Reinforced Battery Pack Carrier Structure for Space and Vibration Control
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Solution Overview
Problem
Existing battery pack designs for electric and hybrid vehicles face challenges in optimizing space utilization and mechanical vibration reduction, particularly due to draft angles and structural frames that can lead to inefficiencies and increased vibration.
Innovation Solution
A reinforced carrier device with inner and outer reinforcement pieces forming hollow sections and fastening portions, secured to the side walls, which absorb shocks and reduce mechanical vibrations, while optimizing the arrangement of battery modules within a carrier device made of high-strength steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tray with draft angle is used to house battery modules, then the modules can be easily inserted and protected, but a lost zone is created that reduces space optimization
Solution Approach 1:
The reinforcement structure is divided into separate inner and outer reinforcement pieces that are positioned at opposite faces of the side wall, creating a segmented approach to reinforcement that eliminates the need for a continuous thick-walled structure with draft angles
Solution Approach 2:
The reinforcement is moved from a volumetric approach (thick walls with draft angles) to a surface-based approach (reinforcement pieces attached to opposite faces), effectively utilizing the dimensional space more efficiently while maintaining protective function
2Strength
If inner and outer frames are fixed to the tub to reinforce modules protection, then the structural strength is improved, but mechanical vibration is generated that may be problematic for the modules
Solution Approach 1:
Instead of using continuous frames that span the entire structure, the invention applies localized reinforcement pieces at specific positions on the side wall, reducing the overall mass and vibration-generating potential while maintaining local protective strength
Solution Approach 2:
The reinforcement structure combines the base tub material with additional reinforcement pieces made of high-strength steel, creating a composite structure that achieves superior strength-to-weight ratio and reduced vibration compared to solid frame structures
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a carrier device comprising a reinforcement arrangement (9) comprising: • 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.