Integrated Battery Housing with Chassis Flanges
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Solution Overview
Problem
Conventional high-voltage battery housings are vulnerable to side collisions due to gaps between the battery and chassis, leading to deformation and damage, and they increase vehicle weight and manufacturing costs with a complex structure of cross members and side fixing brackets.
Innovation Solution
An integrated high-voltage battery housing design with flanges and a reinforcing portion that couples directly to the chassis side member, eliminating the need for a cross member and side fixing brackets, disperses impact forces and enhances structural support through a simplified, lightweight configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate side fixing brackets and cross members are used to connect the battery housing to the chassis, then the structural support and collision resistance are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the side fixing bracket, cross member, and battery housing into a single integrated component. The U-shaped bracket forms a continuous structure that connects both sides of the battery housing to the chassis simultaneously, eliminating the need for separate cross members and multiple fixing brackets, thus reducing device complexity while maintaining structural support strength
2Strength
If separate side fixing brackets and cross members are used to connect the battery housing to the chassis, then the structural support and collision resistance are improved, but the manufacturing cost increases
Solution Approach 1:
The integrated U-shaped bracket reduces the total number of parts that need to be manufactured, assembled, and welded. By combining multiple functions into one component, the patent reduces manufacturing steps, assembly time, and welding operations, thereby lowering manufacturing cost while maintaining the required structural support strength
3Force
If a cross member is added to support the bottom housing, then the load support capability is improved, but the vehicle weight increases
Solution Approach 1:
The patent integrates the cross member function directly into the U-shaped bracket structure. The horizontal bottom portion of the U-shaped bracket serves as the cross member, providing load support without requiring a separate component. This integration eliminates redundant materials while maintaining the load support capability needed to bear the battery housing weight
4Strength
If separate side fixing brackets are used to connect the battery housing to the chassis, then the connection strength is improved, but the space between the bracket and side wall allows deformation during side collision
Solution Approach 1:
The integrated U-shaped bracket eliminates gaps between separate components by forming a continuous structure that directly connects the battery housing side walls to the chassis. The vertical legs of the U-shape are integrally formed with the horizontal bottom portion, creating a rigid structure that prevents deformation during side collisions without requiring additional spacing or adjustment clearances
Data Source
AI summary
The present invention relates to an integrated high-voltage battery housing. More particularly, it relates to an integrated high-voltage battery housing adapted to secure safety against side impact collisions while reducing the weight of a vehicle by integrating a connecting structure between a battery housing and a side member of a chassis of the vehicle. In particular, the integrated high-voltage battery housing includes: a bottom housing configured to receive a battery; a battery fixing bracket configured to fix the battery to a top surface of the bottom housing; and a plurality of flanges extending from an upper end edge of a side wall of the bottom housing and each having a coupling aperture for coupling the flange to a chassis side member. A protruding reinforcing portion extends transversely between opposite sides of the bottom housing on a bottom surface of the bottom housing.