Battery Tray With Integrated Beam for Dense EV Pack Packaging
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Solution Overview
Problem
Existing rechargeable energy storage systems face challenges in achieving efficient manufacturing, high volumetric efficiency for packaging electrical energy storage elements, and favorable packaging within vehicles.
Innovation Solution
A tray structure composed of sheet metal side walls and a bottom, with integrated beams and continuous welds, designed to efficiently package electrical energy storage elements and provide structural support, along with a cooling system to prevent fluid exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tray structure with integrated beams and continuous welds is used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple structural components (tray, beams, side walls) into an integrated assembly where the beam is positioned within the tray and secured through continuous welds along the side walls. This merging of components creates a unified structural system that enhances overall integrity while distributing the manufacturing process across standardized parts.
Solution Approach 2:
The beam is positioned and aligned within the tray structure before the welding process begins. This preliminary positioning ensures proper structural configuration is established prior to joining, allowing the continuous welds to be applied systematically along the side walls to secure the beam in its predetermined location.
2Quantity of substance
If electrical energy storage elements are densely packaged in the tray, then volumetric efficiency is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The energy storage system is divided into modular components including individual energy storage elements that can be separately handled, and a tray structure that can be accessed as a unit. This segmentation allows for efficient packing of multiple elements while maintaining the ability to access and service individual components or the entire tray assembly.
Data Source
AI summary
A method of manufacturing an electrical energy storage system includes procuring a sheet metal blank. The method also includes bending the sheet metal blank to form a tray having at least a first wall, a second wall, and a bottom, with the first wall extending generally perpendicularly from the bottom and the second wall extending generally perpendicularly from the bottom. A plurality of electrical storage elements are placed in the interior of the tray. A beam may pass through an interior of the tray and may be affixed to a first structural element and a second structural element of a vehicle.