Battery Tray Cross Members for Load Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery support structures for high voltage electric vehicle batteries fail to effectively distribute and manage high loads, leading to potential damage from external forces and interaction with electrical components during high load events.
Innovation Solution
A battery tray with integrated cross members, where each cross member has a base portion fixed to the tray and an elongated body with varying widths, providing increased stiffness and load distribution, and attached using self-piercing rivets for a continuous, single-piece structure that supports battery cells and reduces weight and noise, vibration, and harshness issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery support structures are used, then the structure is simpler and easier to manufacture, but the structure cannot effectively distribute and manage high loads, leading to potential damage from external forces
Solution Approach 1:
The support structure is divided into multiple cross members positioned between adjacent battery cells, with each cross member having a base portion fixed to the battery tray and an elongated body. This segmentation allows the structure to effectively distribute high loads across multiple points while maintaining manufacturing feasibility through modular components.
Solution Approach 2:
The cross members feature varying widths along their length, with the elongated body having a first width at the base portion and a second width at the opposite end that is less than the first width. This local variation in geometry optimizes load distribution where needed while reducing material usage in less critical areas, thereby improving strength without proportionally increasing complexity.
2Strength
If heavier support structures are used, then the load-bearing capacity and stiffness are improved, but the overall vehicle weight increases, affecting energy efficiency
Solution Approach 1:
The cross members are designed with non-uniform width distribution, featuring a wider base portion for maximum stiffness and load transfer to the battery tray, and a narrower elongated body section where full stiffness is less critical. This local quality variation provides the necessary stiffness for load-bearing while minimizing material usage and overall weight.
Solution Approach 2:
The support structure utilizes aluminum alloy materials that provide high strength-to-weight ratio, enabling the cross members to achieve the required stiffness and load-bearing capacity with reduced mass compared to traditional steel structures, thereby improving energy efficiency without compromising structural integrity.
3Strength
If more cross members are added to improve load distribution, then the load management capability is enhanced, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The support structure is segmented into multiple identical or similar cross member units that can be manufactured using the same process and then assembled in a standardized manner between adjacent battery cells. This segmentation enables economies of scale in manufacturing while simplifying assembly through repetition of proven connection details.
Solution Approach 2:
Each cross member is designed as a universal component that serves multiple functions: providing structural support, distributing loads between battery cells, and serving as a mounting structure for electrical components. This multi-functionality reduces the total number of different component types needed, thereby simplifying manufacturing and assembly processes.
Data Source
AI summary
An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery tray configured to support a plurality of battery cells and at least one cross member positioned between adjacent battery cells. The at least one cross member comprises a base portion that is fixed to the battery tray and an elongated body extending outwardly from the base portion. The elongated body extends from a first end at the base portion to a second end that is opposite the first end, and wherein the first end has a first width and the second end has a second width that is less than the first width.