Battery Pack Protective Frame with Integrated Energy Absorption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery packs using stamped sheet metal lack sufficient rigidity and strength, are heavy, have low energy density, and lack anti-collision and anti-crushing protection, leading to potential accidents during vehicle collisions or crushing.
Innovation Solution
A battery pack protective frame integrated with a lower box body, battery assemblies, box cover, gasket, bottom plate, and protective plate, where the protective frame is directly connected to the vehicle, absorbing energy through deformation to prevent battery assembly damage, and is made of aluminum alloy to reduce weight and enhance strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamped sheet metal is used for the battery pack, then processing technique is improved, but rigidity and strength are insufficient
Solution Approach 1:
The battery pack frame adopts a composite structure combining aluminum alloy protective portions with steel connecting portions. The aluminum alloy provides excellent corrosion resistance and sufficient strength for protection, while the steel portions provide high strength for connecting to the vehicle body. This composite material approach resolves the contradiction between ease of manufacture and sufficient rigidity/strength.
2Ease of manufacture
If stamped sheet metal is used for the battery pack, then processing technique is improved, but weight is high and energy density is small
Solution Approach 1:
The frame uses aluminum alloy for protective portions where high strength is not critical, significantly reducing weight compared to all-steel constructions. Steel is used only for connecting portions where high strength is essential. This selective material distribution reduces overall weight while maintaining necessary strength, resolving the contradiction between ease of manufacture and weight reduction.
3Device complexity
If independent mounting structure and protecting structure are used, then structural simplicity is maintained, but integration of components is poor
Solution Approach 1:
The mounting structure and protecting structure are merged into a single integrated frame component. The frame simultaneously serves as the protective enclosure for battery modules and the mounting structure for securing the battery pack to the vehicle body. This integration improves component versatility and adaptability while maintaining reasonable structural complexity.
4Device complexity
If no anti-collision device is provided, then device complexity is reduced, but safety performance is poor
Solution Approach 1:
The anti-collision protection function is merged into the frame structure itself through specially designed protective portions with energy-absorbing features. These integrated protective portions eliminate the need for separate anti-collision devices while maintaining safety performance, resolving the contradiction between device complexity and safety performance.
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 integrated protective frame effectively absorbs collision and crushing energy, preventing battery assembly damage and improving the overall structural performance of the battery pack, enhancing safety and energy density.
Implementation Method 1
the protective portions of the battery pack protective frame can absorb the energy generated in the colliding process or crushing process by generating deformation
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention provides a battery pack protective frame and a battery pack. The battery pack protective frame comprises a plurality of frame components connected together. Each frame component comprises: a sealing portion extending in an up-down direction for sealing a plurality of battery assemblies to be mounted; a battery fixed portion protruding from a lower portion of the sealing portion toward an inner side in an inner-outer direction for fixing the plurality of battery assemblies to be mounted; and a protective portion protruding from the lower portion of the sealing portion toward an outer side in the inner-outer direction for connecting with a vehicle fixing member. The battery pack comprises a lower box body, a plurality of battery assemblies, a box cover, a gasket, a bottom plate and a protective plate. The lower box body comprises the battery pack protective frame.