Battery Support Beam U-Shaped Nut Channel Buckling
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Solution Overview
Problem
Automobile battery enclosures made with lighter materials face challenges in resisting buckling under impact due to reduced strength and stiffness, particularly in their support members.
Innovation Solution
A support beam design featuring a u-shaped nut channel secured to the body with a mechanical fastener, laser welded for enhanced strength, which includes a hollow rectangular body with base supports to increase bending stiffness and resist buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lighter materials are used for the battery enclosure support members, then the weight of the battery enclosure is reduced, but the strength and stiffness of the support members deteriorate, causing them to buckle under impact
Solution Approach 1:
The support member uses a composite structure combining a U-shaped channel section with a flat plate, creating a hybrid geometry that optimizes both weight and strength. The channel portion provides high strength-to-weight ratio while the flat plate extends surface area for additional stiffness without significant weight penalty, resolving the contradiction between lightweight design and structural strength.
Solution Approach 2:
The support member transitions from a simple flat bar to a three-dimensional U-shaped channel structure with a flat plate extension. This dimensional change creates a more complex geometry that increases moment of inertia and bending stiffness, allowing the member to resist buckling under impact while maintaining lightweight construction through optimized material distribution.
2Weight of moving object
If lighter materials are used for the battery enclosure support members, then the weight of the battery enclosure is reduced, but the bending stiffness of the support members deteriorates, causing them to buckle under impact
Solution Approach 1:
The composite geometry of the U-shaped channel combined with the flat plate creates a structure with enhanced bending stiffness. The channel portion resists bending through its closed-section geometry while the flat plate extends the neutral axis distance, significantly increasing the moment of inertia and bending stiffness without adding substantial weight.
Solution Approach 2:
By transitioning from a one-dimensional flat bar to a two-dimensional U-shaped channel with flat plate extension, the design increases the distribution of material away from the neutral axis, thereby increasing the moment of inertia and bending stiffness. This dimensional enhancement provides superior resistance to buckling under impact while maintaining lightweight construction.
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 effectively strengthens the battery enclosure support beam, reducing buckling under load and enhancing bending stiffness, thereby protecting the battery from impact while maintaining a lightweight structure.
Implementation Method 1
securing the nut channel further includes laser welding the nut channel to the body
Data Source
AI summary
A battery enclosure, support beam for a battery enclosure and method of manufacturing the support beam. The battery enclosure includes a base and the support beam is securable within the base. The support beam includes a body, a nut channel secured to the body, and a mechanical fastener attached to the nut channel. The nut channel is formed into a u-shaped channel. The mechanical fastener is attached to the nut channel and the nut channel is secured to the body of the support beam.