Fiber-Reinforced Battery Tray Structure for Secure EV Battery Mounting
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Solution Overview
Problem
Existing battery trays for electric automobiles face challenges in securely mounting large batteries or multiple batteries without increasing vehicle size, weight, or complicating the manufacturing process, particularly when using fiber-reinforced plastics.
Innovation Solution
A battery tray made of integrally molded fiber reinforced plastics with a design that includes a bottom, peripheral wall, flange, first and second inner walls, and stud bolt pedestal, all seamlessly molded to provide secure mounting without separate components, reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cross members are provided separately to fix batteries, then batteries can be fixed to the battery tray, but the weight of the battery tray increases and the manufacturing process becomes complicated
Solution Approach 1:
The patent integrates the cross members directly into the battery tray body as integral structures, eliminating the need for separate cross member components. The tray body and cross members are formed as a single piece through integral molding, which reduces the number of parts, simplifies the manufacturing process, and eliminates assembly steps while maintaining the battery fixing function.
Solution Approach 2:
The patent employs fiber reinforced plastic materials with discontinuous fibers to achieve high strength and rigidity in the integrally molded battery tray. This composite material approach allows the tray to maintain structural integrity and fixing capability without requiring additional reinforcing cross members, thereby reducing overall complexity.
2Strength
If a frame-shaped metal frame is used to reinforce the battery tray, then the strength and rigidity are enhanced, but the weight reduction goal cannot be achieved
Solution Approach 1:
The patent uses fiber reinforced plastics containing discontinuous fibers as the primary material for the battery tray. This composite material provides high strength-to-weight ratio, eliminating the need for additional metal reinforcing frames. The fibers are embedded within the plastic matrix to create a lightweight yet strong integrally molded structure.
Solution Approach 2:
The reinforcing structures are merged into the tray body itself through integral molding, rather than being added as separate metal frames. The cross members and tray body form a unified structure, reducing weight by eliminating the need for heavy metal reinforcements while maintaining necessary strength.
3Ease of operation
If large battery brackets are provided on both sides of the battery tray, then batteries can be mounted, but the size of the battery tray increases and vehicle design flexibility is reduced
Solution Approach 1:
The battery mounting function is merged into the tray body structure itself through integrally molded fixing portions. The cross members and tray body form a unified structure with built-in mounting capabilities, eliminating the need for large external brackets and reducing the overall width of the battery tray.
Solution Approach 2:
The patent incorporates fixing portions and mounting structures at specific locations within the tray body where they are most effective. The integrally molded cross members are positioned to provide optimal battery support and mounting capability without extending the overall dimensions of the tray, thus maintaining compact size while ensuring proper battery fixation.
Data Source
AI summary
A battery tray for mounting a battery for driving a vehicle includes a bottom; a peripheral wall erected on an outer circumference of the bottom; a flange connected to a top of the peripheral wall and extending outwards of the peripheral wall; a first inner wall connected to the bottom, a bending angle between the first inner wall and the bottom being between 90 degrees and 135 degrees; a second inner wall connected to the bottom, a bending angle between the second inner wall and the bottom being between 90 degrees and 135 degrees; and a stud bolt pedestal connected to both the first inner wall and the second inner wall and provided above the bottom. The bottom, the peripheral wall, the flange, the first inner wall, the second inner wall, and the stud bolt pedestal being integrally molded from fiber reinforced plastics containing discontinuous fibers.