Battery Frame Assembly for Frontal and Side Collision Load Transfer
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Solution Overview
Problem
Existing battery units fail to adequately protect battery cells from both vehicle frontal and side collisions by effectively transmitting collision loads to the appropriate frames.
Innovation Solution
A battery unit design featuring a pair of frames (longitudinal and lateral) with step-shaped connection portions that facilitate efficient transmission of collision loads, ensuring protection against both frontal and side collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end portion of the longitudinal frame and the end portion of the lateral frame merely abut each other with corner brackets, then the device complexity is reduced, but the collision load cannot be sufficiently transmitted between frames
Solution Approach 1:
The connection portion of one frame is inserted into the hollow cross-section of the other frame, creating a nested structure where the longitudinal frame's connection portion fits inside the lateral frame's hollow section and vice versa. This nested arrangement enables effective collision load transmission between frames while maintaining a relatively simple overall structure.
Solution Approach 2:
The frames are designed with hollow cross-sections that allow connection portions to be inserted from different spatial dimensions. The longitudinal frame connects to the lateral frame's hollow section, creating a three-dimensional interlocking arrangement that improves load transmission without significantly increasing structural complexity.
2Ease of manufacture
If corner brackets are used to connect longitudinal and lateral frames, then the ease of manufacture is improved, but the protection against frontal and side collisions is insufficient
Solution Approach 1:
The connection portions are designed to be inserted into the hollow cross-sections of the opposing frames, creating a nested configuration. This allows the longitudinal and lateral frames to interlock securely, providing reliable battery cell protection against both frontal and side collisions while maintaining ease of assembly through simple insertion operations.
Solution Approach 2:
The frames utilize hollow cross-sectional geometries that facilitate the nesting connection. The curved or rounded hollow sections allow the connection portions to fit securely, enhancing both the protective reliability and the ease of assembly through intuitive insertion.
Data Source
AI summary
A battery case has a pair of first frames extending in a first direction, one of longitudinal-and-lateral directions, and a pair of second frames extending in a second direction, the other of the longitudinal-and-lateral directions, and is configured in a square frame shape such that the first and second frames enclose battery cells. The first frame includes a first contact face arranged to face the second frame and a first connection portion to connect to the second frame. The second frame includes a second contact face arranged to face the first frame and a second connection portion to connect to the first frame. The first frame has a step-shaped first step portion which forms a first space where at least part of the second connection portion of the second frame is stored in least part of the first contact face is provided at the first step portion.