Stackable Battery Module Mounting With Nested Face Plates
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Solution Overview
Problem
Current battery trays in hybrid or electric vehicles are bulky, heavy, and costly due to reinforcement requirements, which complicate assembly and occupy valuable space, necessitating a more efficient and lightweight mounting system.
Innovation Solution
A stackable battery module mounting system featuring a side wall structure with cross members and nested face plates on battery modules, allowing for direct module stacking and secure bolted connections, eliminating the need for separate trays and reducing the number of crossbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plain-carbon ferritic steel is used for battery tray construction, then structural strength is achieved, but weight and packaging space increase due to required reinforcements
Solution Approach 1:
The patent uses aluminum alloy material for the battery tray instead of plain-carbon ferritic steel. Aluminum alloy provides sufficient structural strength while being significantly lighter than steel, eliminating the need for heavy reinforcements and stiffening features while maintaining structural integrity under battery loads.
2Strength
If reinforcements and stiffening features are added to battery tray, then structural performance is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, which fundamentally alters the structural requirements. The aluminum alloy's inherent strength-to-weight ratio allows the tray to achieve required structural performance without additional reinforcements, simplifying the design and reducing assembly complexity.
3Strength
If numerous crossbars are used in battery tray design, then structural support is improved, but packaging space and weight increase
Solution Approach 1:
The patent extracts and eliminates the need for numerous crossbars by using aluminum alloy material that provides sufficient structural support on its own. The material properties of aluminum alloy allow the tray to maintain structural integrity with fewer support elements, freeing up packaging space for battery installation.
4Reliability
If separate battery trays are used for each battery module, then individual support is provided, but system weight and assembly complexity increase
Solution Approach 1:
The patent merges the function of separate battery trays into a single integrated aluminum alloy tray structure. This unified tray provides support for all battery modules simultaneously, reducing the total number of components while maintaining individual module support through the tray's continuous structure and optimized aluminum alloy construction.
Data Source
AI summary
A stackable battery module mounting system includes a side wall structure and a plurality of cross members extending between opposite sides of the side wall structure, the plurality of cross members each having a plurality of first spaced apertures. A plurality of battery modules each include a face plate on opposite sides thereof and each face plate includes a plurality of protruding sections which nest with protruding sections of the face plate of adjacent battery modules. At least some of the protruding sections include second apertures aligned with a respective one of the first spaced apertures of the plurality of cross members. A plurality of bolts are received in corresponding ones of the second apertures of the plurality of battery modules and the first spaced apertures in the plurality of cross members for securing the plurality of battery modules to the plurality of cross members.