Roll-Formed Battery Tray with Interlocking Top and Bottom
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Solution Overview
Problem
Conventional car battery trays lack strength and are expensive to manufacture due to limitations in existing methods, which fail to adequately withstand crashes and impacts.
Innovation Solution
The method involves using a roll-forming process to shape metal sheets into durable and cost-effective battery trays, comprising a top tray with protrusions, a bottom tray with compartments, and a cooling tray with airflow and heat dissipation features, allowing for secure battery placement and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stamping method is used to make battery trays, then manufacturing process is simple, but strength is insufficient
Solution Approach 1:
The patent changes the manufacturing method from stamping to roll forming, which fundamentally alters the forming parameters and process characteristics. Roll forming creates continuous curved profiles that inherently provide greater structural strength compared to stamped panels, while maintaining manufacturing simplicity through a continuous forming process.
Solution Approach 2:
The patent creates a composite structure by forming multiple layers of metal sheets through roll forming, with each layer contributing to the overall strength. The interconnected curved profiles of multiple layers work together to create a composite structure that is stronger than single-layer stamped trays.
2Productivity
If conventional stamping method is used, then manufacturing cost is high, but production speed is slow
Solution Approach 1:
Roll forming is a continuous forming process where metal sheets are continuously fed through rolling dies to create the battery tray structure. This continuous action eliminates the stop-start nature of stamping operations, significantly increasing production speed while reducing manufacturing costs through efficient material utilization and continuous processing.
Solution Approach 2:
The roll forming process performs preliminary shaping of the metal sheets into curved profiles before final assembly. This preliminary action creates the structural framework in advance, allowing for faster final assembly and reducing overall manufacturing time and cost.
3Reliability
If stamping method is used, then manufacturing process is simple, but structural durability is insufficient
Solution Approach 1:
The patent employs roll forming to create continuous curved profiles in the battery tray structure. The curved geometry provides superior structural durability compared to flat stamped panels, as the curves naturally resist deformation and distribute stresses more effectively. The curvature is achieved through the roll forming process, which maintains structural integrity throughout the forming operation.
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 results in battery trays that are stronger, faster to manufacture, and more economical than conventional methods, while providing secure battery containment and effective cooling.
Implementation Method 1
roll forming one or more sheets of metal
Data Source
AI summary
A method of forming a car battery tray, the method includes continuously roll-forming a first sheet of metal into a bottom tray, the bottom tray having a first compartment with side walls and to receive a first battery, and the bottom tray having an opening formed into one of the side walls; and continuously roll-forming a second sheet of metal into a top tray, the top tray having a protrusion to engage with the opening of the bottom tray; the bottom tray and top tray connect to secure the first battery in place; the bottom tray and top tray form the car battery tray.