The brackets secured and thermally coupled battery modules while reducing structural mass.
The customer’s challenge
Heavy brackets added mass, vibration loosened attachments and poor heat transfer increased module temperature.
Material and fabrication route
2.0 mm 6061 aluminum; steel connection plates.
Process route: Laser cutting → bending → hardware insertion → anodizing → assembly → vibration testing.
Manufacturing changes
A lighter optimized aluminum structure, thermal pads, locking fasteners and locating pins addressed the combined requirements.
Engineering analysis
The bracket redesign balanced lower mass with secure location and thermal contact. The aluminum structure addressed weight, locating and locking features addressed movement, and the pads addressed the interface with the battery module. The reported percentage reduction compares this project with its earlier bracket arrangement. It should not be treated as an automatic saving available for a different module geometry or load case.
Inspection and project results
The project recorded 30% lower bracket weight, no loosening in the stated vibration test and module temperature rise ≤20 K.
| Project measurement or production detail | Recorded value |
|---|---|
| Weight reduction | 30% |
| Vibration test | 5 g, 10–2,000 Hz |
| Temperature rise | ≤20 K |
| Module mass | ≥20 kg |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Module mass and locating interfaces.
- Weight comparison baseline.
- Vibration profile and fastener retention.
- Thermal-contact and insulation requirements.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Battery Module Rack and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
