Integrated Battery Frame as Vehicle Longitudinal Members
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Solution Overview
Problem
Existing motor vehicles with high-voltage batteries face challenges in minimizing structural space, weight, and production costs, while also requiring a simple and cost-effective assembly method.
Innovation Solution
A motor vehicle design that incorporates a high-voltage battery with a one-piece frame that forms both the battery housing and longitudinal members, along with a support plate that serves as the base for the battery cells, allowing for reduced structural space and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a closed battery housing with multiple individual parts is used, then the battery can be disassembled for maintenance, but the structural space requirement increases and the number of components increases
Solution Approach 1:
The patent combines the battery housing and longitudinal members into a single integrated load-bearing structure. The housing forms the lateral delimitation while also serving as structural support elements, eliminating the need for separate battery frames and reducing the total number of components while maintaining disassembly capability through standardized fastening points.
2Reliability
If gaps are left between the battery and vehicle structure, then rubbing is avoided and collision-free assembly is enabled, but the structural space requirement increases
Solution Approach 1:
The battery housing is integrated directly into the load-bearing structure, eliminating gaps between the battery and vehicle frame. The unified design maintains protective functions through the structural integrity of the combined system while maximizing the use of available space for battery capacity.
3Ease of repair
If the whole battery is disassembled for maintenance, then all components can be serviced, but the productivity decreases and time is lost
Solution Approach 1:
The battery system is designed with modular battery cell assemblies that can be independently accessed and serviced. The housing provides standardized access points and fastening mechanisms that allow technicians to service specific battery modules without disassembling the entire battery system, significantly reducing maintenance time while maintaining complete servicing capability.
Data Source
AI summary
A motor vehicle, and a method for producing a motor vehicle. The motor vehicle includes a load-bearing structure having at least two longitudinal members, and a battery that includes a single-piece battery frame that laterally delimits the battery to form at least radially internal portions of the at least two longitudinal members, a support plate that forms a base which covers an underside of the battery frame, and a plurality of battery cells arranged in the battery frame and fastened on the support plate.