Reinforced Battery Pack Carrier for Space and Vibration Control
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Solution Overview
Problem
Existing battery pack designs in electric and hybrid vehicles face issues with space optimization and mechanical vibration due to the draft angle of the tray and the structure of inner and outer frames, which compromise the protection and arrangement of battery modules.
Innovation Solution
A reinforced carrier device with inner and outer reinforcement pieces secured to the side walls, forming a reinforcement arrangement that includes hollow portions and fastening sections, made of high-strength steel, to enhance protection and reduce mechanical vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tray with draft angle is used to house battery modules, then the carrier device can be easily manufactured and assembled, but space utilization is reduced due to the lost zone created by the draft angle
Solution Approach 1:
The reinforcement structure utilizes the draft angle space by extending reinforcement pieces along the inclined surface of the side wall, transforming the previously wasted draft angle zone into a functional reinforcement region that does not encroach on battery module placement space
2Strength
If inner and outer frames are fixed to the tub for reinforcement, then protection against physical intrusion is improved, but mechanical vibration is generated that may be problematic for the modules
Solution Approach 1:
The reinforcement pieces are designed with hollow sections that can deform elastically under impact, absorbing mechanical energy and reducing vibration transmission to the battery modules while maintaining protective function
Solution Approach 2:
The reinforcement structure combines metal reinforcement pieces with the plastic carrier device, creating a composite structure that provides both strength and vibration damping characteristics
3Strength
If reinforcement pieces are added to the side wall, then protection against mechanical shocks and physical intrusions is enhanced, but the device complexity increases
Solution Approach 1:
The reinforcement pieces are integrated into the molding process of the carrier device, combining the reinforcement function with the existing side wall structure rather than adding separate components, thereby reducing assembly complexity
Data Source
AI summary
A carrier device including a reinforcement arrangement (9) including: at least two adjacent reinforcement hollow portions (24, 25) both being traversed by the side wall (3) of the carrier device (2) and each made of an inner reinforcement hollow section (26, 27) of the inner reinforcement piece (14) and an outer reinforcement hollow (28, 29) section of the outer reinforcement piece (19), both reinforcement hollow sections being at least partially facing each other, and a longitudinal reinforcement fastening portion (30) located between the adjacent reinforcement hollow portions (24, 25), secured to the side wall (3), and made of an inner reinforcement fastening section (31) of the inner reinforcement piece (14) and an outer reinforcement fastening section (32) of the outer reinforcement piece (19), both reinforcement fastening sections (31, 32) being at least partially facing each other.