EV Battery Tray Reinforcement for Precise Crash-Resistant Mounting
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Solution Overview
Problem
Existing battery trays in electric vehicles face challenges with mechanical stability, assembly complexity, and positional accuracy due to numerous components and weld distortions, leading to increased tolerances and tolerance chains.
Innovation Solution
A battery carrier with a reinforcing structure featuring a hollow profile and a strike plate, incorporating sleeves and shims to ensure precise mounting and compensation for tolerances, while maintaining high stiffness and crash performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple individual components and welds are used to create the reinforcement structure, then the structural strength and crash performance are improved, but the manufacturing precision and positional accuracy deteriorate due to weld distortion and accumulated tolerances
Solution Approach 1:
The patent combines multiple separate reinforcement components into a single integrated reinforcement structure that is formed as one piece from a profile tube. This merging eliminates the need for multiple welds between separate components, thereby preventing weld distortion and accumulated tolerances while maintaining the structural strength and crash performance through the integrated design of the reinforcement elements.
Solution Approach 2:
The reinforcement structure is designed with integrated segmentation where different functional elements (longitudinal reinforcements, transverse reinforcements, mounting point integrations) are incorporated as distinct features within the single-piece structure. This allows each functional segment to be optimally positioned and shaped without requiring separate components and welds, thus maintaining manufacturing precision while achieving the required structural strength.
2Stability of the object's composition
If multiple individual components are used to form the reinforcement structure, then the structural stability is improved, but the device complexity increases due to the large number of components and assembly steps
Solution Approach 1:
The patent merges multiple reinforcement components into a single integrated structure formed from one profile tube. This consolidation maintains the mechanical stability provided by multiple reinforcement elements while dramatically reducing assembly complexity, as the integrated structure can be installed as a single unit rather than requiring the assembly of multiple separate components with multiple welds.
3Stability of the object's composition
If traditional bolted connections with multiple fasteners are used to attach the battery tray to the vehicle body, then the mechanical stability is improved, but the manufacturing precision requirements increase due to high demands on mounting point positional accuracy
Solution Approach 1:
The patent integrates the mounting points directly into the reinforcement structure as built-in features of the single-piece design. This integration eliminates the need for separate mounting brackets and multiple fasteners, thereby maintaining mechanical stability while reducing the positional accuracy demands, as the mounting points are precisely positioned during the forming of the integrated structure rather than requiring high-precision assembly of separate components.
Data Source
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AI summary
The invention relates to a battery carrier (1) for holding battery elements for providing electrical energy in electrically powered vehicles. The battery carrier (1) has a battery tray (2) with a reinforcing structure (16) arranged externally in front of a side wall of the battery tray (2). The reinforcing structure (16) has a hollow profile with a first upper leg (20) having a first opening (25) and a second lower leg (21) with a second opening (26). A sleeve (24) extends between the vertically spaced legs (20, 21), connecting the openings (25, 26) in the legs (20, 21). A fitting plate (29) covers the first opening (25) in the first leg (20), the fitting plate (29) having a passage (32) through which the sleeve (24) is guided with a sleeve section.