Fiber-filled Polypropylene Battery Carrier for EV Chassis
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Solution Overview
Problem
Traditional electrical vehicle battery carriers are heavy, susceptible to corrosion, and have complex assemblies, failing to meet high mechanical performance requirements such as stiffness and strength.
Innovation Solution
A component carrier made from injection-molded long glass fiber-filled polypropylene, designed as a stressed member of the vehicle chassis, providing high stiffness and strength while reducing weight through a more efficient manufacturing process that replaces traditional stamped steel parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stamped steel parts are used for battery carriers, then strength and stiffness requirements are met, but weight increases and corrosion susceptibility occurs
Solution Approach 1:
The patent changes the material parameters by transitioning from steel to fiber-filled thermoplastic composite materials. This material substitution maintains structural strength while significantly reducing weight and eliminating corrosion susceptibility, directly resolving the contradiction between strength requirements and weight reduction goals
Solution Approach 2:
The patent employs composite materials (fiber-filled thermoplastic) to achieve both high strength-to-weight ratio and corrosion resistance. The composite structure provides the necessary mechanical properties while avoiding the weight and corrosion issues associated with traditional steel construction
2Strength
If multiple stamped steel parts are assembled with welding, then mechanical strength is achieved, but assembly complexity increases
Solution Approach 1:
The patent merges multiple separate steel parts into a single integrated thermoplastic component. This consolidation eliminates the need for complex welding assemblies while maintaining structural strength, directly addressing the contradiction between strength requirements and assembly simplicity
3Ease of operation
If traditional battery carrier design is used, then component carrying function is provided, but vehicle weight reduction and packaging efficiency are limited
Solution Approach 1:
The thermoplastic battery carrier is designed to serve multiple functions: it carries battery components, provides structural support as a stressed chassis member, and contributes to vehicle weight reduction. This multi-functionality resolves the contradiction by enhancing the carrier's role beyond simple component holding while achieving weight reduction goals
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 solution achieves a high performance-to-weight ratio, reducing vehicle weight by up to 39% and improving structural rigidity, with the component carrier effectively supporting battery modules and other electrical components without significant plastic deformation under varying temperature conditions.
Implementation Method 1
melting the fiber-filled polymeric material to form a melt in a plasticizing unit
Implementation Method 2
dissolving the blowing agent into the melt
Data Source
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AI summary
The disclosure concerns component carriers including: (i) a first support structure having a generally rectangular cross-section; and (ii) a second support structure having a generally rectangular cross-section, where the first support structure and the second support structure are formed of fiber-filled polypropylene; and where the component carrier is configured to be part of an electrical vehicle.