Composite Battery Tray Structure for Lightweight Load Support

The battery tray is divided into two functional components: the frame structure that provides load-bearing support, and the tray bottom plate that provides sealing and containment. This segmentation allows each component to be optimized for its specific function, with the frame bearing the battery core weight and the bottom plate being thin and lightweight.

The tray bottom plate is made from lightweight composite materials that provide sufficient structural integrity and sealing performance without requiring thick sections. This enables the bottom plate to be thin while still meeting strength and sealing requirements, reducing overall weight.

By separating the load-bearing function (frame) from the sealing function (bottom plate), the design eliminates the need for welding between these components. The bottom plate can be independently manufactured and installed, removing welding and air tightness testing from the production process, thereby improving manufacturing efficiency.

The thickness parameter of the tray bottom plate is reduced by changing its material properties (using lightweight composite materials) rather than increasing structural thickness. This parameter change allows thin plates to provide sufficient sealing without requiring thick sections that would need welding.

The division of labor between the frame (load-bearing) and bottom plate (sealing) allows the bottom plate to use minimal material thickness since it doesn't need to bear weight. This segmentation reduces material consumption while maintaining both load-bearing capability and sealing function.

Using lightweight composite materials for the bottom plate provides high strength-to-weight ratio and sufficient sealing performance with minimal material thickness, reducing overall material usage and cost compared to traditional thick metal plates.