Unitary Cast Subframe Supporting Ring for Battery Protection
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Solution Overview
Problem
Existing subframes in motor vehicles do not provide a structurally simple and stable solution for holding electric energy accumulators, particularly high-voltage batteries, while also protecting them from deformation and damage during accidents.
Innovation Solution
A unitarily cast metal subframe with a supporting ring design, incorporating upper and lower supporting structures made of fiber-reinforced plastic or aluminum diecasting, which encloses the energy accumulator and includes bifurcations for holding power electronics units, and features integral fastening regions for attaching to the vehicle body, along with crash elements for energy absorption in crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex cast structure with multiple components is used for the subframe, then the holding stability and protection of the energy accumulator is improved, but the structural complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple subframe components (longitudinal members, cross members, and support structures) into a single unitarily cast supporting ring structure. This integration maintains the holding stability and protective functions while reducing structural complexity and the number of separate parts that need to be assembled and secured.
Solution Approach 2:
The supporting ring structure performs multiple functions simultaneously: it holds the energy accumulator, provides structural support, offers crash protection, and serves as a mounting platform for power electronics units. This multi-functionality eliminates the need for separate dedicated structures for each function, reducing overall structural complexity.
2Strength
If traditional metal subframes are used, then structural strength is ensured, but weight increases reducing vehicle efficiency
Solution Approach 1:
The patent employs fiber-reinforced plastic materials for the supporting structures and subframe components. These composite materials provide sufficient structural strength to hold and protect the energy accumulator while being significantly lighter than traditional metal subframes, thereby reducing overall vehicle weight and improving efficiency.
3Ease of manufacture
If aluminum diecasting is used for supporting structures, then cost is reduced and thermal conductivity is improved, but manufacturing precision may be compromised
Solution Approach 1:
The patent utilizes aluminum diecasting technology with optimized casting parameters and mold designs to achieve the required manufacturing precision. By controlling casting parameters such as temperature, pressure, and cooling rates, the process produces accurate supporting structures with complex geometries while maintaining cost-effectiveness and good thermal conductivity.
4Object-affected harmful factors
If the supporting ring is designed to enclose the energy accumulator completely, then protection during accidents is improved, but the device complexity and fastening requirements increase
Solution Approach 1:
The supporting ring is integrated directly with the vehicle body through unitary casting and built-in fastening regions, eliminating the need for separate complex fastening systems. The ring structure itself provides both the enclosing protection and the attachment mechanism, simplifying the overall design while maintaining crash protection effectiveness.
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 lightweight, cost-effective, and thermally conductive subframe that securely holds and protects electric energy accumulators and power electronics units, ensuring structural integrity and safety during accidents by distributing crash energy effectively.
Implementation Method 1
The supporting structures preferably are composed of fiber-reinforced plastic as a particularly lightweight solution; or of aluminum diecasting as a cost-effective solution with good thermal conductivity.
Implementation Method 2
The subframe also can have crash elements.
Implementation Method 3
A unitarily cast metal subframe with a supporting ring design, incorporating upper and lower supporting structures made of fiber-reinforced plastic or aluminum diecasting, which encloses the energy accumulator
Data Source
AI summary
A subframe (1) in a body of a motor vehicle is provided for connecting longitudinal and cross members for wheels (12) of an axle of the motor vehicle. A region (2) of the subframe (1) is designed as a supporting ring (3) for holding an electric energy accumulator (4). The subframe achieves a structurally simple and stable holding of an electric energy accumulator in the motor vehicle.