Segmented Sheet Metal Battery Housing for EV Crash Safety
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Solution Overview
Problem
Existing battery housings for electric motor vehicles face challenges in achieving high rigidity, crash safety, and cost-effectiveness while being complex and expensive to produce, with limited flexibility in design changes.
Innovation Solution
A battery housing design utilizing formed sheet metal parts for the side frame, which offers high rigidity, strength, and deformability, allowing for easy production and modification of complex geometries, combined with a separate base plate and cover, and an additional reinforcing structure for enhanced impact safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a deep-drawn sheet metal trough with one-piece side walls is used, then the battery housing achieves high rigidity and strength, but the production becomes complicated and expensive
Solution Approach 1:
The battery housing is divided into separate components: a base plate, a side frame made of profile struts, and a cover. This segmentation allows each component to be manufactured independently using simpler, more cost-effective processes while maintaining the overall structural integrity and rigidity of the assembly.
Solution Approach 2:
The profile struts are combined with connection elements that integrate forming and joining operations. This merging of functions allows the side frame components to be produced as separate parts and then assembled, reducing production complexity while achieving the required strength through the combined structure.
2Stability of the object's composition
If an extruded one-piece frame profile is used, then the battery housing achieves high stability, but the production becomes expensive and design changes are limited
Solution Approach 1:
The frame structure is segmented into multiple profile struts that can be independently manufactured and assembled. This allows different geometries, sizes, and configurations to be achieved by selecting and arranging different profile sections, providing high design flexibility while maintaining structural stability through the modular assembly.
Solution Approach 2:
The profile struts are designed as universal components that can serve multiple functions: structural support, connection points for battery modules, and adaptable geometries for different housing configurations. The connection elements provide multi-functional joining capabilities, enabling the same basic profile design to be used across various applications and design requirements.
3Strength
If profile sections formed by extrusion are used, then the battery housing achieves high rigidity, but the production becomes complicated and costly
Solution Approach 1:
The side frame is segmented into profile struts made from formed sheet metal parts rather than complex extruded sections. This segmentation allows the use of simpler, more cost-effective forming processes while maintaining high rigidity through the profiled geometry and strategic placement of connection elements that provide structural reinforcement at key joints.
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 provides a stable, impact-resistant, and cost-effective battery housing with improved static and dynamic rigidity, enabling efficient energy absorption and easy adaptation to various shapes and sizes, while maintaining a compact and space-saving configuration.
Implementation Method 1
great deformability in the sense of a high energy absorption potential in the event of an impact
Data Source
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Figure 2B
AI summary
The invention relates to a battery housing for a vehicle that can be operated at least temporarily or at least partially by an electric motor, wherein the battery housing is designed to accommodate one or more battery modules. The battery housing comprises a base plate, a side frame connected to the base plate, and a cover connected to the side frame, wherein the base plate, the side frame, and the cover are joined to form a closed housing body. The base plate, the side frame, and the cover are manufactured as separate parts. The side frame is made of at least one profile strut, wherein the at least one profile strut is designed as a sheet metal forming part.