Battery Pack Reinforcement Frame for Crash Protection and Cell Layout
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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 for the battery pack that includes a fastening portion secured to both the battery pack and the vehicle body, and a hollow portion surrounding the battery cells, made from press hardenable steel or laser welded blanks, with optional features such as a covering frame and longitudinal reinforcement members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tray with upward bent walls is used to hold battery cells, then the battery cells are protected, but the clearance angle 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 its simple geometry for space optimization while the frame provides the necessary protection without creating lost zones.
Solution Approach 2:
The reinforcement frame is positioned around the tray, with the tray nested inside the frame structure. This nesting arrangement allows both structures to work together, with the frame providing external protection and the tray providing internal support, eliminating the need for the tray walls to be both protective and space-optimizing simultaneously.
2Reliability
If the battery pack structure is designed only to host and protect battery cells, then cell protection is achieved, but the overall vehicle crash management performance is not improved
Solution Approach 1:
The reinforcement frame is designed to serve multiple functions: it protects the battery cells from intrusion, provides structural reinforcement during vehicle crashes, and integrates with the vehicle body structure. This multi-functionality allows a single component to address both battery protection and overall vehicle crash management.
Solution Approach 2:
The reinforcement frame combines multiple protective and structural functions into a single integrated structure that works with both the battery pack and the vehicle body, merging cell protection and crash management functions rather than treating them as separate requirements.
3Reliability
If four different elements are welded together to form inner and outer frame structures, then the frame provides comprehensive protection, but the manufacturing complexity increases
Solution Approach 1:
The frame is divided into an inner part and an outer part that can be manufactured separately using standardized processes, then assembled together. This segmentation allows for simpler manufacturing of each component while maintaining the comprehensive protection of the complete frame structure.
Solution Approach 2:
The inner and outer parts are designed to be assembled together through standardized connection methods, merging two simpler components into a complete protective frame structure, reducing manufacturing complexity compared to forming a single complex structure.
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.