Vehicle Battery Receptacle Structure for Crash Load Absorption
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Solution Overview
Problem
Existing battery assemblies in vehicles, particularly structural battery assemblies, face challenges in providing mechanical stability while simplifying production processes.
Innovation Solution
A battery assembly design comprising a receptacle for battery cells, a cover plate, and structural members that absorb mechanical loads, utilizing a metal receptacle and beam members to distribute and deflect forces, with integrated deformation zones and filler materials for enhanced load absorption and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a structural battery assembly is designed to provide mechanical stability and support loads, then the vehicle's mechanical stability is improved, but the production complexity increases due to integration requirements
Solution Approach 1:
The patent combines the battery assembly with structural components by integrating a receptacle that houses battery cells and simultaneously serves as a load-bearing element. The cover plate closes the receptacle to enclose battery cells while the structural member arranged adjacent to the receptacle provides mechanical support, merging energy storage and structural support functions into a unified assembly that reduces production complexity while maintaining mechanical stability
2Reliability
If multiple components are used to enclose the battery cells, then the structural integrity is improved, but the number of assembly steps increases
Solution Approach 1:
The receptacle is designed as an integrated component that both houses the battery cells and provides structural support, eliminating the need for separate enclosing structures. The cover plate simply closes the receptacle opening, creating a complete enclosure with minimal components. This integration maintains structural integrity while significantly reducing the number of parts and assembly steps required
3Ease of manufacture
If the receptacle is formed as a single integral part, then the manufacturing simplicity is improved, but the design flexibility for complex structures is reduced
Solution Approach 1:
The battery assembly is segmented into distinct functional components: the receptacle for housing battery cells, the cover plate for enclosure, and the structural member for mechanical support. This segmentation allows each component to be manufactured independently with optimal simplicity while maintaining overall design flexibility. The receptacle can be formed as a simple integral part for ease of manufacture, while the separate structural member provides the necessary design flexibility for complex structural requirements
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 design enhances load absorption capability, reduces the risk of battery cell damage, and simplifies production by minimizing components and connections, improving structural integrity and safety during crashes.
Implementation Method 1
Due to these forces, the structural member and/or the receptacle may be deformed, thereby absorbing the forces at least partially
Data Source
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AI summary
The disclosure relates to a battery assembly (18) for a vehicle. The battery assembly (18) comprises a receptacle (20), a cover plate (36), and at least one structural member (42). A plurality of battery cells (34) is arrangeable in the receptacle (20). The cover plate (36) closes the receptacle (20) such that the plurality of battery cells (34) is enclosable by the receptacle (20) and the cover plate (36). The at least one structural member (42) is arranged adjacent to the receptacle (20) on an outside of the receptacle (20). Additionally, an underfloor structure (12) for a vehicle is described. Furthermore, a vehicle comprising a battery assembly (18) and/or an underfloor structure (12) is shown. Moreover, a method for manufacturing an underfloor structure (12) for a vehicle is presented.