Battery Housing with Circumferential Channel for Modular EV Packs
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Solution Overview
Problem
Existing battery housing solutions for electric and hybrid vehicles require numerous fastening means for accumulator or accumulator pack attachment, leading to increased time and cost for replacement, as well as inefficient space utilization and safety concerns during transport.
Innovation Solution
A box-like container with a circumferential channel on the bottom, allowing for flexible size adaptation, airtight and chemical-resistant design, and quick replacement capabilities, utilizing fastening means and wall bushings for secure mounting, and made from sheet metal or deep-drawn tubs for cost-effectiveness and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous fastening means are used to attach accumulators or accumulator packs to the vehicle, then the secure mounting and transport safety are improved, but the time and cost for replacement increase significantly
Solution Approach 1:
The battery housing is divided into modular sections with standardized interfaces. Each accumulator pack can be independently accessed and replaced by removing only the specific housing section rather than the entire assembly, reducing the number of fastening means that need to be manipulated during replacement while maintaining secure mounting during normal operation
Solution Approach 2:
The fastening system transitions from a static, permanent attachment state to a dynamic, quickly reversible state. Quick-release fastening mechanisms allow the housing to securely hold accumulators during transport, then rapidly release them for replacement without requiring tools or complex disassembly procedures
2Volume of moving object
If the box-like container is designed to maximize space utilization, then the accommodation efficiency is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The box-like container is designed as a universal housing structure that can accommodate different sizes and configurations of accumulator packs through adjustable internal fixtures and standardized mounting interfaces. This single design serves multiple functions: structural support, environmental protection, secure mounting, and easy replacement, eliminating the need for custom-designed housings for different battery configurations
Solution Approach 2:
The housing design incorporates adjustable parameters such as removable partitions, repositionable mounting brackets, and flexible internal structures that can be configured to optimize space utilization for different accumulator pack sizes. This allows the same basic housing design to adapt to various battery configurations without requiring complex custom manufacturing
3Object-affected harmful factors
If the container is made airtight and chemical-resistant, then the protection of batteries from environmental hazards is improved, but the manufacturing cost and production difficulty increase
Solution Approach 1:
The airtight and chemical-resistant protection is achieved using flexible sealing gaskets and thin-film protective coatings applied to the container housing. These sealing elements can be easily installed and replaced, providing environmental protection without requiring complex integrated sealing structures or expensive specialized materials in the housing itself
4Productivity
If deep-drawing production method is used for the box-like container, then the manufacturing speed and cost are improved, but the space utilization is reduced due to large corner radii
Solution Approach 1:
The corner radii created by deep-drawing are utilized by nesting the accumulator packs strategically within the housing. The curved corner spaces are filled with smaller accumulator units or protective elements, effectively using the previously wasted space. Alternatively, the housing internal dimensions are adjusted to account for the corner radii, ensuring optimal space utilization while maintaining the fast, cost-effective deep-drawing manufacturing process
Data Source
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AI summary
In order to create a battery housing (1) for rechargeable batteries for electric and hybrid vehicles, for the secure mounting and transport-safe storage of a rechargeable battery or battery pack on a vehicle, which enables an airtight and, if necessary, chemical-resistant mounting of the batteries or battery packs, which enables particularly quick and easy replacement of individual batteries or battery packs, which, if necessary, can be adapted to existing space conditions in the vehicle by means of flexible sizing, which is also cost-effective and easy to manufacture and has a long service life, it is proposed that the battery housing (1) be formed by a box-like container (2) with a lid.