Integrated EV Battery Frame as Load-Bearing Side Members
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Solution Overview
Problem
Existing motor vehicles with high-voltage batteries face challenges in terms of installation space, weight, manufacturing costs, and maintenance due to the use of multiple components and the need for separate installation and removal of the battery unit.
Innovation Solution
A motor vehicle design incorporating a one-piece battery frame that integrates the battery housing with the vehicle structure, using a carrier plate and fireproof cover to reduce installation space, weight, and manufacturing costs, while allowing for pre-assembly and in-house leak testing of the battery unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-part battery housing is used with gaps between battery and vehicle structure, then collision-free installation and chafing prevention are achieved, but installation space increases and weight increases
Solution Approach 1:
The battery housing is integrated directly with the vehicle structure, eliminating the gap between battery and vehicle body. The laterally delimiting battery housing forms portions of the side members, merging two previously separate components into a unified structure that reduces installation space while maintaining collision-free installation through integrated design.
2Ease of repair
If a multi-part battery housing with separate components is used, then maintenance and repair are enabled, but device complexity and manufacturing costs increase
Solution Approach 1:
The battery housing combines multiple functions into a single integrated structure that forms portions of the side members. This merging reduces the number of components and simplifies the overall device structure while maintaining ease of repair through the modular battery unit design that can be accessed and removed as a complete unit.
3Adaptability or versatility
If traditional multi-component battery housing is used, then structural flexibility is achieved, but weight and manufacturing costs increase
Solution Approach 1:
The battery housing is merged with the vehicle structure to form an integrated load-bearing component. This combination eliminates redundant structural elements, reducing weight while maintaining structural flexibility through the integrated design that allows the battery housing to form portions of the side members.
Solution Approach 2:
The battery housing serves multiple functions simultaneously: it provides structural support as part of the side members, contains the battery cells, and maintains the required spatial relationships. This multi-functionality reduces the need for separate components, thereby reducing weight and manufacturing costs.
Data Source
AI summary
A motor vehicle that includes a support structure that includes at least two side members, a high-voltage battery that includes a battery frame having a single, unitary battery frame body that forms portions of the side members lying at least radially inwards, the battery frame operable to laterally delimit the high-voltage battery, and a plurality of battery cells arranged in the battery frame, a carrier plate forming a base of the high-voltage battery that covers an underside surface of the battery frame to enable fastening of the battery cells to the carrier plate; and a fireproof cover arranged above the battery cells to enclose the high-voltage battery with respect to an ambient environment.