Integrated Battery Frame Assembly for Lightweight EV Pack Housing
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Solution Overview
Problem
Traditional battery housings in automobiles are heavy, expensive, and prone to corrosion, requiring significant construction time and materials, while providing limited structural support and complicating weight distribution and serviceability.
Innovation Solution
A frame assembly with a battery housing that is partially integrated with the automobile frame, using a combination of upper covers and base plates connected to longitudinal beams and cross-members, providing a lightweight, structurally supportive design that simplifies assembly and service access.
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 housings while maintaining structural strength and fire resistance through the frame's inherent properties.
Solution Approach 2:
The patent employs composite material construction for the battery housing, combining materials that provide both structural strength and fire resistance without the weight penalty of traditional metal-intensive designs. The housing may incorporate fire-retardant polymers or composite panels that meet safety requirements while reducing overall weight.
2Strength
If traditional metal intensive battery housings are used, then strength and fire resistance requirements are met, but vulnerability to corrosion increases
Solution Approach 1:
By merging the battery housing with the vehicle frame, the design leverages the frame's corrosion resistance properties and protective coatings already present on automotive structures, eliminating the need for separate corrosion-prone metal housing components.
Solution Approach 2:
Composite materials used in the housing provide inherent resistance to corrosion and galvanic corrosion, eliminating the vulnerability associated with traditional metal-intensive constructions while maintaining required strength and fire resistance.
3Strength
If traditional battery housings are constructed with aluminum extrusions welded to aluminum plates, then structural requirements are met, but manufacturing complexity and time increase
Solution Approach 1:
The battery housing is combined with the vehicle frame structure, eliminating the need for separate manufacturing and assembly of complex aluminum extrusion and plate welding processes. The frame members themselves serve as the housing, significantly simplifying manufacturing.
Solution Approach 2:
The housing design may utilize modular or segmented components that can be easily assembled without complex welding operations, allowing for simpler manufacturing processes while maintaining structural integrity.
4Reliability
If traditional battery housings are used, then battery protection is provided, but serviceability and accessibility are reduced
Solution Approach 1:
The battery housing design incorporates separable or removable sections, particularly the base plate or access panels, that allow service personnel to access batteries for maintenance, replacement, or inspection while maintaining protection during normal operation.
Solution Approach 2:
The housing design allows for dynamic access, where protective covers or panels can be opened or removed during service operations and then securely closed to restore protection, providing both protection and serviceability.
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.