Multi-Material Battery Case Side Frame With Reduced Weld Area
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Solution Overview
Problem
The existing side frames for battery cases, typically made of aluminum or aluminum alloys, face challenges in reducing weld areas, increasing costs, and compromising on weight and impact resistance due to high material expenses and low production yield, while also lacking optimal mechanical balance between the side frame and mounting frame.
Innovation Solution
A side frame design utilizing two different materials for the first and second frame parts, with the first frame part formed to have an open cross-section and the second frame part closing it, both parts being bent and molded without welds, allowing for reduced weld areas and integrated mounting frames for enhanced structural rigidity and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum or aluminum alloy is used for the side frame, then weight reduction and ease of molding are achieved, but material cost and production cost increase significantly
Solution Approach 1:
The side frame is divided into multiple frame parts (first frame part, second frame part, third frame part) that can be manufactured separately and assembled together. This segmentation allows each part to be optimized for its specific function, with critical impact areas using high-strength steel and non-critical areas using lighter materials, thereby reducing overall weight while controlling production costs through standardized manufacturing processes for each segment.
Solution Approach 2:
Different materials are applied to different regions of the side frame based on local requirements. The first frame part (front side frame) and second frame part (rear side frame) use high-strength steel for impact resistance, while the third frame part (side wall frame) can use aluminum or aluminum alloy for weight reduction. This local differentiation optimizes both weight and cost by applying material properties where they are most needed.
2Strength
If welding is used to assemble frame parts, then structural integrity is achieved, but weld area defects and production complexity increase
Solution Approach 1:
The mounting frame is merged with the side frame structure, forming an integrated assembly where the mounting frame serves dual purposes: securing the battery case to the vehicle body and providing additional structural support. This merging eliminates the need for separate welding operations between the mounting frame and side frame, reducing weld area and associated quality issues while maintaining structural integrity through the integrated design.
Solution Approach 2:
A coupling part is introduced as an intermediary element to connect the first frame part and second frame part. This coupling part provides a standardized interface that simplifies assembly and reduces the complexity of direct welding between frame parts. The coupling part can be designed with features that facilitate easier joining methods or reduce the weld area required, thereby improving reliability while maintaining structural integrity.
3Ease of manufacture
If the side frame structure is simplified, then manufacturing cost is reduced, but impact resistance and structural rigidity decrease
Solution Approach 1:
The side frame is designed with dynamic characteristics that allow it to respond differently to various types of loads. The frame parts are configured to provide high rigidity during normal operation while allowing controlled deformation during impact events to absorb energy. This dynamic design maintains impact resistance without requiring excessive material, thereby controlling manufacturing costs.
Solution Approach 2:
The side frame employs composite construction using different materials (steel and aluminum alloy) with complementary properties. High-strength steel provides impact resistance and structural rigidity where needed, while aluminum alloy reduces weight and manufacturing cost in less critical areas. This composite approach achieves optimal balance between strength, weight, and cost by leveraging the advantages of each material type.
Data Source
AI summary
The present invention relates to a side frame for a battery case which can enable weight reduction and cost reduction simultaneously while sufficiently protecting battery cells from external shock, and also can fundamentally solve the defects of a weld area by significantly reducing the weld area. The side frame comprises: a first frame part formed to have an open cross-section; and a second frame part coupled to the first frame part by being disposed in the first frame part so as to close the open cross-section of the first frame part, wherein the first frame part and the second frame part are formed of different materials, and the respective corners of the first frame part and the second frame part may be bent.