Battery Pack Frame Insert Structure for Even Crash Load Distribution
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Solution Overview
Problem
Traditional vehicular battery pack frame assemblies are inadequate in distributing crash loads evenly during a crash event, failing to provide sufficient protection for battery modules.
Innovation Solution
A battery pack frame assembly featuring a reinforcing insert with a plurality of ridges and valleys within a cavity, combined with foam material to enhance rigidity and secure the insert, allowing for even load distribution and minimizing deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional extruded aluminum or cold rolled steel side frame structure is used, then the structure is simple and easy to manufacture, but it is incapable of protecting the battery and distributing the crash load evenly
Solution Approach 1:
The patent combines aluminum extrusion with a separate insert component made of different material properties, creating a composite structure that leverages the advantages of both materials to achieve superior crash load distribution while maintaining manufacturing simplicity
Solution Approach 2:
The side frame structure is divided into multiple components: the aluminum extrusion and the separate insert. This segmentation allows each component to be optimized independently for its specific function, with the insert providing enhanced crash load distribution capabilities within the cavity of the extrusion
2Strength
If the side frame structure is made of single material (aluminum or steel), then the manufacturing process is simple, but the structure cannot evenly distribute crash load across internal cross members
Solution Approach 1:
The patent employs a composite construction combining aluminum extrusion with an insert of different material properties, enabling even crash load distribution across internal cross members while maintaining relatively simple manufacturing processes for each component
Solution Approach 2:
The insert is placed specifically within the cavity of the aluminum extrusion at locations where enhanced load distribution is needed. This local quality approach enhances crash load distribution capability at critical areas without requiring the entire structure to be complex or use expensive materials throughout
Data Source
AI summary
A battery pack frame is disclosed. The battery pack frame includes a front cross member, a rear cross member, and a pair of side cross members extending between the front cross member and the rear cross member. Each of the pair of side cross members include a pair of sidewalls, a top wall, and a bottom wall defining a cavity. A reinforcing insert is disposed within the cavity, and includes a plurality of ridges and a plurality valleys.