Resin Battery Case with Metal Frames for Vehicle Power Supply
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Solution Overview
Problem
Conventional power supply devices for vehicles face challenges in achieving a balance between high strength and low weight, with metal frames providing necessary rigidity but increasing weight and complicating waterproofing, while resin cases offer reduced weight but insufficient strength and heat dissipation.
Innovation Solution
A power supply device design featuring a resin-made battery case covered by metal frames on both sides, allowing for complex shapes, improved waterproofing, and enhanced heat dissipation, with strategically placed metal frames for thermal separation and shielding against electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal frame or metal case is used to provide high strength and rigidity, then the structural strength is improved, but the weight increases and fuel consumption worsens
Solution Approach 1:
The patent employs a composite structure combining resin and metal materials. The battery case is made of resin material while metal frames are attached to specific portions (upper, lower, and side surfaces) to provide localized strength enhancement. This composite approach allows the device to achieve high structural strength where needed while maintaining overall lightweight characteristics, resolving the contradiction between strength and weight.
2Reliability
If a metal frame or metal case is used to ensure high rigidity, then the resistance to vibration and impact is improved, but the waterproof property becomes difficult to achieve
Solution Approach 1:
The patent applies local quality by using resin material for the battery case in portions requiring waterproofing, while metal frames are strategically attached only to surfaces requiring high strength (upper, lower, and specific side surfaces). The resin material provides excellent waterproofing properties and ease of manufacturing sealed structures, while metal frames provide localized reinforcement for vibration and impact resistance, resolving the contradiction between reliability and ease of manufacture.
3Weight of moving object
If a resin case is used to reduce weight, then the fuel consumption is improved, but the strength becomes insufficient
Solution Approach 1:
The patent uses a composite structure where the battery case is made of lightweight resin material while metal frames are attached to specific portions to provide necessary strength enhancement. This allows the device to achieve significant weight reduction compared to full metal construction while maintaining structural strength through the strategically placed metal reinforcements, resolving the contradiction between weight and strength.
4Ease of manufacture
If a resin case is used to achieve complex shapes and improve waterproofing, then the ease of manufacture is improved, but the strength and heat dissipation become insufficient
Solution Approach 1:
The patent applies local quality by using resin material for the battery case in portions requiring waterproofing and complex shaping, while metal frames are attached to specific surfaces (upper, lower, and side surfaces) where high strength and heat dissipation are needed. This localized material assignment allows the device to achieve excellent waterproofing and complex geometry through resin molding while compensating for strength and heat dissipation limitations through strategic metal frame placement, resolving the contradiction between ease of manufacture and strength.
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 lightweight yet robust power supply device with improved heat dissipation and electromagnetic immunity, reducing weight and fuel consumption while maintaining structural integrity and waterproofing.
Implementation Method 1
By covering the periphery of the battery case with the metal-made frames, the heat dissipation can be improved
Implementation Method 2
the shielding effect of the metal plates can improve the immunity to electromagnetic noise (EMC)
Data Source
AI summary
In order to provide a power supply device having a high rigidity and a light weight, power supply device includes: one or more cell stacked bodies each formed by stacking secondary battery cells; a circuit board including a control circuit electrically connected to the cell stacked bodies; resin-made battery case for storing the cell stacked bodies and circuit board; metal-made lower frame for covering the bottom surface of battery case; and metal-made upper frame for covering the upper surface of battery case. Battery case has a waterproof structure. Battery case is grasped by connecting upper frame to lower frame.