Modular Vehicle Battery Housing with Steel Frame and Sandwich Lid
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Solution Overview
Problem
Existing vehicle battery housings are expensive, heavy, and inefficient in terms of space, weight, and stability, particularly as they need to accommodate increasing battery capacities and ranges while ensuring waterproofing, crash protection, and maintenance-free operation.
Innovation Solution
A modular battery housing design featuring a frame with a rolling profile or C-profile made of high-strength steel, a strong bottom plate, and a lid plate with a metal-plastic sandwich material, incorporating spacers and reinforcement elements for enhanced stability and weight reduction, along with a simple and disassemblable structure for easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional complex housing designs are used to meet requirements for weight support, crash protection, and waterproofing, then the housing achieves adequate protection and functionality, but the housing becomes heavy and expensive to manufacture
Solution Approach 1:
The housing is divided into modular components: a frame structure, base plate, cover plate, and optional cross-member elements. These segments can be independently optimized for weight and strength, and assembled to meet specific protection requirements without over-engineering the entire housing.
Solution Approach 2:
The housing employs composite construction combining high-strength steel frame elements with lighter base and cover plates. This allows critical structural areas to use high-strength materials while non-critical areas use lighter materials, reducing overall weight while maintaining crash protection.
2Strength
If traditional complex housing designs are used to meet requirements for weight support, crash protection, and waterproofing, then the housing achieves adequate protection and functionality, but the housing becomes expensive to manufacture
Solution Approach 1:
The housing is divided into modular components: a frame structure, base plate, cover plate, and optional cross-member elements. These segments can be independently optimized for weight and strength, and assembled to meet specific protection requirements without over-engineering the entire housing.
Solution Approach 2:
The frame elements are designed with adjustable parameters including cross-sectional dimensions, wall thickness, and material grade. This allows the housing to be customized for different battery sizes and protection requirements without redesigning the entire structure, reducing development and manufacturing costs.
3Volume of moving object
If more installation space is allocated to accommodate increasing battery capacities, then battery capacity greater than 20 kWh can be achieved, but the housing requires higher stability and increased weight
Solution Approach 1:
The housing is divided into modular components: a frame structure, base plate, cover plate, and optional cross-member elements. These segments can be independently optimized for weight and strength, and assembled to meet specific protection requirements without over-engineering the entire housing.
Solution Approach 2:
The frame structure serves multiple functions: providing structural strength for crash protection, defining the housing volume for battery installation, and offering mounting points for thermal management and electrical connections. This multi-functionality reduces the need for additional components that would increase weight.
4Ease of manufacture
If the frame is designed as a one- or multi-part rolled profile for easy assembly and scaling, then the housing becomes easy to assemble and manufacture, but the manufacturing precision and structural integrity must be maintained
Solution Approach 1:
The frame elements are designed with adjustable parameters including cross-sectional dimensions, wall thickness, and material grade. This allows the housing to be customized for different battery sizes and protection requirements without redesigning the entire structure, reducing development and manufacturing costs.
Solution Approach 2:
The housing is divided into modular components: a frame structure, base plate, cover plate, and optional cross-member elements. These segments can be independently optimized for weight and strength, and assembled to meet specific protection requirements without over-engineering the entire housing.
Data Source
Figure 1
Figure 2~3b
Figure 4~5b
AI summary
Disclosed is a housing (1) for a vehicle battery, comprising a top plate (2) and a base plate (3) between which a frame (4) is arranged; the frame (4) is connected to the top plate (2) and the base plate (3); at least one cross-beam element (5) is arranged in the space surrounded by the frame (4).