Battery Housing Module with Segmented Profile Frame
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Solution Overview
Problem
Existing battery housing modules for electric vehicles are heavy due to their homogeneous structure, which compromises impact safety and increases weight, making them costly and inefficient.
Innovation Solution
A battery housing module with a profile-shaped frame body and reinforcement stiffening bodies that divide the interior space, connected via a force-transmitting structure to the vehicle structure, allowing for a lightweight and cost-effective design with enhanced impact safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a homogeneous structure is used for the entire frame or peripheral wall of the battery housing, then impact safety is ensured, but the weight increases significantly
Solution Approach 1:
The battery housing is divided into a frame structure with separate longitudinal and transverse profile bodies, allowing different sections to have different structural requirements. The longitudinal profile bodies form the main load-bearing frame, while transverse profile bodies provide additional support where needed, enabling weight reduction through selective structuring rather than uniform reinforcement throughout the entire housing.
Solution Approach 2:
Different sections of the battery housing are given different structural qualities based on their specific functional requirements. The longitudinal profile bodies are designed with specific wall thicknesses and cross-sectional geometries to handle bending and torsional loads, while transverse profile bodies are optimized for their specific positioning and support functions, allowing each local area to have the minimum necessary strength rather than uniform over-engineering.
2Stability of the object's composition
If a homogeneous structure is used for the entire frame, then structural integrity is maintained, but the manufacturing cost increases
Solution Approach 1:
The battery housing is segmented into modular frame components (longitudinal and transverse profile bodies) that can be manufactured separately using standardized processes and then assembled. This segmentation allows for optimized manufacturing of each component type, potential reuse of tooling, and simplified quality control, reducing overall manufacturing costs while maintaining structural integrity through the modular assembly approach.
3Strength
If the housing frame is designed with high mechanical strength, then impact safety is improved, but the weight and cost increase
Solution Approach 1:
The force-transmitting structure is designed to dynamically manage impact forces through the connecting means that attach to the vehicle structure. Rather than making the entire housing frame uniformly strong, the design allows forces to be transmitted path-dependently through the frame to the vehicle structure, enabling the housing to be lighter while still providing adequate protection through intelligent force routing rather than brute-force reinforcement.
Data Source
Figure 1
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Figure 4~5
AI summary
Battery housing module (1, 1') for receiving at least one battery unit (2), in particular a battery unit (2) of a traction battery, of an electrically propelled vehicle (3), comprising: - at least one housing frame (4) which defines an interior space (7) for receiving at least one battery unit (2), wherein the housing frame (4) comprises at least one profile-shaped frame body (5), - at least one stiffening body (6) which is arranged in the interior space (7) and divides the interior space (7) into separate areas (11), and - at least one connecting means (8) which has a connecting interface (9) for connecting to the stiffening body (6) forming a force-transmitting structure (12) of the battery housing module (1, 1'), wherein the force-transmitting structure (12) of the battery housing module (1, 1') is configured to transmit forces to a vehicle structure (13) supporting the battery housing module (1, 1').