Ridged Double-Floor Battery Box for Lightweight EV Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicle battery boxes face a challenge in achieving a balance between being lightweight and maintaining high mechanical stability while protecting batteries from mechanical deformation, moisture, and dirt, with existing designs often requiring significant volume and weight.
Innovation Solution
A battery box design featuring a trough-shaped part made from lightweight high-strength sheet metal, with internal ridged portions and a doubled floor structure for enhanced reinforcement, connected via positive and non-positive connections, and optionally filled with filler material for additional protection and reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery box designs are used to ensure mechanical stability and protection, then the batteries are protected from mechanical deformation, moisture, and dirt, but the weight and volume increase significantly
Solution Approach 1:
The battery box combines sheet metal components with plastic elements to create a composite structure that achieves high mechanical stability while maintaining low weight. The sheet metal provides structural strength and rigidity, while the plastic components reduce overall mass and provide additional protection against corrosion and moisture.
Solution Approach 2:
The battery box is divided into multiple modular components including a base, side walls, and a lid, each optimized for specific functions. This segmentation allows each component to be designed with optimal material selection and thickness, reducing overall weight while maintaining necessary strength through strategic reinforcement at connection points.
2Strength
If traditional battery box designs are used to ensure mechanical stability and protection, then the batteries are protected from mechanical deformation, moisture, and dirt, but the volume required increases
Solution Approach 1:
The battery box incorporates curved and rounded design elements in its geometry, which provide structural strength through distributed stress patterns while maximizing internal volume efficiency. The curved transitions and optimized corner radii reduce material requirements while maintaining protection against mechanical deformation.
3Weight of moving object
If lightweight materials are used to reduce battery box weight, then the weight decreases, but the mechanical stability and protection capability deteriorate
Solution Approach 1:
The battery box employs varying wall thicknesses and material densities at different locations based on local stress requirements. Critical areas such as connection points, corners, and mounting regions use thicker, higher-strength materials, while non-critical areas use thinner, lighter materials, achieving optimal weight-to-strength ratio throughout the structure.
Data Source
AI summary
A battery box for an electric vehicle includes a trough-shaped part made of sheet metal, comprising a bottom floor portion which extends horizontally, lateral wall portions are arranged on both sides in the transverse direction (Y) extending in the upward direction therefrom. An internal sheet metal part is arranged between the wall portions and connected to the trough-shaped part and has floor portions facing the bottom floor portion as well as at least one ridged portion protruding relative to the floor portions and connected in one piece to at least one of the floor portions and extending in the transverse direction (Y), wherein at least one of the floor portions is spaced apart horizontally at least in some regions from the bottom floor portion so that a first intermediate space is formed therebetween.