Battery Holder Frame Structure for Space-Efficient Corner Assembly
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Solution Overview
Problem
Existing battery holders for electric or hybrid vehicles face challenges in accommodating a larger quantity of battery modules or cells while maintaining structural integrity and manufacturing cost-effectiveness. Current designs often compromise on space due to high curvature corners and complex manufacturing processes.
Innovation Solution
A battery holder design featuring a frame with a closed shape comprising a main profile and a closing element, where the main profile is formed in one piece and extends along a bending curve, and the closing element is distinct and secured to the main profile to form corners, allowing for a more spacious configuration without increasing the number of joining points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece bent frame is used to reduce joining points, then structural integrity is improved, but the radius of curvature in corners increases reducing battery capacity
Solution Approach 1:
The frame is divided into multiple straight segments (first frame member, second frame member, third frame member, fourth frame member) connected by joining points, allowing right-angled corners that maximize battery space while maintaining structural integrity through the joining connections
2Volume of moving object
If multiple frame members are joined to maximize battery space, then battery capacity is improved, but the number of joining points increases complicating manufacturing
Solution Approach 1:
The joining points serve multiple functions: they connect frame members to form right-angled corners for maximum space utilization, provide structural reinforcement, and enable modular assembly. The standardized joining mechanism simplifies manufacturing despite the multi-segment design
3Strength
If traditional bolting or welding is used to assemble frame parts, then structural strength is improved, but distortion and flatness irregularities occur
Solution Approach 1:
The joining mechanism uses controlled connection parameters (pre-drilled holes, standardized bolt sizes, torque specifications) to assemble frame members without excessive heat or force that would cause distortion. This maintains both structural strength and flatness for proper lid sealing
Data Source
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Figure 3~4(C)
Figure 5~6
AI summary
The invention concerns a battery holder (1) comprising a frame (3) and a floor (5) delimiting between them a housing (4) intended to receive all or part of a battery, said frame (3) having a closed shape comprising a first corner (6) and a second corner (8), and comprising: - a main frame part (10) comprising a main profile (11) formed in one piece ; and - a closing frame part (30) comprising a closing element (31) presenting externally a cooperation surface (37); the main profile (11) being secured to the cooperation surface (37) so as to form the first corner (6), the main profile (11) being secured to the cooperation surface (37) so as to form the second corner (8). The invention also concerns a manufacturing process of such battery holder (1).