Battery Frame Hollow Profile Crash Absorption and Cooling
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Solution Overview
Problem
Existing battery carriers for electric and hybrid vehicles face challenges in protecting batteries during crashes due to lack of installation space and inefficient heat dissipation.
Innovation Solution
The battery carrier features hollow profiles with crash absorption zones and integrated holders for electrical lines, along with ventilation systems and fastening mechanisms, constructed from lightweight aluminum with U-shaped cross-sections and reinforcement for enhanced stability and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hollow profiles with deformation zones are introduced to absorb crash loads, then crash protection is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The hollow profile is divided into multiple functional zones: deformation zones for crash absorption and through-going regions for heat dissipation. This segmentation allows each zone to perform its specific function optimally without interfering with the other.
Solution Approach 2:
Different sections of the hollow profile have different structural characteristics - some sections have wall thickness optimized for crash absorption while other sections maintain thinner walls to facilitate heat dissipation. This local differentiation resolves the contradiction between protection and cooling.
2Reliability
If crash-relevant structures are introduced to meet protection requirements, then safety is improved, but installation space deteriorates
Solution Approach 1:
The hollow profile serves multiple functions simultaneously: it provides crash protection through deformation zones, enables heat dissipation through through-going regions, and offers mounting possibilities for battery carriers. This multi-functionality eliminates the need for separate protective structures that would consume additional space.
3Device complexity
If conventional battery carriers are used, then simplicity is maintained, but heat dissipation capability deteriorates
Solution Approach 1:
The cooling function is merged into the structural element itself. The hollow profile's through-going regions serve dual purposes as both structural components and cooling channels, eliminating the need for separate cooling systems while maintaining simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively absorbs crash forces, securely manages electrical lines, and provides efficient cooling, ensuring the battery carrier's safety and functionality within limited vehicle spaces while being cost-effective and easy to produce.
Implementation Method 1
The hollow profile or each hollow profile section has a structure for crash absorption enclosing a cavity as a first zone
Implementation Method 2
a battery tray of the generic type is known which is suitable and intended for enabling the cooling or ventilation of accumulators by directing cooling air through the profiles
Data Source
Figure 1~4
Figure 5~8
AI summary
To create a battery carrier for electric and hybrid vehicles, comprising a frame (1) for securely holding one of the rechargeable batteries arranged within the outline of a vehicle, wherein the frame (1) fully encloses the batteries, has fastening means for attaching the batteries to the frame (1) and for attaching the frame (1) to vehicle parts, and the frame (1) consists of a hollow profile (2) which has a deformation zone, enabling cooling and/or ventilation of the enclosed batteries, it is proposed that a structure enclosing a cavity (3) of the hollow profile (2) has means for ventilating and/or cooling the enclosed batteries and/or is connectable to ventilation and/or cooling systems, so that the cavity (3) is permeable to ventilation and/or cooling.