The patent merges the bottom plate and side walls into a single integrally formed tub structure. This eliminates the need for separate sealing operations between these components, removing the sealing interface that was previously prone to leaking and fracture. The tub is formed as one continuous piece, ensuring structural integrity while simplifying the assembly process.
Solution Approach 2:
The patent segments the battery enclosure into distinct functional components: the integrally formed tub (bottom plate + side walls), the separately formed lid, and the cross member. This segmentation allows each component to be optimized and manufactured independently using appropriate processes, then assembled with simple fastening operations rather than complex sealing.
2Manufacturing precision
If strict tolerances are applied between components for assembly, then the sealing interface can be maintained, but the manufacturing complexity and cost increase
Solution Approach 1:
By combining the bottom plate and side walls into a single integrally formed tub, the patent eliminates the need for tight tolerance control between these components. The integral construction removes the sealing interface, so no precision alignment or tolerance management is required at this joint, significantly simplifying the fabrication process.
3Reliability
If traditional sealing methods are applied between side walls and bottom, then the enclosure can be made water-tight, but the process adds labor and time to manufacturing
Solution Approach 1:
The patent merges the bottom plate and side walls into a single integrally formed tub structure, eliminating the need for any sealing operations between these components. The continuous material structure inherently provides water-tight integrity without requiring additional sealing materials or procedures, thereby improving manufacturing efficiency.
4Strength
If existing tub designs are used, then the enclosure provides sufficient structural support, but the designs are heavy and require excessive material
Solution Approach 1:
The patent incorporates a cross member that can be formed using roll forming processes, allowing for optimized structural geometry. The cross member design provides necessary structural support while using less material than traditional heavy-walled tub designs. The dynamic forming process enables efficient material distribution that maintains strength while reducing overall weight.
Solution Approach 2:
The patent changes the material parameters and structural configuration by using an integrally formed tub with strategically placed cross members. This allows for optimized wall thickness and material distribution that maintains structural support requirements while significantly reducing the total material quantity compared to conventional designs.
Data Source
AI summary
A battery enclosure includes a tub defining an internal volume, a lid, a cross member within the internal volume, and a mounting bracket. The tub has a bottom and a wall integrally formed with the bottom. The lid is configured to couple to the wall to enclose the internal volume. The cross member is coupled to the tub. The mounting bracket is attached to the bottom of the tub and is configured to releasably secure a battery.