Lattice Battery Tray Segmentation for Rigidity
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Solution Overview
Problem
The existing battery unit designs for vehicles, such as hybrid or electric vehicles, face complexity and increased weight due to the need for rigid structures, which complicates manufacturing and may not effectively protect high-voltage devices during impacts.
Innovation Solution
A vehicle battery unit design featuring a lattice-shaped arrangement of lengthwise and lateral reinforcing members within a tray, which connects batteries and provides additional structural support without increasing tray thickness, allowing for simplified assembly and effective protection of high-voltage devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If front-rear-direction partitions are formed to be integrated with the tray to secure rigidity, then the rigidity in the front-rear-direction is improved, but the shape of the tray becomes complicated and manufacturing steps increase
Solution Approach 1:
The reinforcing structure is segmented into separate components: the tray remains simple and flat, while L-shaped reinforcing members are added as distinct elements that connect to the tray. This segmentation allows the tray to maintain its simple shape for easy manufacturing while the separate reinforcing members provide the necessary rigidity.
Solution Approach 2:
The L-shaped reinforcing members are positioned such that they nest within the battery accommodation structure, with the horizontal portion resting on the tray and the vertical portion extending upward to provide reinforcement. This nesting arrangement adds structural complexity only where needed without complicating the tray itself.
2Reliability
If a rigid tray structure is used to hold batteries, then battery holding reliability is improved, but weight increases
Solution Approach 1:
The structure is divided into a simple tray and separate L-shaped reinforcing members. The tray can be made from lighter gauge material since it doesn't need to provide all the structural strength alone, while the reinforcing members provide additional support only where needed to hold the batteries securely.
Solution Approach 2:
Reinforcement is applied locally at specific positions where batteries need support, rather than making the entire tray uniformly rigid. The L-shaped reinforcing members are strategically positioned to provide strength exactly where required, reducing overall material usage and weight.
3Strength
If multiple reinforcing members are added to the tray, then structural rigidity is improved, but device complexity increases
Solution Approach 1:
The L-shaped reinforcing members combine two functions in one component: the horizontal portion provides base support by resting on the tray, while the vertical portion provides upward reinforcement. This merging of functions into a single L-shaped component reduces the total number of parts compared to using separate horizontal and vertical reinforcing elements.
Solution Approach 2:
The L-shaped reinforcing members serve multiple purposes: they provide structural reinforcement, act as mounting surfaces for batteries, and can be configured to create divided accommodation chambers. This multi-functionality reduces the need for additional specialized components.
Data Source
AI summary
In a battery unit 10 in which plural high-voltage batteries 31a to 33a are accommodated in a battery case 50, the battery case 50 includes: a bottom plate 51A on which the batteries 31a to 33a are mounted; and a cover 52 covering the batteries 31a to 33a from above. The bottom plate 51A includes a tray 54 having a plate shape, lengthwise reinforcing members 55, and brackets 53. The lengthwise reinforcing members 55 are disposed so as to connect at least adjacent brackets 53. The lengthwise reinforcing members 55 and the brackets 53 are disposed in a lattice shape with the tray 54 interposed therebetween. The batteries 31a to 33a are fixed to the lengthwise reinforcing members 55 such that a longitudinal direction thereof faces the vehicle width direction. The battery case 50 is fixed under a floor of a vehicle V by the brackets 53.