Extruded Aluminum Battery Pack Frame for Strength-Weight Balance
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Solution Overview
Problem
Conventional electric vehicle battery pack frames made of steel are excessively heavy, and attempts to use cast aluminum have been unsuccessful due to its insufficient strength, leading to a need for a lighter yet stronger material solution.
Innovation Solution
The use of extruded aluminum for the structural members of the battery pack frame, which provides a stronger and lighter alternative to both cast aluminum and steel, allowing for a modular design that can accommodate batteries of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel frames are used for battery packs, then strength and protective capability are improved, but weight increases excessively
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, fundamentally altering the density and strength characteristics. This material substitution enables achieving the required protective strength while reducing frame weight by more than 20%, directly resolving the contradiction between strength and weight
Solution Approach 2:
The patent employs aluminum alloy as a composite material solution that combines the advantages of light weight with enhanced strength through alloying elements. This composite approach provides sufficient crash protection and structural integrity while maintaining significantly lower weight compared to conventional steel frames
2Weight of moving object
If cast aluminum is used for battery pack frames, then weight is reduced, but strength becomes insufficient
Solution Approach 1:
The patent changes the material parameters by selecting specific aluminum alloy compositions and热处理 processes that enhance strength properties. This parameter optimization allows cast aluminum to achieve sufficient strength for battery protection while maintaining the weight advantage, resolving the strength deficiency of conventional cast aluminum frames
3Weight of moving object
If extruded aluminum members are used, then weight is reduced and strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the battery pack frame into separate extruded aluminum members that can be manufactured independently and then assembled. This segmentation allows each component to be optimized for extrusion manufacturing while simplifying the overall production process and enabling modular assembly, thus resolving the manufacturing complexity concern
Data Source
AI summary
Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.