Modular Battery Support Using Hollow Profiles
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Solution Overview
Problem
Existing battery supports for electric motor vehicles face challenges in optimizing interior space usage and manufacturing costs, particularly in corner regions during shaping, which affects leak tightness and maximum space utilization.
Innovation Solution
A modular battery support design featuring a tray with a base and peripheral side wall formed by coupled hollow profiles, a hood for partial height coverage, and a cooling system, allowing for efficient use of space, cost-effective production, and enhanced safety through a protective base that can be replaced independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sheet-metal shaped battery support is used, then structural integrity is improved, but manufacturing complexity and cost increase due to corner region shaping issues
Solution Approach 1:
The battery support is divided into multiple profile sections (front, rear, left, right profiles) that are manufactured separately and then joined together. This segmentation allows each profile to be produced using cost-effective extrusion processes rather than complex sheet metal shaping, while maintaining structural integrity through the joining of these standardized components.
2Productivity
If deep drawing is used for manufacturing, then production efficiency is improved, but corner region quality and leak tightness deteriorate
Solution Approach 1:
Instead of attempting to deep draw the entire battery support as a single complex shape, the structure is segmented into profiles that can be manufactured using simpler extrusion processes. This avoids the corner region quality issues inherent in deep drawing while maintaining high production efficiency through standardized manufacturing of modular components.
3Ease of manufacture
If a modular design with hollow profiles is used, then manufacturing cost is reduced, but structural stiffness may deteriorate
Solution Approach 1:
Multiple hollow profiles are merged together through joining (welding, bonding, or mechanical connection) to form the complete battery support structure. This combining approach maintains structural stiffness by creating a rigid framework while keeping individual components simple and cost-effective to manufacture using extrusion processes.
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
The modular design improves manufacturing efficiency, enhances leak tightness, and provides increased freedom in design and safety by allowing for separate replacement of the protective base, reducing damage risk and maintaining battery integrity.
Implementation Method 1
individual hollow profile pieces, preferably produced by extrusion from a light metal alloy, are coupled to one another in the corner regions formed, in particular by thermal joining
Implementation Method 2
below the base, a cooling system is arranged
Implementation Method 3
cooling system... through which a cooling fluid can flow
Data Source
AI summary
The invention relates to a battery support for an electric motor vehicle, having a tray for holding batteries, with a base and a peripheral side wall and a cover, wherein the cover is formed as a hood and the peripheral side wall is formed by a peripheral frame composed of hollow profiles, wherein the frame is coupled to a base, wherein the hood, in the closed state, is mounted on the hollow profile, and a cooling system is formed below the base, and in that a protective base is arranged below the base, in particular below the cooling system.