Integrated Battery Frame Assembly for Lightweight EV Structures
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Solution Overview
Problem
Traditional battery housings in automobiles are heavy, expensive, and require significant construction time and materials, often leading to increased weight, weak points in the frame, and opportunities for corrosion, while not providing adequate structural support.
Innovation Solution
A frame assembly with a battery housing that is partially integrated with the automobile frame, using a base plate and upper cover connected to longitudinal beams and cross-members, providing a lightweight, easily serviceable design that distributes weight and structural support to both the frame and battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal intensive battery housings are used, then strength and fire resistance requirements are met, but weight increases and vulnerability to corrosion occurs
Solution Approach 1:
The battery housing is merged with the vehicle frame structure, where the frame members themselves serve as the housing structure. This integration eliminates the need for separate heavy metal housing while maintaining structural strength and fire resistance through the frame's inherent properties.
Solution Approach 2:
The frame members serve multiple functions: they provide structural support for the vehicle and simultaneously serve as the battery housing structure. This multi-functionality reduces the need for additional components and decreases overall weight while maintaining required strength.
2Strength
If traditional metal intensive battery housings are used, then strength requirements are met, but opportunities for galvanic corrosion increase
Solution Approach 1:
By merging the battery housing with the frame structure, the invention eliminates the interface between dissimilar metals that would create galvanic corrosion cells. The unified structure reduces galvanic corrosion opportunities while maintaining required strength.
3Reliability
If traditional separate battery housings are used, then battery protection is achieved, but construction time and capital increase
Solution Approach 1:
The battery housing is combined with the frame structure, reducing the number of separate components that need to be manufactured and assembled. This integration simplifies construction processes, reduces manufacturing steps, and decreases both construction time and capital requirements while maintaining battery protection.
4Reliability
If traditional separate battery housings are used, then battery protection is achieved, but weight distribution and structural support are compromised
Solution Approach 1:
By integrating the battery housing with the frame structure, the weight of the battery system is distributed through the frame members, improving weight distribution. The frame structure provides inherent structural support, eliminating the need for additional heavy housing components.
5Reliability
If traditional battery housings are used, then battery enclosure is achieved, but serviceability decreases
Solution Approach 1:
The battery system is segmented into modular battery packs that can be independently accessed and serviced. The frame structure is designed to allow easy access to these modular units, improving serviceability while maintaining the protective enclosure through the integrated frame design.
Data Source
AI summary
A frame assembly for an automobile includes a pair of front frame rails disposed in spaced relationship with a pair of rear frame rails. An upper cover is connected to and extends between the pair of front frame rails and the pair of rear frame rails to define a roof portion. The upper cover includes a pair of longitudinal sidewalls and a pair of cross sidewalls each extending downwardly from the roof portion to define an upper pocket bounded by each of the roof portion, the pair of longitudinal sidewalls and the pair of cross sidewalls. A base plate includes a plate portion for supporting at least one battery module. The base plate is disposed in abutting and connected relationship with the upper cover to dispose the at least one battery module within the upper pocket.