US20260144369A1
2026-05-28
19/403,752
2025-11-28
Smart Summary: A pre-tensioned battery shelf is designed to hold batteries securely. It has a base plate that supports the batteries and multiple side walls that are attached to it. Fastening panels and fasteners help reinforce the connection between the side walls and the base plate. The base plate has dimples that help spread out stress evenly, making it stronger. Additionally, both the base plate and side walls are pre-tensioned and inclined for better stability. 🚀 TL;DR
A pre-tensioned battery shelf includes a base plate configured to support one or more loads, multiple side walls attached to sides of the base plate, multiple fastening panels to reinforce the attachment between the multiple side walls and the base plate and multiple fasteners connected through multiple fastening panels to securely attach the multiple side walls to the base plate. Further, multiple dimples are integrated to the base plate to distribute stress across the base plate, wherein the base plate is pretensioned and inclined, and wherein the multiple side walls are pre-tensioned.
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A47B96/027 » CPC main
Details of cabinets, racks or shelf units not covered by a single one of groups  - ; General details of furniture; Shelves Cantilever shelves
A47B96/021 » CPC further
Details of cabinets, racks or shelf units not covered by a single one of groups  - ; General details of furniture; Shelves Structural features of shelf bases
B21D47/00 » CPC further
Processing sheet metal or metal tubes, or processing metal profiles according to any of groups - , in the manufacture of finished or semi-finished articles
B21D47/00 » CPC further
Making rigid structural elements or units, e.g. honeycomb structures
A47B96/02 IPC
Details of cabinets, racks or shelf units not covered by a single one of groups  - ; General details of furniture Shelves
This application claims priority to and benefit of IN Patent Application No. 202421093284, “PRE-TENSIONED BATTERY SHELF” and filed Nov. 28, 2024, which is expressly incorporated herein by reference in its entirety.
In general, load bearing assemblies used in industries withstand varying load conditions, environmental factors and dynamic stresses. Conventional load bearing assemblies face challenges in holding and balancing the weight when subjected to continuous use in demanding environments. The conventional load bearing assemblies may be unable to sustain their structural stability under seismic conditions, transportations, etc. Therefore, there is a need for an efficient pre-tensioned battery shelf capable of sustaining operational loads under demanding environmental and dynamic conditions while maintaining cost-effectiveness and ease of manufacturing.
This summary is provided to introduce aspects related to a pre-tensioned battery shelf, a pressing machine and the method to manufacture the pre-tensioned battery shelf. The pre-tensioned battery shelf ensures that it can carry one or more loads withstanding various environmental factors like earthquake, temperature changes, corrosion etc. The pre-tensioned battery shelf improves the lifespan of the load it carries and the pre-tensioned battery shelf. The pre-tensioned battery shelf does not get damaged or deformed when carrying operational loads. Additionally, the present provides a cost effective and time efficient manufacturing process.
In one embodiment, the present disclosure provides a pre-tensioned battery shelf, comprising a base plate configured to support one or more loads, multiple side walls attached to sides of the base plate, multiple fastening panels positioned at edges of the multiple side walls and the base plate, wherein the multiple fastening panels reinforces the attachment between the multiple side walls and the base plate and multiple fasteners connected through the multiple fastening panels to securely attach the multiple side walls to the base plate. Further, multiple dimples integrated to the base plate to distribute stress across the base plate, wherein the base plate is inclined and pre-tensioned, and wherein the multiple side walls are pre-tensioned.
In an aspect, the base plate is pre-tensioned and integrated with the multiple dimples simultaneously in a pressing operation.
In an aspect, the multiple side walls are pre-tensioned in a pressing operation.
In an aspect, the multiple dimples are integrated to the base plate in an arranged pattern to distribute the stress across the pre-tensioned battery shelf.
In an aspect, the base plate, the multiple side walls, the multiple fastening panels and the multiple fasteners are made from a lightweight alloy or metal.
In an aspect, thickness of the base plate and the multiple side walls is directly proportional to weight of the one or more loads.
In an aspect, the pre-tensioned battery shelf comprising the base plate, the multiple side walls, the multiple fastening panels and the multiple fasteners is coated with a corrosion resistant coating.
In another embodiment, the present disclosure provides a pressing machine for manufacturing a pre-tensioned battery shelf comprising a lower die positioned to support a metal sheet during a pressing operation, a hydraulic ram connected to an upper die, wherein the upper die is configured to move downward and apply pressure to the metal sheet, a convex profile is formed between the upper die and the lower die during the pressing operation. Further, the upper die and the lower die are configured to fabricate the metal sheet into a base plate or multiple side walls, and the metal sheet is pre-tensioned and integrated with multiple dimples simultaneously in the pressing operation. The pressing machine further includes a control system configured to regulate movement and adjust the pressure of the upper die.
In an aspect, the upper die is configured to pre-tension and integrate the multiple dimples to the base plate simultaneously in the pressing operation.
In an aspect, the upper die is configured to pre-tension the multiple side walls, in the pressing operation.
In an aspect, the lower die is further configured to move upward and apply pressure during the pressing operation.
In an aspect, the upper die and the lower die include features configured to create reinforcement structures such as the multiple dimples on the base plate and the multiple side walls.
In an aspect, a safety system stops the pressing operation when there is an improper placement on the lower die.
In an aspect, the control system adjusts the pressure applied by the upper die according to thickness of the metal sheet.
In another embodiment, the present disclosure provides a method for manufacturing a pre-tensioned battery shelf using a pressing machine comprising the steps of positioning a metal sheet on a lower die of the pressing machine, wherein the lower die is configured to provide support to the metal sheet during a pressing operation. Then applying pressure during the pressing operation to the metal sheet using an upper die to form a base plate and multiple side walls to create a box structure. Further, performing pre-tensioning and forming dimples during the pressing operation wherein the base plate is pre-tensioned and dimpled simultaneously and wherein the multiple side walls is pre-tensioned. Further, regulating movement and adjusting pressure of the upper die and the lower die applied on the metal sheet using a control system. Finally, attaching the multiple side walls to the base plate using a multiple fastening panels and a multiple fasteners to construct the pre-tensioned battery shelf.
In an aspect, the metal sheet is pre-tensioned and dimpled simultaneously when applying pressure to form a base plate.
In an aspect, the metal sheet is pre-tensioned when applying pressure to form the multiple side walls.
In an aspect, the metal sheet is pre-tensioned when applying pressure to form the multiple side walls.
In an aspect, applying a corrosion resistant coating to the pre-tensioned battery shelf comprising the base plate, the multiple side walls, the multiple fastening panels and the multiple fasteners.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
The accompanying figures of the drawing, which are included to provide a further understanding of general aspects of the assembly, are incorporated in and constitute a part of this specification. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the suffix.
FIG. 1 illustrates a conventional load carrying assembly, in accordance with the present disclosure.
FIGS. 2A-2B illustrate a shelf used in a conventional load carrying assembly, in accordance with the present disclosure.
FIGS. 3A-3B illustrate a pre-tensioned battery shelf, according to an exemplary embodiment of the present disclosure.
FIG. 4 illustrates various pre-tensioned curves after a metal sheet undergoes a pre-tensioning process, according to an exemplary embodiment of the present disclosure.
FIGS. 5A-5B illustrate a pre-tensioned battery shelf integrated with dimples, according to an exemplary embodiment of the present disclosure.
FIGS. 6A-6B illustrate a pressing machine to manufacture a pre-tensioned battery shelf, according to an exemplary embodiment of the present disclosure.
FIG. 7 illustrates a method flow for manufacturing a pre-tensioned battery shelf, according to an exemplary embodiment of the present disclosure.
A conventional loading assembly may be used to carry operational loads. The conventional loading assembly may not be able to distribute the stress across a shelf when carrying the operational loads. This may lead to damage and deformation of the conventional assembly and the loads carried by the conventional assembly.
In order to overcome the above-mentioned challenges, the present disclosure provides a pre-tensioned battery shelf. The present disclosure suggests pre-tensioning and integrating multiple dimples to a metal sheet to form a shelf with stress distribution.
FIG. 1 illustrates a conventional load carrying assembly 100, in accordance with the present disclosure. The conventional load carrying assembly 100 may include a support structure 103, multiple shelves 101a-101c and one or more batteries 102a-102c. The multiple shelves 101a-101c may be attached to the support structure 103 to hold and support the one or more batteries 102a-102c. The one or more batteries 102a-102c may be arranged in any manner on the multiple shelves 101a-101c as per the load capacity of the multiple shelves 101a-101c. The one or more batteries 102a-102c may also be referred to as one or more loads throughout the specification. The one or more batteries 102a-102c may be securely held in place by the multiple shelves 101a-101c. The multiple shelves 101a-101c may be flat structures configured to accommodate and distribute the weight of the one or more batteries 101a-101c, ensuring stability of the conventional load carrying assembly 100 during operation. The one or more batteries 101a-101c may be exposed on one side of the support structure 103 to make accessibility to the one or more batteries 102a-102c easier during maintenance or operation. Movement and heavy vibrations may be generated during earthquake and transportation. This may disrupt the stability and balance of the conventional load carrying assembly 100. Further leading to damage of the one or more batteries 101a-101c and interruption in the signal connectivity of the one or more batteries 101a-101c.
FIGS. 2A-2B illustrate a conventional shelf used in a conventional load carrying assembly, in accordance with the present disclosure. FIG. 2A illustrates the conventional shelf 200 to hold one or more loads. The conventional shelf 200 can include multiple side walls 201a-201c, a base plate 203, multiple fastening panels 202a-202c and multiple fasteners 204a-204d. The multiple side walls 201a-201c can be attached to the base plate 203 to form a box-like structure. The multiple fastening panels 202a-202c can be positioned at edges of the multiple side walls 201a-201c and the base plate 203, wherein the multiple fastening 202a-202c panels can reinforce the attachment between the multiple side walls 201a-201c and the base plate 203. The multiple side walls 201a-201c can provide lateral support and prevent the one or more loads from shifting during an operation.
FIG. 2B illustrates a stress analysis focusing on an equivalent Von Mises Stress in the conventional shelf 200 under a load. According to an exemplary embodiment, various stress levels with specific nodes and corresponding stress values can be indicated across the conventional shelf 200. The stress may be measured in MPa. Each node on the conventional shelf 200 can correspond to a respective stress value. The stress at Node 6773 can be 20.248 MPa, the stress at Node 10007 can be 37.198 MPa, the stress at Node 2809 can be 35.799 MPa, the stress at Node 1805 can be 64.184 MPa, the stress at Node 2921 can be 35.391 and the stress at Node 3719 can be 20.514. Regions exhibiting high stress concentration on the conventional shelf 200 can indicate areas subject to potential structural weakness or deformation and regions with low stress concentration on the conventional shelf 200 can indicate areas that are more stable under operational loads. According to the illustration, the distribution of weight is uneven across the surface of the conventional shelf 200. The maximum recorded stress can be 64.184 MPa at Node 1805 and the lowest recorded stress can be 20.248 MPa at Node 6773. The stress analysis can illustrate the structural behavior of the conventional shelf 200 under the one or more loads and can identify the high stress areas of the conventional shelf 200. This can be used to improve performance by redistributing stress efficiently and evenly across the conventional shelf 200.
FIGS. 3A-3B illustrate a pre-tensioned battery shelf, according to an exemplary embodiment of the present disclosure. FIG. 3A illustrates the pre-tensioned battery shelf 300. The pre-tensioned battery shelf 300 can include multiple side walls 301a-301c, a base plate 303, multiple fastening panels 302a-302c and multiple fasteners 304a-304d. The base plate 303 can be configured to support one or more loads. The multiple side walls 301a-301c can be attached to the base plate 303 to form a box-like structure. The multiple fastening panels 302a-302c can be positioned at the edges of the multiple side walls 301a-301c and the base plate 303, wherein the multiple fastening 302a-302c panels can reinforce the attachment between the multiple side walls 301a-301c and the base plate 303. The multiple fasteners 304a-304d can be connected through the multiple fastening panels 302a-302c to securely attach the multiple side walls 301a-301c to the base plate 303. The base plate 303 can be inclined and pre-tensioned and the multiple side walls 301a-301c can be pre-tensioned.
In an exemplary embodiment, the pre-tensioned battery shelf 300 can be inclined with an inclination of 1 or 2 degrees. FIG. 3A illustrates the top view of the pre-tensioned battery shelf 300. The inclination of the pre-tensioned battery shelf 300 can reduce the stress and distribute the weight of the one or more loads efficiently across the shelf 300.
FIG. 3B illustrates a stress analysis focusing on an equivalent Von Mises Stress in the pre-tensioned battery shelf 300 under a load. According to an exemplary embodiment, various stress levels with specific nodes and corresponding stress values can be indicated across the pre-tensioned battery shelf 300. The stress may be measured in MPa. Each node on the pre-tensioned battery shelf 300 can correspond to a respective stress value. The stress at Node 30819 can be 9.0603 MPa, the stress at Node 28999 can be 15.236 MPa, the stress at Node 35129 can be 20.603 MPa, the stress at Node 26780 can be 32.555 MPa, the stress at Node 33649 can be 20.113 and the stress at Node 28535 can be 8.0328. Regions with high stress concentration on the pre-tensioned battery shelf 300 can indicate areas with potential structural weakness or deformation and regions with low stress concentration on the pre-tensioned battery shelf 300 can indicate areas that are more stable under operational loads. According to the illustration, the stress across the surface of the pre-tensioned battery shelf 300 can be less when compared to the conventional shelf in the conventional load carrying assembly as described in FIG. 2B. The maximum recorded stress can be 32.555 MPa at Node 33649 and the lowest recorded stress can be 8.0328 MPa at Node 28535. The stress analysis can illustrate the structural behavior of the pre-tensioned battery shelf 300 under the load and can identify the high stress areas of the pre-tensioned battery shelf 300.
FIG. 4 illustrates various pre-tensioned curves after a metal sheet undergoes a pre-tensioning process, according to an exemplary embodiment of the present disclosure. In the first example, the metal sheet can be introduced as a flat sheet. After pre-tensioning process, the metal sheet can form into a convex curve and the middle region of the metal sheet can be elevated to form a convex curve. This can indicate a uniform lifting effect across the entire shelf and can improve its load bearing capacity. In the second example, the shelf can be pre-tensioned to form a trapezoidal shape. The outer edges can be inclined downwards and the middle region remain flat. The pre-tensioning can be targeted only on the outer edges of the metal sheet to improve stress distribution. In the third example, the shelf can be pre-tensioned into two distinct convex curves. The curves can indicate two primary tension points created across the shelf to distribute load efficiently across multiple points. Each type of pre-tensioning process improves the structural integrity and load distribution of the shelf in operating conditions. In an aspect, the shelf can be used to carry one or more loads not confirming to batteries.
FIGS. 5A-5B illustrate a pre-tensioned battery shelf integrated with multiple dimples, according to an exemplary embodiment of the present disclosure. FIG. 5A illustrates the pre-tensioned battery shelf 500 integrated with the multiple dimples. The pre-tensioned battery shelf 500 integrated with the multiple dimples can also be referred to as a shelf, hereinafter. The shelf 500 can include multiple side walls 501a-501c, a base plate 503, multiple fastening panels 502a-502c and multiple fasteners 505a-505d. The base plate 503 can be configured to support one or more loads. The multiple side walls 501a-501c can be attached to the base plate 503. The multiple fastening panels 502a-502c can be positioned at edges of the multiple side walls 501a-501c and the base plate 503, wherein the multiple fastening 502a-502c panels can reinforce the attachment between the multiple side walls 501a-501c and the base plate 503. The multiple fasteners 505a-505d can be connected through the multiple fastening panels 502a-502c to securely attach the multiple side walls to the base plate 503. The base plate 503 can be integrated with the multiple dimples 504 to distribute stress across the base plate 503. The multiple side walls 501a-501c can be pre-tensioned.
In an exemplary embodiment, the multiple side walls 501a-501c can be pre-tensioned in a pressing operation. The pre-tensioning reduces the stress and increases the load bearing capacity of the shelf 500. The pre-tensioning increases the stiffness of the shelf 500. The base plate 503 can be pre-tensioned and integrated with the multiple dimples 504 simultaneously in the pressing operation.
The multiple dimples 504 can be integrated to the base plate 503 in an arranged pattern to distribute the stress across the shelf 500. In an aspect, the pre-tensioning process can increase the load bearing capacity of the shelf 500 by at least 55%. This can prevent the shelf from sagging and deforming under the weight of one or more loads. The multiple dimples 504 can increase resistance of the shelf 500 to mechanical stresses such as vibration, impact forces, and operational loads.
According to an embodiment, the base plate 503, the multiple side walls 501a-501c, the multiple fastening panels 502a-502c and the multiple fasteners 505a-505d can be made from a lightweight alloy or metal. Thickness of the base plate 503 and the multiple side walls 501a-501c can be directly proportional to weight of the one or more loads. A corrosion resistant coating can be applied to the shelf 500 and its comprising components such as the base plate 503, the multiple side walls 501a-501c, the multiple fastening panels and the multiple fasteners 505a-505d to protect the shelf from environmental degradation, ensuring long term durability and reduce maintenance. The shelf 500 can carry one or more batteries or other loads.
In a non-limiting example, it may be observed that stress on the 2.5 mm thick shelf 500 under a 292 kg load may be reduced from 63 MPa to 28 MPa. The inclined pre-tensioned metal sheet with reduced thickness can be capable of having higher load bearing capacity when compared to a flat, non-tensioned metal sheet. According to another embodiment, the metal sheet can be pre-tensioned in a convex orientation and the one or more loads can be placed on the convex-curved side.
FIG. 5B illustrates a stress analysis focusing on an equivalent Von Mises Stress in the pre-tensioned battery shelf 500 integrated with the multiple dimples 504 under a load. According to an embodiment, various stress levels with specific nodes and corresponding stress values can be indicated across the shelf 500. The stress may be measured in MPa. Each node on the shelf can correspond to a respective stress value. The stress at Node 31575 can be 8.0154 MPa, the stress at Node 29043 can be 30.533 MPa, the stress at Node 28559 can be 19.51 MPa, and the stress at Node 36140 can be 5.7065. The stress distribution across the shelf 500 represents regions of high stress concentration. The area and edges near the multiple fastening panels 502a-502c can be the areas enduring high stress. The center of the base plate 503 can have comparatively lower stress as the stress can be distributed across the base plate 503 due to the multiple dimples 504. The multiple dimples 504 integrated to the base plate 503 can increase the load bearing capacity and reduced localized stress. This can also help in improving the stiffness of the pre-tensioned battery shelf 500. According to the illustration, the stress across the surface of the shelf 500 can be less when compared to the pre-tensioned battery shelf as illustrated in FIG. 3B. The maximum recorded stress can be 30.533 MPa at Node 29043 and the lowest recorded stress can be 5.7065 MPa at Node 36140. The stress analysis can illustrate the structural behavior of the shelf 500 under the load and can identify the high stress areas of the shelf 500.
FIGS. 6A-6B illustrate a pressing machine to manufacture a pre-tensioned battery shelf, according to an exemplary embodiment of the present disclosure. FIG. 6A illustrates the structure of the pressing machine 600 for manufacturing the pre-tensioned battery shelf (not shown). The pressing machine 600 can include a lower die 603 to support a metal sheet 605 during a pressing operation. The pressing machine 600 can further include a hydraulic ramp 601 connected to an upper die 602. The upper die 602 can be configured to move downward and apply pressure to the metal sheet during the pressing operation. A convex profile 604 can be formed between the upper die 602 and the lower die 603 during the pressing operation. The upper die 602 and the lower die 603 can be further configured to fabricate the metal sheet 605 into a base plate or multiple side walls. The lower die 603 can also move upward to apply pressure to the metal sheet 605. When the metal sheet 605 is sent for the pressing operation, the metal sheet 605 can be pre-tensioned and integrated with multiple dimples simultaneously in the pressing operation. The pressing machine 600 can also include a control system configured to regulate movement and adjust the pressure of the upper die 602. The control system can adjust the pressure of the upper die 602 and the lower die 603 based on thickness of the metal sheet. In another embodiment, the control system can be configured to control the upper die 602 and the lower die 603 to form the metal sheet into a box structure. The control system can control the pre-tensioning and integrating of the multiple dimples in the single pressing operation.
The control system can include a memory, one or more processors configured to monitor and adjust the pressure applied by the upper die 602 and the lower die 603. The control system can adjust the pressure applied by the upper die 602 based on thickness of the metal sheet 605 and can achieve required deformation during the pressing operation. The control system can be configured so that the chosen load generates a specific stress profile, characterized by a compression gradient, within the convex portion of the metallic sheet. The control system can be operated manually or automatically within the pressing machine 600.
The upper die 602 and the lower die 603 can include features configured to create reinforcement structures, such as the multiple dimples, in the base plate and side walls to enhance the load-bearing capacity of the shelf. The pre-tensioning and dimpling operations can be performed simultaneously, optimizing the structural performance of the pre-tensioned battery shelf and increasing production efficiency of the pressing machine 600.
The pressing machine 600 can handle metal sheets of varying thicknesses and materials, providing flexibility for manufacturing different types of shelf assemblies, including battery shelf assemblies. The pressing machine 600 can also include a safety system that can stop the pressing operation when there is an improper placement of the metal sheet 605 on the lower die 603 protecting the machine and user from damage and injury respectively. The safety system can include a memory, one or more processors configured to alert the user and stop the pressing operation by the upper die 602 and the lower die 603 when there can be a misalignment or improper placement of the metal sheet 605.
In an embodiment, the hydraulic ram 601 can be attached to the pressing machine and is responsible for driving the upper die 602 downward during the pressing operation. The hydraulic ram 601 can use hydraulic fluid pressure to generate the necessary force for the upper die 602 to shape or deform the profile 604. The movement and pressure exerted by the hydraulic ram 601 can be precisely controlled to ensure that the metal sheet can be fabricated accurately according to design specifications. The hydraulic ram 601 can provide mechanical power needed to apply consistent and repeatable pressure during each pressing operation, ensuring efficient and high-quality production.
In an embodiment, the metal sheet 605 can undergo precise shaping and forming through the pressing operation using a pressing machine 600. The metal sheet 605 can be placed between the upper die 602 and the lower die 603. During the pressing operation, controlled pressure can be applied by the upper die 602 to the metal sheet 605, which can be supported by the lower die 603. The pressing operation can create a convex profile 604 on the metal sheet 605 to enhance its structural rigidity and load-bearing capacity. The convex profile 604 can formed by the interaction between the upper and lower dies, allowing the metal sheet 605 to meet specific mechanical requirements, such as dimensional accuracy, stiffness, and resistance to deformation. This process may be important for applications where the pre-tensioned battery shelf can support heavy loads while maintaining its shape and integrity over time.
FIG. 6B illustrates a block diagram of the pressing machine to manufacture a pre-tensioned battery shelf. The pressing machine 600 can include the metal sheet positioned between the upper die 602 and the lower die 603, in accordance with an embodiment of the present disclosure. The hydraulic ram 601 can be connected to the upper die 602 which can apply pressure to the metal sheet. The lower die 603 can support the metal sheet during the pressing operation. The convex profile can be formed as a result of the pressing operation by the interaction between the upper die 602 and the lower die 603. The pressing machine 600 can provide accurate shaping and fabricating of the metal sheet to the base plate and the multiple side walls and form a box-like structure through controlled pressure.
FIG. 7 illustrates a method flow for manufacturing a pre-tensioned battery shelf using a pressing machine, according to an exemplary embodiment of the present disclosure. The method for manufacturing the pre-tensioned battery shelf, includes the steps of, positioning a metal sheet on a lower die of the pressing machine, wherein the lower die is configured to provide support to the metal sheet during a pressing operation, as shown in Step 701. According to Step 702, pressure is applied during the pressing operation to the metal sheet using an upper die and the lower die to form a base plate and multiple side walls to create a box structure. At Step 703, pre-tensioning can be performed on the multiple side walls during the pressing operation and the base metal can be pre-tensioned and integrated with multiple dimples simultaneously to distribute stress across the base plate. Movement and pressure of the upper die and the lower die applied on the metal sheet can be regulated using a control system, according to Step 704. Finally, as shown in Step 705, the multiple side walls can be attached to the base plate using multiple fastening panels and multiple fasteners to construct a pre-tensioned battery shelf.
Further, the method to manufacture the pre-tensioned battery shelf includes applying a corrosion resistant coating to the pre-tensioned battery shelf comprising the base plate, the multiple side walls, the multiple fastening panels and the multiple fasteners. According to an embodiment, the process of pre-tensioning and integrating or forming dimples can be done simultaneously in the same pressing operation. The pressure applied to the metal sheet can be adjusted and based on thickness of the metal sheet.
The present disclosure provides methods to manufacture the pre-tensioned battery shelf that is lightweight and with necessary strength and rigidity to hold one or more loads. The pre-tensioned battery shelf minimizes deformation under operational loads enhancing the durability of the system.
The methods, systems, devices, graphs, and/or tables discussed herein are examples. Various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative embodiments, the methods may be performed in an order different from that described, and/or various stages may be added, omitted, and/or combined. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims. Additionally, the techniques discussed herein may provide differing results with different types of context awareness classifiers.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly or conventionally understood. As used herein, the articles “a” and “an” refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element. “About” and/or “approximately” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, encompasses variations of +20% or +10%, +5%, or +0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein. “Substantially” as used herein when referring to a measurable value such as an amount, a temporal duration, a physical attribute (such as frequency), and the like, also encompasses variations of ±20% or ±10%, ±5%, or ±0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein.
As used herein, including in the claims, “and” as used in a list of items prefaced by “at least one of” or “one or more of” indicates that any combination of the listed items may be used. For example, a list of “at least one of A, B, and C” includes any of the combinations A or B or C or AB or AC or BC and/or ABC (i.e., A and B and C). Furthermore, to the extent more than one occurrence or use of the items A, B, or C is possible, multiple uses of A, B, and/or C may form part of the contemplated combinations. For example, a list of “at least one of A, B, and C” may also include AA, AAB, AAA, BB, etc.
While illustrative and presently preferred embodiments of the disclosed systems, methods, and/or machine-readable media have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art. While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.
1. A pre-tensioned battery shelf, comprising:
a base plate configured to support one or more loads;
a plurality of side walls attached to sides of the base plate;
a plurality of fastening panels positioned at edges of the plurality of side walls and the base plate;
a plurality of fasteners connected through the plurality of fastening panels to securely attach the plurality of side walls to the base plate; and
a plurality of dimples integrated to the base plate to distribute stress across the base plate;
wherein the plurality of fastening panels reinforces an attachment between the plurality of side walls and the base plate;
wherein the base plate is pre-tensioned and inclined; and
wherein the plurality of side walls are pre-tensioned.
2. The pre-tensioned battery shelf of claim 1, wherein the base plate is pre-tensioned and integrated with the plurality of dimples simultaneously in a pressing operation.
3. The pre-tensioned battery shelf of claim 2, wherein the plurality of side walls are pre-tensioned in the pressing operation.
4. The pre-tensioned battery shelf of claim 1, wherein the plurality of dimples are integrated to the base plate in an arranged pattern to distribute the stress across the pre-tensioned battery shelf.
5. The pre-tensioned battery shelf of claim 1, wherein the base plate, the plurality of side walls, the plurality of fastening panels and the plurality of fasteners are made from a lightweight alloy or metal.
6. The pre-tensioned battery shelf of claim 1, wherein thickness of the base plate and the plurality of side walls is directly proportional to weight of the one or more loads.
7. The pre-tensioned battery shelf of claim 1, wherein the pre-tensioned battery shelf comprising the base plate, the plurality of side walls, the plurality of fastening panels and the plurality of fasteners are coated with a corrosion resistant coating.
8. A pressing machine for manufacturing a pre-tensioned battery shelf, comprising:
a lower die positioned to support a metal sheet during a pressing operation;
a hydraulic ram connected to an upper die, wherein the upper die is configured to move downward and apply pressure to the metal sheet; and
a control system configured to regulate movement and adjust the pressure of the upper die;
wherein a convex profile is formed between the upper die and the lower die during the pressing operation,
wherein the upper die and the lower die are configured to fabricate the metal sheet into a base plate or a plurality of side walls, and
wherein the metal sheet is pre-tensioned and integrated with a plurality of dimples simultaneously in the pressing operation.
9. The pressing machine of claim 8, wherein the upper die is configured to pre-tension and integrate the plurality of dimples to the base plate simultaneously in the pressing operation.
10. The pressing machine of claim 8, wherein the upper die is configured to pre-tension the plurality of side walls, in the pressing operation.
11. The pressing machine of claim 8, wherein the lower die is further configured to move upward and apply pressure during the pressing operation.
12. The pressing machine of claim 8, wherein the upper die and the lower die comprise features configured to create reinforcement structures such as the plurality of dimples on the base plate and the plurality of side walls.
13. The pressing machine of claim 8, further comprising a safety system that stops the pressing operation when there is an improper placement on the lower die.
14. The pressing machine of claim 8, wherein the control system adjusts the pressure applied by the upper die according to thickness of the metal sheet.
15. A method for manufacturing a pre-tensioned battery shelf using a pressing machine, the method comprising:
positioning a metal sheet on a lower die of the pressing machine, the lower die being configured to provide support to the metal sheet during a pressing operation;
applying pressure during the pressing operation to the metal sheet using an upper die to form a base plate and a plurality of side walls to create a box structure;
performing pre-tensioning and forming dimples during the pressing operation, wherein the base plate is pre-tensioned and dimpled simultaneously;
regulating movement and adjusting pressure of the upper die and the lower die applied on the metal sheet using a control system; and
attaching the plurality of side walls to the base plate using a plurality of fastening panels and a plurality of fasteners to construct the pre-tensioned battery shelf;
wherein the plurality of side walls are pre-tensioned.
16. The method of claim 15, wherein the metal sheet is pre-tensioned and dimpled simultaneously when applying pressure to form the base plate.
17. The method of claim 15, wherein the metal sheet is pre-tensioned when applying pressure to form the plurality of side walls.
18. The method of claim 15, wherein the pressure applied to the metal sheet is adjusted based on thickness of the metal sheet.
19. The method of claim 15, further comprising applying a corrosion resistant coating to the pre-tensioned battery shelf comprising the base plate, the plurality of side walls, the plurality of fastening panels and the plurality of fasteners.