Battery Housing Assembly With Variable Sheet Thickness for Crash Strength
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Solution Overview
Problem
Existing housing arrangements for electrical storage in electric vehicles are either heavy, costly, or compromise on sealing and strength, failing to provide a lightweight, cost-effective solution with good sealing properties.
Innovation Solution
A housing arrangement featuring a trough and cover design made from flexibly rolled metallic material with variable sheet thickness, where end sections have increased thickness for strength and crash resistance, and thinner sections for weight reduction, forming a self-contained, sealed structure with integral rigidity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional housing arrangements use uniform thick metallic material throughout, then strength and crash resistance are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The housing arrangement employs variable sheet thickness in the metallic material, with thicker sections positioned at critical load-bearing areas and thinner sections in non-critical areas. This local differentiation of material properties optimizes strength where needed while reducing weight and cost in less demanding regions, resolving the contradiction between overall strength and weight reduction.
2Strength
If traditional housing arrangements use uniform thick metallic material throughout, then strength and crash resistance are improved, but manufacturing cost increases
Solution Approach 1:
The variable thickness design allows metallic material to be strategically distributed - thicker only where structural integrity is critical for strength and crash resistance, and thinner where less support is needed. This localized material optimization reduces overall material consumption and manufacturing cost while preserving necessary strength characteristics.
3Weight of moving object
If housing arrangements use thinner metallic material, then weight is reduced and manufacturing cost decreases, but sealing properties and structural strength deteriorate
Solution Approach 1:
The housing arrangement implements variable sheet thickness with strategically thickened sections at critical locations that require enhanced sealing and structural strength. This localized reinforcement ensures reliability where needed while maintaining weight reduction and cost benefits in non-critical areas, resolving the contradiction between thinning for weight reduction and thickening for reliability.
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 solution results in a lightweight housing arrangement that can withstand high loads without compromising mechanical properties, ensuring effective sealing and reduced manufacturing costs while maintaining high strength and rigidity.
Implementation Method 1
A metal strip is produced by flexible rolling, resulting in strip sections with different thicknesses along the length of the metal strip, adapted to the respective loads of the component
Implementation Method 2
Blanks are then removed from this metal strip and subsequently hot-formed
Data Source
Figure 1A~1C
Figure 1D~1G
Figure 2A~3C
AI summary
The invention relates to a housing arrangement for receiving electrical storage means for the propulsion of an electrically powered motor vehicle. The housing arrangement (2) comprises a trough arrangement (4) into which electrical storage means (3) can be inserted, and a cover arrangement (5) which can be placed on the trough arrangement (4) and detachably connected to it, wherein the trough arrangement (4) and/or the cover arrangement (5) has a first molded part (6; 21) and a second molded part (7; 22), each having a base (19, 24) and side walls (20, 25); wherein the first molded part (6; 21) and the second molded part (7; 22) are arranged side by side and connected to each other in a longitudinally extending connection area (15, 23); wherein the first molded part (6; 21) and the second molded part (7; 22) are each made of flexibly rolled steel sheet, so that they have a variable sheet thickness in the longitudinal direction of the respective molded part (6, 7; 21, 22).