Battery Housing Coupling Element for Cross-Vehicle Beam Fit
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Solution Overview
Problem
The existing design of motor vehicles requires specific battery housing side members to be tailored for each vehicle type due to the unique geometry of body side members, leading to the need for custom battery housings for optimal support and connection, which complicates the manufacturing process and limits versatility.
Innovation Solution
A coupling element is introduced between the battery housing longitudinal members and the body longitudinal members, with one side matching the body side member geometry and the other side having a standardized shape, allowing for the use of identical or similar battery housing designs across different vehicle types, and enabling the connection of battery housings with non-matching geometries through geometrically compatible coupling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery housing longitudinal members are directly connected to body longitudinal members, then optimal connection and support are achieved, but specific battery housings must be provided for every vehicle type due to varying body longitudinal member geometries
Solution Approach 1:
A coupling element is introduced as an intermediary component between the battery housing longitudinal members and the body longitudinal members. This coupling element has a first geometry adapted to the body longitudinal member and a second geometry adapted to the battery housing longitudinal member, thereby mediating the connection between components with different geometries and enabling universal battery housing designs across multiple vehicle types.
2Reliability
If battery housing longitudinal members are designed to match specific body longitudinal member geometries, then optimal support is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The connection system is segmented into three distinct components: the body longitudinal member, the coupling element, and the battery housing longitudinal member. The coupling element is further segmented into a first geometry portion interfacing with the body longitudinal member and a second geometry portion interfacing with the battery housing longitudinal member. This segmentation allows the battery housing to be manufactured with a standardized geometry while the coupling element absorbs the geometric variations required for different vehicle types.
3Reliability
If different battery housings are installed on different body types, then optimal connection is achieved, but versatility and interchangeability decrease
Solution Approach 1:
The coupling element is designed as a universal component that can interface with multiple types of body longitudinal members through its first geometry and multiple types of battery housing longitudinal members through its second geometry. This multi-functional design enables a single battery housing design to be installed across different vehicle types by simply changing the coupling element, thereby achieving universality and interchangeability while maintaining optimal connection quality.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a body having two longitudinal beams (2) and at least one battery (3) located between the longitudinal beams (2), said battery having a battery case (4) with two longitudinal battery case supports (5), at least one coupling element (6) coupling the two longitudinal beams/supports (2, 5) being arranged between the longitudinal battery case supports (5) and the longitudinal beams (2).