Interlinked Protective Frame Structure for Battery Modules
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Solution Overview
Problem
Existing protective frame structures for battery modules in vehicles are inefficient in terms of weight and space usage, as they require additional dead space for impact absorption and do not effectively distribute impact forces.
Innovation Solution
A protective frame structure comprising a lower frame, an intermediate frame that deforms upward to absorb impact, and an upper frame, which together provide rigidity and reduce weight while eliminating dead space by allowing the intermediate frame to move away from the battery module during impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an impact-absorbing part is provided adjacent to the battery housing as disclosed in JP-A-2003-45392, then the battery module is protected from impact, but the impact-absorbing part creates dead space that cannot be used by the user and increases the overall size
Solution Approach 1:
The patent merges the protective frame structure with the battery housing structure by making the intermediate frame form part of the battery housing. The intermediate frame serves dual purposes: it provides structural support for the battery module and acts as the impact-absorbing element. This eliminates the need for separate impact-absorbing parts that would create dead space, as the protective function is integrated into the existing structural components.
Solution Approach 2:
The intermediate frame is designed to deform dynamically during impact events. The frame can elastically deform to absorb impact energy, and the deformation is controlled to protect the battery module while minimizing permanent damage. This dynamic response allows the structure to absorb impact without requiring excessive static space for rigid impact-absorbing materials.
2Reliability
If additional protective structure is provided for rear seats as disclosed in JP-A-2003-45392, then protection against collision with rear seats is improved, but the device complexity and weight increase
Solution Approach 1:
The protective frame structure is designed to serve multiple protective functions simultaneously. The intermediate frame and upper frame work together to protect both the battery module from rear impacts and the rear seats from collision during battery module displacement. This multi-functional design eliminates the need for separate protective structures for different components, reducing overall complexity while maintaining comprehensive protection.
3Strength
If a rigid protective structure is used to protect the battery module, then the protection capability is improved, but the weight of the protective frame structure increases
Solution Approach 1:
The patent employs parameter changes in the frame structure by varying the thickness, material properties, and geometric configuration of different frame components. The intermediate frame and upper frame are designed with optimized parameters that provide sufficient strength for impact protection while minimizing weight. The frame cross-sections and connection structures are specifically dimensioned to achieve the required protective capability with reduced material usage compared to conventional rigid structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively absorbs impact forces, reduces the overall weight of the protective frame, and conserves space by eliminating dead space, providing enhanced protection for battery modules and other vehicle components.
Implementation Method 1
the intermediate frame is deformed upward when an external load has been applied to the protective frame structure
Implementation Method 2
the intermediate frame is deformed upward (i.e., the direction in which the intermediate frame moves away from the battery module) to absorb the impact force
Data Source
AI summary
A protective frame structure includes: a lower frame; an intermediate frame that is interlinked with the lower frame and is situated above the lower frame; and an upper frame that is interlinked with the intermediate frame and is situated abobe the intermediate frame, wherein a mounting space in which a battery module is configured to be mounted is formed between the lower frame and the intermediate frame, an upper space is formed between the intermediate frame and the upper frame, and the intermediate frame is deformed upward when an external load has been applied to the protective frame structure.