CTB Underbody Casting Architecture for Lightweight EV Battery Integration
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Solution Overview
Problem
The traditional under body structure of electric vehicles, composed of numerous sheet metal parts, is inefficient in terms of weight, development cycle, and collision safety, and does not support rapid iteration or lightweight design, due to overlapping structures and insufficient integration, leading to increased energy consumption and manufacturing complexity.
Innovation Solution
An integrated under body platform architecture for CTB electric vehicles, featuring a front unit, middle unit, and rear unit connected sequentially with integral casting structures, including aluminum alloy die-casting parts for reduced weight and improved rigidity, and a power battery housing groove with a sealing mechanism for enhanced sealing and airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional sheet metal stamping parts are used to assemble the under body, then the structure can be manufactured with conventional processes, but the vehicle weight increases and development cycle lengthens
Solution Approach 1:
The patent merges multiple sheet metal stamping parts into an integrated die-casting structure. The under body structure integrates the front floor welding assembly, rear floor welding assembly, and battery pack structure into a single unified component, eliminating the need for separate parts and reducing overall vehicle weight while maintaining manufacturability through die-casting processes
Solution Approach 2:
The patent transitions from traditional sheet metal materials to die-casting materials (such as aluminum alloy or magnesium alloy) that offer superior strength-to-weight ratio. This material substitution enables weight reduction while achieving the required structural strength and stiffness for the under body
2Adaptability or versatility
If multiple separate assemblies (front engine room assembly, front floor welding assembly, rear floor welding assembly) are used, then manufacturing flexibility is maintained, but the number of parts increases to about 210 sheet metal stamping parts
Solution Approach 1:
The patent combines multiple separate assemblies into a single integrated die-casting structure. The front floor welding assembly, rear floor welding assembly, and battery pack structure are merged into one unified component, reducing the part count from approximately 210 sheet metal stamping parts to a single integrated structure, thereby simplifying the overall system while maintaining manufacturing flexibility through modular die-casting design
3Ease of manufacture
If traditional resistance spot welding is used to connect the under body and upper body, then the connection method is simple and established, but the structural strength and rigidity are insufficient for collision safety
Solution Approach 1:
The patent merges the under body structure with the upper body through integrated die-casting connections, replacing traditional resistance spot welding. The unified die-casting structure provides continuous material flow and stronger atomic-level bonding, significantly enhancing structural strength and rigidity for collision safety while maintaining manufacturing simplicity through established die-casting and assembly processes
4Ease of manufacture
If the battery pack structure is designed with mounting brackets and separate components, then the battery can be assembled in modules, but the structure overlaps with the front floor and under body, increasing overall weight
Solution Approach 1:
The patent merges the battery pack structure with the under body structure into a single integrated die-casting component. The battery housing is formed as an integral part of the under body structure, eliminating the need for separate mounting brackets and overlapping structural elements. This integration reduces the overall vehicle weight while maintaining modular assembly capabilities through designed interface features
5Ease of manufacture
If traditional sheet metal structure is used for the under body, then the manufacturing process is conventional, but the windward area is large causing high wind resistance and energy consumption
Solution Approach 1:
The patent transitions from traditional sheet metal materials to lightweight die-casting materials (such as aluminum alloy or magnesium alloy) that offer superior strength-to-weight ratio. This material substitution reduces the vehicle's windward area and overall mass, thereby decreasing wind resistance and energy consumption while maintaining conventional manufacturing capabilities through die-casting processes
6Strength
If the under body structure is strengthened to improve collision safety, then the safety performance improves, but the vehicle weight increases
Solution Approach 1:
The patent uses lightweight die-casting materials (such as aluminum alloy or magnesium alloy) that provide superior strength-to-weight ratio compared to traditional sheet metal. This material substitution enables the structure to be strengthened for improved collision safety while simultaneously reducing vehicle weight, effectively resolving the trade-off between strength and weight
Data Source
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AI summary
The disclosure provides an integrated under body platform architecture of CTB electric vehicle and an automobile. The integrated under body platform architecture of the CTB electric vehicle includes a front unit, a middle unit and a rear unit connected sequentially. The middle unit includes two sill side beams and a power battery housing groove between the two sill side beams. At least one unit of the front unit, the middle unit and the rear unit is an integral casting structure. The Automobile include the integrated under body platform architecture of the CTB electric vehicle.