EV Battery Tray Reinforcing Structure for Low-Warp Assembly
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Solution Overview
Problem
Existing battery trays for electric vehicles face challenges in mechanical stability and assembly due to the high number of individual components and welded joints, which can lead to warping and increased tolerances, making mass production difficult.
Innovation Solution
A battery tray design featuring a reinforcing structure with a U-shaped outer profile and multiple sleeves for fastening, which improves rigidity and energy dissipation in crashes, while also allowing for tolerance compensation and easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple individual components and welded joints are used to construct the outer reinforcing structure, then the structural strength and rigidity are improved, but the manufacturing complexity and assembly difficulty increase due to warping and tolerance accumulation
Solution Approach 1:
The patent merges multiple individual components (outer profile, inner profile, fastening elements) into a single integrated reinforcing structure that is formed as one piece from a sheet metal blank. This eliminates the need for multiple welded joints while maintaining structural strength, thereby reducing manufacturing complexity and avoiding warping issues associated with multiple welding operations.
Solution Approach 2:
The reinforcing structure utilizes a composite design where a U-shaped outer profile and a U-shaped inner profile are integrated into a single sheet metal component. This composite structure provides both structural strength and rigidity while being manufactured as one piece, avoiding the tolerance accumulation and warping problems of assembled multi-component designs.
2Stability of the object's composition
If multiple welded joints are used to assemble the reinforcing structure components, then the structural rigidity is improved, but the production time and assembly complexity increase
Solution Approach 1:
The patent combines multiple components that would traditionally require welded joints into a single integrated reinforcing structure formed from one sheet metal blank. This eliminates all welding operations, significantly reducing assembly time and complexity while maintaining the structural rigidity through the integrated design and strategic placement of fastening elements.
Solution Approach 2:
The reinforcing structure is pre-formed as a complete integrated unit with all necessary features (outer profile, inner profile, fastening elements) already in their final positions. This preliminary formation eliminates the need for subsequent assembly and welding operations, thereby reducing production time while ensuring proper structural rigidity.
3Loss of energy
If multiple individual components are used in the reinforcing structure, then the energy dissipation capability in crashes is improved, but the tolerance accumulation and warping increase
Solution Approach 1:
The patent integrates multiple components into a single reinforcing structure that maintains the energy dissipation capabilities of multi-component designs through its integrated geometry and material distribution. Since it is formed as one piece, it eliminates tolerance accumulation and warping issues associated with assembling multiple separate components through welding.
Data Source
AI summary
The invention relates to a battery tray for holding battery elements for providing electrical energy in electrically driven vehicles. The battery tray has a battery pan having a reinforcing structure which is arranged on the outside in front of a side wall of the battery pan. The reinforcing structure comprises an outer profile which is configured as U-shaped in cross-section with a web and two legs as well as an opening. The outer profile is directed with the opening towards the battery pan and is connected to the battery pan using the legs. In the longitudinal direction (LR) of the outer profile, multiple sleeves are provided at a distance from one another, wherein a sleeve extends between the legs and connects openings in the legs.