Cavity Support Assembly for Lightweight Battery Box Reinforcement

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery box assemblies are complex, time-consuming to assemble, and costly due to the numerous components and pre-processing requirements for bolt connections.

Innovation Solution

A support assembly comprising at least two plate layers stacked with a separating space between them, featuring a support structure with cavities that extend along specific directions to provide reliable support and reduce weight, while simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional battery box assemblies use numerous components and bolt connections, then structural strength and support performance are improved, but assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent integrates multiple support components into a single support structure with cavities. The support structure combines support plates, support columns, and connecting elements into one unified component that can be directly placed between battery cell groups, eliminating the need for separate bolts and multiple discrete support parts while maintaining structural strength

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support structure serves multiple functions simultaneously: it provides mechanical support between battery cell groups, acts as a structural reinforcement element, and serves as a positioning feature during assembly. The cavities in the support structure can also accommodate wiring or other components, making the single structure multi-functional

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional battery box assemblies use numerous components and pre-processing, then structural support performance is improved, but assembly time and productivity decrease

Engineering Contradiction:

Improvesupport performanceVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The support structure is pre-formed with integrated cavities and support features during manufacturing. This preliminary preparation allows the component to be directly installed between battery cell groups without requiring on-site assembly of multiple parts or pre-drilling of holes, significantly reducing assembly time while ensuring reliable support performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support structure is designed to be self-contained with all necessary support features integrated into a single component. It requires no additional fasteners, seals, or auxiliary parts, and can be directly positioned and secured between battery cell groups, enabling rapid assembly without complex preparation steps

Inventive Principle:

Principle #25Self-service

3Strength

If support structure uses solid material throughout, then structural strength is improved, but weight of the battery box increases

Engineering Contradiction:

Improvesupport strengthVSAvoidbattery box weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The support structure incorporates cavities within its body, creating a porous or hollow internal structure. This reduces the amount of material required and consequently the weight of the support structure, while the outer shell and strategic wall thickness maintain the necessary mechanical strength to support battery cell groups

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The support structure is divided into multiple cavities and walls rather than being a solid block. This segmentation allows material to be placed only where structurally necessary, reducing overall weight while maintaining strength through optimized material distribution in the wall regions

Inventive Principle:

Principle #1Segmentation

4Productivity

If support structure uses fewer components, then assembly simplicity and productivity are improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly efficiencyVSAvoidcavity formation precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The manufacturing process parameters are optimized to achieve the required precision for the integrated cavities. By controlling cavity dimensions, wall thickness, and positional tolerances during manufacturing, the support structure achieves the necessary precision while maintaining assembly simplicity. Standardized manufacturing processes ensure consistent quality across production batches

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250087811A1Support assembly, battery box, battery, and electric device

Publication Date: 2025.03.13 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A support assembly, a battery box, a battery, and an electric device are disclosed. The support assembly includes: at least two plate layers, where the at least two plate layers are stacked, and a separating space is provided between adjacent ones of the at least two plate layers; and a support structure disposed in the separating space, where the support structure includes a plurality of cavities, at least some of the cavities extend along a first direction, and the first direction intersects with opposite surfaces of the adjacent plate layers.