Resin Battery Case with Embedded Metal Framework

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional metal battery frames for electric vehicles increase the weight of the vehicle, reducing its range and drivability, while also compromising crash resistance.

Innovation Solution

A structure comprising a metal body member, a resin battery case with embedded metal framework members, and connecting elements made from iron, which enhances crash resistance and rigidity without increasing weight by using polybutylene resin for the battery case and strategically placing metal components for support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal battery frame is used to support heavy batteries, then the strength and crash resistance are improved, but the weight of the electric vehicle increases

Engineering Contradiction:

Improvecrash resistanceVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining resin (polybutylene) and metal (iron framework members) to create a battery case that achieves both lightweight properties and high strength. The resin battery case provides base structure with reduced weight, while embedded metal framework members provide reinforcement for crash resistance, resolving the contradiction between weight reduction and strength maintenance.

Inventive Principle:

Principle #40Composite materials

2Strength

If a metal battery frame is used to support heavy batteries, then the strength and crash resistance are improved, but the range and drivability become worse

Engineering Contradiction:

Improvecrash resistanceVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The composite structure of resin battery case with embedded metal framework achieves high strength-to-weight ratio, reducing overall vehicle weight and consequently lowering energy consumption for the same driving task, thus improving range and drivability while maintaining crash resistance.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If resin is used for the battery case to reduce weight, then the weight is reduced, but the rigidity and crash resistance decrease

Engineering Contradiction:

Improvebattery case weightVSAvoidrigidity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses composite materials by embedding metal framework members within the resin battery case. The resin provides lightweight properties while the embedded metal frameworks provide rigidity and structural reinforcement, achieving both weight reduction and strength maintenance simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by strategically placing metal framework members at specific locations within the battery case where structural reinforcement is most needed. This localized reinforcement provides rigidity and crash resistance only where required, rather than making the entire battery case heavy, thus maintaining lightweight properties while achieving necessary strength.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS7931105B2Structure for mounting batteries onto electric vehicles

Publication Date: 2011.04.26 MITSUBISHI JIDOSHA ENG KK

AI summary

A structure for mounting a battery onto an electric vehicle comprising: a body member, which is made from metal, forming a body of the electric vehicle a battery case, which is made from resin, containing the battery charging electric power for driving the electric vehicle; a framework member, which is made from metal, being embedded in the battery case; and a connecting member connecting between the framework member and the body member.