Press-Hardened Battery Tray Geometry for Crash and Space Balance
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Solution Overview
Problem
Existing battery trays for electric vehicles are not optimized for simplified manufacturing, internal space utilization, and crash resistance, particularly in the underfloor region of motor vehicles.
Innovation Solution
A hot-formed and press-hardened battery tray made from a sheet steel blank of hardenable steel alloy, with angled side walls and outwardly shaped corners, incorporating reinforcement structures and cooling channels, optimized for manufacturing efficiency and crash performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If side walls are made vertical (90° to base), then crash resistance is improved, but manufacturing complexity increases and internal space is reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the angle of side walls relative to the base. Instead of using vertical side walls (90°), the patent specifies angles between 60° and 80°, which provides an optimal balance between crash resistance and manufacturability. This angular modification allows the tray to absorb impact forces effectively while remaining compatible with standard deep-drawing manufacturing processes.
2Strength
If side walls are made vertical (90° to base), then crash resistance is improved, but internal receiving space is reduced
Solution Approach 1:
By changing the side wall angle parameter from 90° to between 60° and 80°, the patent achieves both improved crash resistance and maximized internal receiving space. The angled configuration creates more usable volume within the tray while maintaining structural integrity for crash scenarios.
3Ease of manufacture
If deep-drawing process is used for manufacturing, then manufacturing simplicity is improved, but material thickness and weight are increased
Solution Approach 1:
The patent optimizes material thickness parameters within specific ranges (0.7-1.2mm for base, 0.5-1.0mm for side walls) to achieve the right balance between manufacturing simplicity via deep-drawing and minimizing weight. These parameter specifications allow standard manufacturing processes while controlling material usage.
4Strength
If material thickness is increased, then crash resistance is improved, but weight and material usage are increased
Solution Approach 1:
The patent applies local quality by differentiating material thickness across different tray components. The base uses thicker material (0.7-1.2mm) for maximum crash resistance where impact forces are highest, while side walls use thinner material (0.5-1.0mm) where less structural support is needed. This localized optimization reduces overall weight while maintaining crash safety.
5Ease of manufacture
If corner regions are rounded, then manufacturing simplicity is improved, but structural strength is reduced
Solution Approach 1:
The patent optimizes the corner radius parameter within a specific range (5-15mm) to balance manufacturing ease and structural strength. This controlled rounding allows standard deep-drawing tools to form corners without excessive stress concentration, while the specified radius range maintains sufficient structural integrity for crash resistance.
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
Enhances manufacturing simplicity, optimizes internal space for battery accommodation and electrical connections, and improves crash resistance, while reducing material and weight through angled design and reinforcement.
Implementation Method 1
For hot forming, the material is first heated to above the austenitizing temperature, i.e., to over 900° C., then hot formed in a press and then cooled or quench hardened.
Implementation Method 2
For hot forming, the material is first heated to above the austenitizing temperature, i.e., to over 900° C., then hot formed in a press and then cooled or quench hardened.
Implementation Method 3
beads are able to be introduced into the base so that, when further coupled with another sheet of the base, a cooling channel structure is created, such that when a cooling medium is passed through, the base is able to be provided as a cooling base for the batteries arranged in the battery tray.
Data Source
AI summary
The present disclosure relates to a battery tray for an electric vehicle, manufactured as a hot-formed and press-hardened component from a sheet steel blank, having a base and side walls rising from the base with a flange running around the top of the battery tray and projecting outwards, characterized in that the side walls run on the longitudinal sides of the battery tray and the side walls run on the transverse sides of the battery tray at an angle of greater than 1° relative to a vertical, and in a respective corner region the base of the battery tray merges into a curved surface in such a way that a transition radius of the curved surface to a transverse side wall is formed and a transition radius of the curved surface to a longitudinal side wall is formed.