Vehicle Battery Frame Structure Using Aluminum Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electric and hybrid vehicles, increasing the on-board weight of secondary battery modules to enhance travel distance requires a corresponding reduction in the weight of the frame structure for mounting, while maintaining structural rigidity and balance.
Innovation Solution
A frame structure comprising aluminum extruded materials for the side, front, rear, and mounting frames, which are fixed to vehicle side members, disperses the load of the battery module across multiple frames, transferring it to the vehicle side members for support, thereby achieving weight reduction and enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the on-board weight of the battery module is increased to enhance travel distance, then the travel distance is improved, but the frame weight must be reduced to maintain weight balance
Solution Approach 1:
The frame structure is divided into multiple separate components: left and right side frames, front frame, rear frame, base frame, front mounting frame, and rear mounting frame. This segmentation allows each component to be optimized independently for weight reduction while maintaining the overall structural integrity needed to support heavy battery modules for extended travel distances.
Solution Approach 2:
The patent specifies using aluminum extruded materials for the side frames and incorporates fixing bracket parts that may use different materials or composite structures. This use of composite materials and aluminum specifically targets weight reduction of the frame structure to enable increased battery module weight for longer travel distances.
2Weight of stationary object
If the frame weight is reduced to maintain weight balance, then the frame weight is decreased, but the structural rigidity must be maintained
Solution Approach 1:
By dividing the frame into multiple rigid components (side frames, front frame, rear frame, base frame, mounting frames) that are fixed together, the structure achieves rigidity through the assembly of multiple rigid elements rather than relying on a single heavy component. Each segment can be optimized for strength-to-weight ratio.
Solution Approach 2:
The frame structure utilizes three-dimensional spatial arrangement with components positioned at front, rear, left, right, and base positions. This multi-dimensional distribution of structural elements provides rigidity through geometric stability and load distribution across multiple axes, reducing the need for excessive material in any single component.
3Weight of stationary object
If a lightweight frame structure is used, then the frame weight is reduced, but the load-bearing capacity must be sufficient for heavy battery modules
Solution Approach 1:
The load-bearing function is distributed across multiple frame components including side frames, front frame, rear frame, and base frame. Each component carries a portion of the battery module weight, allowing the use of lighter materials and thinner sections while maintaining sufficient total load-bearing capacity for heavy battery modules.
Solution Approach 2:
The frame structure utilizes vertical and diagonal bracing elements that create triangular load paths, transferring battery module weight efficiently to the vehicle chassis through multiple transmission paths. This three-dimensional load distribution increases load-bearing capacity without proportionally increasing frame weight.
Data Source
AI summary
A pair of lateral side frames that are fixed along vehicle side members extending in a front-back direction of the vehicle on both sides of the vehicle in a width direction, a front frame that is fixed between front end parts of the lateral side frames, a rear frame that is fixed between rear end parts, and a base frame that is fixed between the front frame and the rear frame are provided. A front mounting frame for fixedly mounting the front side of a battery module on the front side of the base frame, and a rear mounting frame for mounting the rear side of the battery module on the rear side are provided respectively in the width direction of the vehicle.