Battery Storage Case Segmentation for Weight Reduction

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Solution Overview

Problem

Battery units in vehicles face challenges in achieving a lightweight yet mechanically strong storage case design to withstand external forces, such as stepping or accidental drops, without increasing weight, which is a concern for installation in automotive vehicles.

Innovation Solution

The battery unit incorporates a storage case with a first and second casing member, along with an intermediate casing member that is lower in stiffness, creating a clearance between the casing members to form a peripheral wall, allowing the intermediate member to be made of lightweight materials like synthetic resin, while the first and second members are made of metal, ensuring mechanical strength without excessive weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the storage case is made with thicker metal walls to increase mechanical strength, then the ability to withstand external force is improved, but the weight of the battery unit increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidweight of storage case

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The storage case is divided into three separate casing members (first, second, and intermediate) that are joined together. This segmentation allows the intermediate casing member to be made of lighter material while the first and second casing members provide the primary structural strength, resolving the contradiction between strength and weight.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the storage case have different material properties. The first and second casing members are made of metal with higher strength, while the intermediate casing member is made of lighter material. This local differentiation of material quality allows the structure to have sufficient overall strength without excessive weight.

Inventive Principle:

Principle #3Local quality

2Weight of stationary object

If the intermediate casing member is made of lightweight material like synthetic resin, then the weight is reduced, but the mechanical strength and stiffness are lowered

Engineering Contradiction:

Improveweight of storage caseVSAvoidmechanical strength

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The storage case is segmented into three casing members where the intermediate member can be made of lightweight material. The first and second casing members, which are joined together, provide the primary structural support and strength, allowing the intermediate member to use lighter materials without compromising overall mechanical strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The storage case uses a composite structure combining different materials - metal for the first and second casing members providing strength, and synthetic resin for the intermediate casing member providing lightweight properties. This composite approach resolves the contradiction between weight reduction and maintaining mechanical strength.

Inventive Principle:

Principle #40Composite materials

3Weight of stationary object

If the first and second casing members are joined to create a clearance, then the intermediate casing member can be made lighter, but the structural rigidity is reduced

Engineering Contradiction:

Improveweight of storage caseVSAvoidstructural rigidity

Core Design Contradiction:

Weight of stationary objectVSStability of the object's composition

Solution Approach 1:

The storage case is segmented into three separate casing members that are joined together. The joining of the first and second casing members creates a stable framework that maintains structural rigidity, while the intermediate member can be made lighter without compromising the overall structural stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The structural rigidity is concentrated in the first and second casing members which are joined together, while the intermediate casing member has lower stiffness. This local differentiation of rigidity allows the structure to maintain sufficient stability while reducing the weight of the intermediate portion.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9543551B2Lightweight and rigid structure of battery unit

Publication Date: 2017.01.10 DENSO CORP

AI summary

A battery unit is provided which includes a battery and a storage case in which the battery is mounted. The storage case is made up of a base, a cover, and an intermediate case. The cover is jointed to the base with an interspace therebetween. The intermediate case is disposed between the cover and the base and has a peripheral wall which occupies the interspace. The intermediate case is lower in stiffness than the cover and the base, thereby realizing a lightweight structure of the storage case without sacrificing the mechanical strength thereof.