Battery Housing Frame Structure for Weight Reduction
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Solution Overview
Problem
Conventional battery cases for electric vehicles face challenges in weight reduction and improved shock transmission, especially when using steel components, while maintaining structural integrity and moisture sealing.
Innovation Solution
The battery case design incorporates side walls with mounting flanges as part of the frame structure, supplemented by at least two additional frame members, including a closing plate and an L- or U-shaped profiled frame member, which allows for a hollow chamber to house functional elements and provides enhanced structural support without the need for extruded profiles, enabling weight savings and improved shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If extruded light metal hollow chamber profile sections are used to form the frame structure, then weight is reduced and shock absorbing properties are improved, but manufacturing cost increases and welding complexity increases when joining to steel tray part
Solution Approach 1:
The patent applies homogeneity by using steel frame members with consistent material properties throughout the frame structure. The frame members are made from steel sheet blanks through deep drawing, ensuring uniform material composition and eliminating the need for complex welding between dissimilar materials (steel tray part and aluminum extrusions). This homogeneous material approach simplifies manufacturing while maintaining structural integrity.
Solution Approach 2:
The patent changes the geometric parameters of the frame members by forming them with specific curvature radii (R1, R2, R3) and thickness variations. The frame members feature different wall thicknesses in different regions (thicker at connection points, thinner in mid-sections) to optimize both weight and structural strength. This parameter optimization allows the steel frame to achieve light metal-like weight reduction while maintaining manufacturability.
2Ease of manufacture
If the frame structure is made from steel blanks by deep drawing, then manufacturing cost is reduced and structural stability is improved, but weight increases
Solution Approach 1:
The patent segments the frame structure into multiple separate frame members (first frame member, second frame member, third frame member) rather than using a single monolithic steel component. Each frame member is independently formed from steel sheet blanks and can be optimized for its specific function. This segmentation allows for weight reduction by removing unnecessary material from each individual member while maintaining overall structural stability through the coordinated arrangement of all members.
Solution Approach 2:
The patent applies local quality by varying the wall thickness and geometric properties of different regions of the frame members. The frame members have thicker sections at critical connection points (where they join the tray part and cover part) and thinner sections in non-critical areas. This localized material distribution reduces overall weight while ensuring structural stability where it is most needed.
3Strength
If additional fasteners are used to join the frame structure to the tray part, then structural integrity is improved, but weight increases
Solution Approach 1:
The patent merges the joining function into the frame members themselves by forming integral connection features directly on the frame members during the deep drawing process. The frame members have built-in attachment structures (such as flanges, tabs, or interlocking geometries) that are formed as part of the same continuous steel blank, eliminating the need for separate fasteners. This merging of functions maintains structural integrity while avoiding the weight penalty of additional fastening components.
Solution Approach 2:
The frame members are designed to be self-joining through their inherent geometric features. The deep-drawn steel frame members contain self-aligning and self-locking structures that enable them to attach to the tray part and cover part without external fasteners. The frame members essentially join themselves to the other components through their own structural features, eliminating the need for separate joining elements and reducing overall weight.
4Ease of manufacture
If the side wall of the tray part is inclined for demolding, then manufacturing ease is improved, but shock transmission to the tray part increases causing indentation risk
Solution Approach 1:
The patent introduces the frame members as intermediary structural elements between the inclined side walls and the external environment. The frame members are positioned to overlap and reinforce the inclined side wall regions, acting as a protective mediator that absorbs and distributes shock loads. This intermediary structure allows the side walls to maintain their inclined geometry for easy demolding while the frame members prevent shock transmission that would cause indentation.
Solution Approach 2:
The patent creates a composite structural system by combining the tray part (with inclined side walls for demolding) and the frame members (made from deep-drawn steel blanks) into an integrated assembly. The frame members function as a reinforcing layer that complements the tray part structure, providing additional shock resistance to the vulnerable inclined side wall regions while allowing the tray part to maintain its manufacturable inclined geometry.
Data Source
AI summary
A battery case for a vehicle driven by an electric motor, said battery case comprising a tray part (1, 1.1, 1.2, 1.3) which has a base (2, 2.1, 2.2, 2.3) onto which side walls (3, 3.1, 3.2, 3.3) having a mounting flange (4) are molded, and comprising a frame structure (5, 5.1, 5.2) which surrounds the tray part (1, 1.1, 1.2, 1.3) on the outer side thereof and has a hollow chamber (11, 11.1, 11.2). The side walls (3, 3.1, 3.2, 3.3) of the tray part (1, 1.1, 1.2, 1.3) are at the same time part of the frame structure (5, 5.1, 5.2) and separate the tray interior from the hollow chamber (11, 11.1, 11.2) of the frame structure (5, 5.1, 5.2). The side walls (3, 3.1, 3.2, 3.3) with their mounting flange (4) are part of the frame structure (5, 5.1, 5.2) and the frame structure (5, 5.1, 5.2) has at least two additional frame members (6, 8, 3.1, 4.1, 13, 3.2, 4.2, 13.1) connected to the tray part (1, 1.1, 1.2, 1.3) for completing the frame structure (5, 5.1, 5.2), of which a first frame member (6, 3.1, 3.2) has a leg (3, 3.1, 3.2, 6.1) which is opposite the side wall (3, 3.1, 3.2, 3.3) of the tray part (1, 1.1, 1.2, 1.3) and an upper terminating leg (4.1, 4.2, 7) for connection to the tray part (1, 1.1, 1.2), and of which a second frame member is a closing plate (8, 13, 13.1) that connects the first frame member (6, 3.1, 3.2) to the tray part (1, 1.1, 1.2) on the undersides thereof.