Heterogeneous Side Frame Structure for Lightweight Battery Cases
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Solution Overview
Problem
Conventional side frames for battery cases face challenges in achieving lightweightness and cost reductions while ensuring adequate protection against external impacts, as they often rely on single materials like aluminum or aluminum alloys, which are expensive and have limitations in production yield and structural rigidity.
Innovation Solution
A side frame design utilizing heterogeneous materials, where a first frame unit formed of a heavy metal like steel provides structural strength and a second frame unit formed of a lighter material like aluminum is used to achieve optimal weight and cost reduction, with the two units being coupled through mechanical and chemical bonding to enhance structural efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum or aluminum alloy is used for the side frame, then lightweightedness and ease of extrusion molding are achieved, but manufacturing cost increases and production yield decreases
Solution Approach 1:
The side frame is divided into two separate frame units: a first frame unit made of steel and a second frame unit made of aluminum alloy. These units are coupled together through coupling protrusions and coupling grooves. This segmentation allows each material to be optimized independently - steel provides structural strength while aluminum provides lightweighting - and resolves the contradiction between using expensive aluminum and maintaining manufacturing efficiency.
2Ease of manufacture
If aluminum or aluminum alloy is used for the side frame, then ease of extrusion molding is achieved, but structural rigidity is insufficient
Solution Approach 1:
Different parts of the side frame are made from different materials with different properties. The first frame unit (steel) provides high structural rigidity and strength, while the second frame unit (aluminum alloy) provides ease of extrusion molding and lightweighting. This local differentiation of material properties allows each region to perform its optimal function, resolving the contradiction between manufacturability and structural performance.
3Weight of moving object
If heterogeneous materials are used in the side frame, then weight reduction and cost reduction are achieved, but structural rigidity must be maintained
Solution Approach 1:
The side frame employs a composite structure combining steel and aluminum alloy materials. The steel first frame unit provides high strength and rigidity, while the aluminum alloy second frame unit reduces weight. The coupling mechanism between the two units ensures structural integrity while maintaining the benefits of material heterogeneity, thus achieving weight reduction without sacrificing structural rigidity.
Data Source
AI summary
The present invention relates to a side frame for a battery case, which can achieve lightweight and cost reduction simultaneously while sufficiently protecting battery cells against the external shock, and the side frame for a battery case according to an embodiment comprises: a first frame unit formed to have an open end surface; and a second frame unit which is arranged in the first frame unit to close the open end surface of the first frame unit and is coupled to the first frame unit, wherein the first frame unit and the second frame unit may be formed of different materials from each other.