Battery Frame Structure With Offset Reinforcement Walls
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Solution Overview
Problem
Existing battery frame designs face challenges in effectively transmitting collision loads to reinforcement members, particularly at connecting parts, leading to potential deformation and interference with battery cells, while increasing weight and cost with additional reinforcement.
Innovation Solution
A battery frame configuration with offset reinforcement wall parts, comprising a frame member and reinforcement member with specific cross-sectional shapes, allows efficient load transmission and reduced deformation, using hollow long members with varying wall part thicknesses to enhance strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcement members are added or increased in size to prevent frame deformation under concentrated load, then the protective function is improved, but the weight and cost of the battery frame increase
Solution Approach 1:
The patent applies local quality by providing reinforcement wall parts at specific locations within the frame member cross-section rather than uniformly throughout. The reinforcement wall parts are positioned at regions experiencing higher stress concentrations, allowing the frame to have adequate strength where needed while maintaining lighter weight in less critical areas. This localized reinforcement approach resolves the contradiction by optimizing material distribution based on actual stress patterns.
Solution Approach 2:
The patent employs asymmetry by configuring the reinforcement wall parts with different thicknesses at different positions within the frame member. The wall thickness varies to match the asymmetric stress distribution that occurs during collision, with thicker sections at high-stress zones and thinner sections elsewhere. This asymmetric design provides superior load-bearing capacity where required while reducing overall material usage and weight.
2Strength
If reinforcement members are added or increased in size to prevent frame deformation under concentrated load, then the protective function is improved, but the manufacturing cost increases
Solution Approach 1:
The reinforcement wall parts are manufactured as integrated features of the frame member cross-section, with varying thicknesses at different locations. This localized reinforcement approach reduces material consumption compared to uniform thickening, thereby lowering material costs. The design allows for cost-effective manufacturing by concentrating material only where structurally necessary.
Solution Approach 2:
The patent merges the reinforcement function directly into the frame member structure itself, eliminating the need for separate reinforcement components. The reinforcement wall parts are formed as integral portions of the frame member cross-section, combining the structural frame and reinforcement functions into a single unified component. This integration reduces part count, assembly complexity, and overall manufacturing cost while maintaining protective functionality.
3Strength
If the number of beam members is increased to transmit load effectively, then the load transmission is improved, but the inner volume of the battery frame decreases
Solution Approach 1:
Instead of adding multiple beam members throughout the frame, the patent applies reinforcement wall parts at specific critical locations within the existing frame member cross-section. This localized reinforcement provides effective load transmission capability at key stress points without occupying additional space that would reduce battery volume. The approach maintains adequate structural strength while preserving maximum inner volume for battery placement.
Data Source
AI summary
A battery unit including a battery cell in a battery case, wherein the battery case includes a battery frame including a frame member and a reinforcement member, the frame member including first and second frame members surrounding the battery cell, the frame and reinforcement member are hollow and have a specific cross-sectional shape, the frame member is joined to the reinforcement member, each second frame member includes a first stage reinforcement wall partitioning an inside of the second frame member, the reinforcement member includes a second stage reinforcement partitioning an inside of the reinforcement member, thickness centers of the first stage reinforcement wall part and the second stage reinforcement wall part are offset in the up-down direction, and an upper or lower surface of the second stage reinforcement wall part is between upper and lower surfaces of the first stage reinforcement wall part in the up-down direction.