Composite Battery Module Lower Plate for Lightweight Sealed Assembly
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Solution Overview
Problem
Conventional battery cases for electric cars are heavy due to metal construction, increasing vehicle weight and cost, and lack effective water-tightness and robust coupling structures.
Innovation Solution
A lower protecting plate made of fiber-reinforced plastic composites, integrated with a fastening member, forms a support layer that reduces weight while ensuring mechanical performance, water-tightness, and facilitates easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal material is used for battery case, then mechanical strength is improved, but vehicle weight increases
Solution Approach 1:
The battery case uses fiber-reinforced plastic composite materials combining resin matrix with glass fiber or carbon fiber reinforcements. This composite structure provides mechanical strength comparable to metal while reducing weight by approximately 40-50%, directly resolving the contradiction between strength and weight requirements.
2Weight of moving object
If aluminum material is used for battery case, then vehicle weight is reduced, but manufacturing cost increases due to welding process
Solution Approach 1:
The battery case is divided into multiple modular components including upper case, lower case, and side panels that can be separately manufactured and assembled. This segmentation enables simplified joining methods such as adhesive bonding or mechanical fastening instead of complex welding processes, reducing manufacturing cost while maintaining lightweight design.
Solution Approach 2:
Multiple functional components are merged into integrated structures. For example, the lower case combines support function with protection function, and the side panels integrate structural support with aesthetic covering. This merging reduces the number of separate parts and assembly steps, lowering manufacturing complexity and cost.
3Device complexity
If conventional battery case structure is used, then assembly is simplified, but water-tightness between interior and exterior is insufficient
Solution Approach 1:
A waterproof film or coating layer is applied to the inner surfaces of the battery case components. This flexible barrier layer provides effective water-tightness protection while maintaining the simplicity of the overall case structure and not complicating the assembly process.
Solution Approach 2:
The battery case incorporates hydrophobic resin materials and sealed composite structures at joints and connections. These materials provide inherent water resistance while maintaining structural integrity, achieving reliable water-tightness without requiring complex sealing mechanisms.
4Weight of moving object
If fiber-reinforced plastic composite is used, then weight is reduced, but manufacturing complexity increases due to lamination process
Solution Approach 1:
Fiber reinforcements are pre-arranged in predetermined patterns and positions within mold cavities before resin injection. This preliminary preparation of fiber layouts simplifies the lamination process, reduces manufacturing complexity, and ensures consistent structural properties while maintaining the weight advantages of fiber-reinforced composites.
Data Source
AI summary
Provided is a lower protecting plate of a battery module for an electric car. The lower protecting plate may include a fiber-reinforced plastic composite formed of a lamination sheet including at least one of first and second sheets. The first sheet may include matrix resin and reinforced fiber in the form of long fiber. The second sheet may include matrix resin and reinforced fiber in the form of fabric woven by continuous fiber.