Stack Frame Mounting Hole Distribution for Battery Vibration
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Solution Overview
Problem
The existing manufacturing methods for stack frames, which involve joining multiple molded products, face challenges in providing adequate mounting holes for battery stacks, leading to reduced fixing strength due to vibrations from heavy battery stacks, especially when space and dimension restrictions are considered.
Innovation Solution
A stack frame design featuring frame members arranged in the right-left direction with a cross member extending across all end surfaces, where the end surface covered region has more mounting holes than the exposed region, allowing for better vibration transmission to the cross member and reduced force on mounting holes, ensuring fixing strength while adhering to shape and dimension restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a manufacturing method including a joining step of joining a plurality of molded products is employed, then manufacturing cost is reduced, but the number of mounting holes that can be provided is limited
Solution Approach 1:
The stack frame is divided into a plurality of molded products that are joined together. By segmenting the frame into multiple parts, the patent enables the provision of mounting holes in specific regions (end surface covered regions) while maintaining the cost advantages of multi-piece manufacturing. Each segment can be optimized independently to include necessary mounting holes.
Solution Approach 2:
The patent applies local quality by concentrating mounting holes in the end surface covered regions rather than distributing them uniformly. This allows the majority of mounting holes (more than half) to be located in regions where the end surface is covered, providing adequate mounting capability while maintaining the joined molded product structure.
2Reliability
If mounting holes are provided in multiple molded products, then the battery stack can be mounted, but vibration from the heavy battery stack causes excessive force on the mounting holes
Solution Approach 1:
The patent merges multiple mounting holes into the end surface covered regions of the joined molded products. By combining the mounting function into specific concentrated regions rather than distributing holes across all surfaces, the structure better absorbs and distributes vibration forces, reducing the force on individual mounting holes while maintaining reliable battery stack mounting.
3Length of moving object
If a cross member shorter than the total width of the plurality of molded products is used, then space restrictions are satisfied, but the fixing strength may be compromised
Solution Approach 1:
The patent applies local quality by concentrating mounting holes in the end surface covered regions rather than distributing them uniformly. This allows the majority of mounting holes (more than half) to be located in regions where the end surface is covered, providing adequate mounting capability while maintaining the joined molded product structure.
Solution Approach 2:
The patent changes the dimensional approach by positioning mounting holes in specific regions (end surface covered regions) rather than relying solely on the overall length of the cross member. This regional concentration of mounting holes provides adequate fixing strength even when the cross member length is reduced to satisfy space restrictions.
Data Source
AI summary
A stack frame is mounted with a battery stack, and is installed in a vehicle. The stack frame includes: a plurality of frame members arranged in a right-left direction of the vehicle; and a cross member extending in the right-left direction of the vehicle and joined to all end surfaces of the plurality of frame members. An end frame member located at least at one end in the right-left direction of the plurality of frame members, includes: an end surface covered region having an end surface covered with the cross member; and an end surface exposed region having an exposed end surface, and the end surface covered region is provided with more mounting holes used for mounting the battery stack than the end surface exposed region.