Integrated Tub Battery Tray for Electric Vehicles

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Solution Overview

Problem

Existing vehicle battery support trays for electric and hybrid electric vehicles lack effective protection against environmental factors and impact, with separate support structures potentially causing leaks or penetrations, and existing designs often require multiple components that increase complexity and risk of failure.

Innovation Solution

A battery tray with a tub component that provides a sealed perimeter wall and integral structural features, reducing the need for additional support structures and components, while also subdividing the containment area into compartments to manage impact energy and prevent cross-contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If separate support structures are used to support battery weight, then structural support function is achieved, but the number of components increases and risk of leaks or penetrations increases

Engineering Contradiction:

Improvestructural supportVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines the support structure and tub component into a single integrated unit. The tub component includes an integrated support structure with longitudinal members and cross members that are formed as one piece, eliminating the need for separate support structures and reducing assembly complexity while maintaining structural integrity for supporting battery weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tub component serves multiple functions simultaneously: it provides structural support through integrated longitudinal and cross members, contains battery modules through its enclosed structure, and offers protection against environmental factors. This multi-functional design eliminates the need for separate dedicated support structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple separate components are used to make the battery tray, then structural flexibility is improved, but the risk of leaks or penetrations increases

Engineering Contradiction:

Improvestructural flexibilityVSAvoidrisk of leaks or penetrations

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The support structure and tub component are merged into a single integrated unit, eliminating multiple connection points and joints where leaks or penetrations could occur. The integrated design maintains structural flexibility through its formed geometry while ensuring continuous protection against environmental factors.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If the tub component provides sealed perimeter wall, then protection against environmental factors is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveprotection against environmental factorsVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The tub component is pre-formed as a single integrated piece with sealed perimeter walls during the molding or forming process. This preliminary formation of the sealed structure eliminates the need for post-assembly sealing operations, reducing manufacturing complexity while ensuring effective protection against environmental factors.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If cross member portions are added to subdivide the containment area, then impact energy management is improved, but the number of components increases

Engineering Contradiction:

Improveimpact energy managementVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cross members are integrated into the tub component as a single piece, forming compartments that subdivide the battery containment area. These cross members provide impact energy management by creating separate compartments while being manufactured as part of the unified tub structure, avoiding the need for separate additional components.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11691493B2Vehicle battery tray having tub-based component

Publication Date: 2023.07.04 SHAPE CORP

AI summary

A battery tray for an electric vehicle includes a tub component that has a floor portion and a perimeter wall portion that integrally extends upward around a peripheral edge of the floor portion to border a battery containment area of the tub component. The tub component may include a plurality of cross member portions that integrally interconnect with the floor portion and the perimeter wall portion so as to span laterally across the battery containment area to divide the battery containment area into separate compartments. A support structure of the battery tray may have an elongated member coupled at an exterior side of each of opposing longitudinal sections of the perimeter wall portion of the tub component.