EV Battery Tray Integrated Retention Elements
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Solution Overview
Problem
Existing vehicle battery support structures for electric and hybrid electric vehicles lack effective retention mechanisms to securely hold battery modules and associated components, such as coolant lines and electrical cables, while also providing impact protection and a sealed environment.
Innovation Solution
A battery tray with integrated retention elements that engage peripheral or corner portions of battery modules and other components, including a flange or extension that secures to a cross member, forming a sealed containment area resistant to leaks or penetration, thereby improving connection reliability and reducing the number of components needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate retention components are used to secure battery modules, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The retention element is integrally formed with the battery tray as a single unified component, merging the tray structure and retention function into one piece. This eliminates the need for separate retention components while maintaining secure connection of battery modules, directly resolving the contradiction between connection reliability and device complexity
Solution Approach 2:
The integrated retention element serves multiple functions: it provides structural support for the battery tray, secures battery modules in place, and maintains the sealed containment environment. This multi-functionality reduces the overall number of components needed while ensuring reliable connections
2Strength
If multiple separate components are used for battery support structure, then structural support is improved, but ease of manufacture deteriorates
Solution Approach 1:
The battery tray and retention element are formed as a single integrated component, eliminating multiple assembly operations and connection points. This simplifies manufacturing while maintaining the structural support necessary for battery module containment through the integral design
3Device complexity
If retention elements are integrally formed with the tray, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The retention element is formed integrally with the battery tray as one component, reducing device complexity to a single piece. The manufacturing process is designed to form both the tray structure and retention features in one operation, managing precision requirements through integrated manufacturing rather than assembly
Data Source
AI summary
A battery tray for an electric vehicle includes a battery support structure that has a floor and a perimeter wall extending around a peripheral portion of the floor to border a battery containment area. A plurality of cross members are coupled with the perimeter wall at opposing sides of the battery support structure, where the cross members extend laterally across the battery containment area. A cover is engaged with an upper portion of the perimeter wall of the battery support structure. The cover, the floor, and/or the cross members may include a retention element that is integrally formed therewith and that is configured to engage a component that is disposed in the battery containment area.