Composite Battery Tray Assembly for Impact and Fire Containment
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Solution Overview
Problem
Conventional battery containment systems for electric and hybrid vehicles face challenges with weight savings, safety performance, manufacturing complexity, and insufficient protection against impacts and fires due to the use of metal bolts and composite materials that are prone to corrosion and water penetration.
Innovation Solution
A high-strength, lightweight battery containment system comprising a unitary tray with energy absorption components, a cover, and a shield, which provides impalement resistance, impact resistance, and fluid penetration prevention, using a composite sandwich structure with energy absorption components and fire-resistant materials to protect batteries from impacts and fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal bolts and nuts are used to join composite material containment boxes, then the boxes can be assembled, but the manufacturing process becomes complex and slow requiring additional machining of through holes, placement of bolts, and securing with nuts
Solution Approach 1:
The invention extracts and eliminates the complex bolt and nut joining system from the composite containment box assembly. Instead of using through-holes with bolts and nuts, the patent uses self-contained attachment mechanisms where the lid and base are joined through integrated fastening features that require no separate fasteners, thereby simplifying the manufacturing process and increasing throughput
Solution Approach 2:
The invention introduces an intermediary attachment mechanism that mediates between the lid and base of the containment box. This intermediary system uses recesses and protrusions with snap-fit or friction-fit connections that automatically secure the components together without requiring external bolts or nuts, thus eliminating the complex multi-step joining process
2Ease of manufacture
If metal bolts and nuts are used to join composite containment boxes, then the boxes can be assembled, but the cost of manufacturing increases due to complex techniques and slow throughput
Solution Approach 1:
The invention removes the complex metal bolt and nut joining system from the design. The containment box uses integrated attachment features molded directly into the composite material, eliminating the need for separate fasteners and reducing both manufacturing complexity and overall device complexity
Solution Approach 2:
The invention changes the physical parameters of the joining mechanism from mechanical fasteners (bolts and nuts) to monolithic integrated features formed during composite molding. This parameter change transforms the joining process from a multi-component assembly to a single-step integration, reducing complexity
3Weight of moving object
If conventional composite containment boxes are used, then weight savings are achieved, but the boxes do not provide sufficient protection against impact and impalement
Solution Approach 1:
The invention employs advanced composite materials with optimized fiber reinforcement patterns and material formulations that provide superior strength-to-weight ratio. The composite structure incorporates high-strength fibers arranged to resist impact and impalement forces while maintaining lightweight characteristics, achieving both weight savings and enhanced protection
4Weight of moving object
If conventional composite containment boxes are used, then weight is reduced, but the boxes are prone to degraded seals and failure
Solution Approach 1:
The invention uses composite materials with integrated sealing features that are molded as part of the containment box structure. The sealing elements are made from elastomeric or flexible composite materials that maintain their sealing properties over time, preventing degradation and failure while keeping the overall box weight low
Solution Approach 2:
The invention changes the sealing mechanism from separate gaskets or adhesives to integrated molded sealing features. This parameter change ensures consistent seal quality, improved reliability, and eliminates the degradation issues associated with separate sealing components while maintaining lightweight design
Data Source
AI summary
A battery containment system is provided that includes a unitary battery tray having a bottom and walls that from the bottom of said tray and defining a cavity within the tray. A cover is includes having a cover body portion and a first flange extending from the cover body portion, the cover body portion configured to overlie the cavity within the tray and the walls of the tray, the first flange of said cover configured to extend beyond the walls of the tray. A shield having a shield body portion and a second flange extending from the shield body portion, the shield body portion is configured to underlie the bottom of the tray, the second flange of the shield is configured to extend beyond the bottom of the tray and configured to engage the first flange of the cover.