Integrated HV Battery Tray Structure for Lighter EV Pack Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-voltage batteries in motor vehicles require significant space, weight, and manufacturing costs due to separate components like battery frames and covers, limiting the energy capacity and vehicle range.
Innovation Solution
A high-voltage battery design using a tray that forms both side walls and a cover, integrated into the vehicle body, eliminating separate components and optimizing material thickness and quality for weight and crash rigidity, with battery cells mounted on a carrier plate and assembled without curing adhesive, allowing continuous vehicle production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate battery housing components (side walls, cover, frame) are used, then structural integrity and ease of assembly are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines separate battery housing components (side walls and cover) into a single integrated tray structure. This merging eliminates the need for separate lateral housing or frame components, reducing device complexity while maintaining structural integrity. The tray is formed from at least two sheets of different material thickness and/or quality, optimizing both manufacturing ease and structural requirements in a single integrated component.
Solution Approach 2:
The tray structure serves multiple functions simultaneously: it acts as the battery housing, provides structural support, and integrates with the vehicle floor assembly. The cover of the tray can close off the floor assembly from below and/or form the floor panel, eliminating the need for separate battery cover and floor components, thereby reducing overall device complexity.
2Ease of manufacture
If uniform material thickness is used in battery housing, then manufacturing simplicity is improved, but weight and material efficiency worsen
Solution Approach 1:
The patent applies different material thicknesses and/or qualities to different regions of the tray structure. The tray is formed from at least two sheets of different material thickness and/or quality, allowing optimization of material usage based on local structural requirements. This reduces overall weight while maintaining necessary strength and rigidity in critical areas.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A motor vehicle with a high-voltage battery, wherein the high-voltage battery comprises a battery housing, wherein the battery housing comprises at least side walls (1.1) and a cover (1.2) covering the side walls (1.1) on top, wherein a plurality of battery cells (2) are arranged in the battery housing, wherein the side walls (1.1) and the cover (1.2) are formed in one piece by a tray (1) that is open at the bottom, wherein a carrier plate (4) forms the base of the high-voltage battery that covers the tray (1) on its underside, wherein the battery cells (2) are mounted on the carrier plate (4), wherein the tray (1) is joined from at least two sheets (1.3, 1.4) of different material thickness and/or material quality, as well as a method for producing such a motor vehicle.