Integrated HV Battery Tray Structure for More Installation Space
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Solution Overview
Problem
High-voltage batteries in motor vehicles require significant space and weight, and existing designs are costly due to separate components and air gaps, which limit energy storage and vehicle range, and complicate maintenance.
Innovation Solution
A high-voltage battery housing formed by a single-piece trough with side walls and lid, integrated into the vehicle body, eliminating separate components and air gaps, allowing upright battery cell mounting and direct installation, with a carrier plate forming the base and supporting structure, enabling increased installation space and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If separate battery housing components and air gaps are used, then manufacturing and maintenance are simplified, but installation space is wasted and energy storage capacity is reduced
Solution Approach 1:
The patent merges the battery housing sides and cover into a single integrated tray component, eliminating the need for separate housing parts and reducing the number of assembly steps. This integration directly increases the usable installation space by eliminating gaps between components while maintaining structural integrity for protective functions.
2Weight of moving object
If conventional battery housing with separate components is used, then manufacturing and assembly are easier, but weight and manufacturing costs increase
Solution Approach 1:
The battery housing is designed as a single integrated tray that combines the functions of sides and cover, reducing the total number of parts and associated fastening elements. This consolidation decreases overall weight while simplifying the manufacturing process through fewer production steps and assembly operations.
3Reliability
If air gaps are maintained between battery and vehicle structure, then protection from chafing and corrosion is improved, but installation space is reduced
Solution Approach 1:
The integrated tray design eliminates air gaps between battery housing components, maximizing installation space. The tray is positioned to close off the floor assembly from below, maintaining protective separation from the vehicle structure while utilizing the full available volume for battery cell placement.
Data Source
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AI summary
A motor vehicle with a high-voltage battery, wherein the high-voltage battery comprises a battery housing, the battery housing comprising at least side walls (1.1) and a lid (1.2) covering the side walls (1.1) at the top, wherein a plurality of battery cells (2) are arranged in the battery housing, wherein the side walls (1.1) and the lid (1.2) are formed integrally by a bottom-opened tray (1), wherein a support plate (4) forms the bottom of the high-voltage battery covering the tray (1) at its underside, wherein the battery cells (2) are mounted upright on the support plate (4) such that the electrical contacts of the battery cells (2) are directed upwards and the cell bottoms are directed downwards, and a method for manufacturing such a motor vehicle.