Reinforcement Frame Assembly for Intrusion-Resistant Battery Packs
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Solution Overview
Problem
Existing battery pack designs for electric and hybrid vehicles lack efficient protection against physical intrusion and mechanical shock, and do not optimize the arrangement of battery cells for space utilization, while also failing to enhance overall vehicle crash management.
Innovation Solution
A reinforcement frame is introduced for the battery pack, comprising a fastening portion secured to the vehicle body and a hollow portion surrounding the battery cells. This frame is designed to absorb crash energy and prevent intrusion, while optimizing cell arrangement and enhancing vehicle safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a tray with upward bent walls is used to hold battery cells, then the battery cells are protected from physical intrusion, but the clearance angle of the tray creates a lost zone that reduces space optimization
Solution Approach 1:
The protection structure is divided into two separate components: a tray for holding battery cells and a reinforcement frame for enhanced protection. This segmentation allows the tray to maintain a simple flat-bottom design for optimal space utilization, while the reinforcement frame adds protective functionality without compromising the tray's volume efficiency.
Solution Approach 2:
The reinforcement frame is positioned around and integrates with the tray structure, with the tray nested within the reinforcement frame. This nested arrangement allows the protective functions to be added without significantly increasing the overall volume, as the reinforcement frame utilizes the same spatial envelope as the tray.
2Ease of manufacture
If a traditional tray structure is used for battery cells, then assembly is simple, but the structure does not contribute to vehicle crash management
Solution Approach 1:
The reinforcement frame serves multiple functions simultaneously: it provides structural reinforcement for the battery pack, contributes to vehicle crash management by absorbing and distributing impact forces, and maintains attachment simplicity through standardized fastening mechanisms. This multi-functionality resolves the contradiction between assembly simplicity and crash management performance.
3Volume of moving object
If battery cells are arranged in a compact tray, then space is optimized, but the cells lack sufficient protection against mechanical shock
Solution Approach 1:
The protection system is segmented into the tray for space-optimized cell arrangement and a separate reinforcement frame for shock protection. This allows the cells to be densely packed in the tray while the reinforcement frame provides an additional protective layer against mechanical shocks without interfering with the compact arrangement.
Solution Approach 2:
The reinforcement frame is designed to absorb and dissipate mechanical shock forces before they reach the battery cells. This beforehand cushioning effect protects the cells from mechanical shocks while maintaining the space-optimized arrangement within the tray.
Data Source
AI summary
A reinforcement frame (1) for a battery pack (2) of an electric or hybrid vehicle (37), the battery pack including a plurality of battery cells lying on and secured to a shield element, the reinforcement frame including at least: a reinforcement frame fastening portion (3) provided to be secured to both the battery pack and the body of the vehicle, and a reinforcement frame hollow portion (4) provided to surround at least the battery cells.