Battery Holder Frame With Dual-Yield Profiles for Impact Absorption
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Solution Overview
Problem
Existing battery enclosures for electric or hybrid vehicles are complex and heavy, leading to high material costs and limited shape flexibility, which hinders the use of high-strength alloys for weight savings and effective impact absorption.
Innovation Solution
A battery holder design featuring a frame with internal and external profiles made from materials with different yield strength values, where the internal profile is more rigid and the external profile is more ductile, allowing for energy absorption during impacts while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex multi-cavity structural frame is used to absorb side crush kinetic energy, then impact protection is improved, but weight and manufacturing cost increase
Solution Approach 1:
The frame part combines two distinct materials with different yield strengths: a first material for the internal profile providing structural integrity, and a second material for the external profile providing energy absorption. This composite approach enables the frame to achieve both high impact protection and reduced weight compared to traditional homogeneous complex structures.
Solution Approach 2:
Different regions of the frame part are assigned different material properties tailored to their specific functions: the internal profile uses high-strength material to maintain structural integrity and protect the battery, while the external profile uses more ductile material optimized for energy absorption during impact. This local differentiation optimizes overall performance while reducing total weight.
2Weight of moving object
If high strength alloys are used to increase energy absorption per unit weight, then weight saving is improved, but ductility and extrusability deteriorate
Solution Approach 1:
The frame part combines two distinct materials with different yield strengths: a first material for the internal profile providing structural integrity, and a second material for the external profile providing energy absorption. This composite approach enables the frame to achieve both high impact protection and reduced weight compared to traditional homogeneous complex structures.
Solution Approach 2:
Different regions of the frame part are assigned different material properties tailored to their specific functions: the internal profile uses high-strength material to maintain structural integrity and protect the battery, while the external profile uses more ductile material optimized for energy absorption during impact. This local differentiation optimizes overall performance while reducing total weight.
3Weight of moving object
If high strength alloys are used for weight saving, then material cost is reduced, but shape complexity and tolerances are limited
Solution Approach 1:
The frame part combines two distinct materials with different yield strengths: a first material for the internal profile providing structural integrity, and a second material for the external profile providing energy absorption. This composite approach enables the frame to achieve both high impact protection and reduced weight compared to traditional homogeneous complex structures.
Solution Approach 2:
Different regions of the frame part are assigned different material properties tailored to their specific functions: the internal profile uses high-strength material to maintain structural integrity and protect the battery, while the external profile uses more ductile material optimized for energy absorption during impact. This local differentiation optimizes overall performance while reducing total weight.
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
The design provides improved shock resistance, reduced weight, and lower manufacturing costs by optimizing energy absorption and mechanical strength, allowing for a more efficient and cost-effective battery enclosure.
Implementation Method 1
the at least one external profile is formed from a second material distinct from the first material and having a second yield strength value, the at least one external profile being configured to deform prior to the internal profile, so as to absorb all or part of the energy coming from shocks
Data Source
AI summary
The invention concerns a battery holder (1) for an electric or hybrid motorized transport vehicle, the battery holder (1) comprising a frame (3) comprising at least one frame part (9) being configured to absorb all or part of shocks by an external element (7) likely to be applied to the battery holder (1).The frame part (9) comprising at least one internal profile (10) and at least one external profile (30), said at least one internal profile (10) being positioned between said at least one external profile (30) and the floor (5).The at least one internal profile (10) is formed from a first material having a first yield strength value, and the at least one external profile (30) is formed from a second material distinct from the first material and having a second yield strength value.The invention also concerns a manufacturing process of a battery holder (1).