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Patent Information & Production OptionsLightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles · Patent CN112896076B

Patent CN112896076B: bibliographic data, legal status, family, a plain-language reading of the claims, plus customization, US compliance points and how a manufacturing project runs.

At a glance

Patent numberCN112896076B (application CN202110339249)
TypeChina invention patent (发明专利) - protects product structure and method
Original titleLightweight double-layer battery box with stepping function for commercial vehicles (一种商用车用轻量化双层带上车踏步功能电瓶箱)
Patent ownerChina National Heavy Duty Truck Group Jinan Power Co Ltd
InventorsTeng Yongqi, Lang Hua, Shi Shiwei, Ma Shenglong, Feng Qifei, Ning Jiapeng, Xu Jingjie, Yang Yi, Su Yayun
Filing date2021-03-30
Grant date2023-02-03
Status (China)In force - valid until at most 2041-03-30, provided annual fees are paid
Patent familyChinese filings only - no US, European, Japanese, PCT or other filings listed
Cited by4 later documents
SourceGoogle Patents (search for CN112896076B)

What the claims cover, in plain language

Claim 1 - A lightweight double-layer battery box for commercial vehicles comprising a main frame, side panels, and securing hardware. The main frame is stamped from high-strength steel into an L-shape with reinforcement grooves. Side panels are riveted to the frame. Batteries are held in two layers: the lower layer uses limiters bolted to the frame, and the upper layer rests on a corrugated tray. Pressure plates, connected via threaded hooks, clamp the batteries. An integrated boarding step is bolted to the frame’s base. Injection-molded plastic covers enclose the unit, secured by hand-tightened studs.

This is a simplified reading for orientation only. The legal scope is defined by the exact claim wording in the official Chinese document.

What this means for US production

This patent was filed only in China and is currently in force. Making or selling this specific design in China requires the owner’s permission. It has no US or other foreign counterpart.

Two points to settle early:

  • Other patents may exist. Automotive battery enclosures and integrated step designs are a competitive field. While no foreign patents citing this one were found in our check, independent US patents may cover similar structural combinations. A freedom-to-operate (FTO) review is recommended before volume production in the US.
  • Material Specifications. The patent specifies “high-strength steel” and “lightweight materials” without defining exact grades. US buyers must specify automotive-grade steel (e.g., HSLA) and UV-stable polymers (ABS/PC) to meet durability standards not explicitly detailed in the patent text.

Customization and manufacturing

What can be customized

AreaOptions
DimensionsLength, width, and height to fit specific chassis rails
Battery CountConfiguration for 2, 4, or 6 batteries per layer
Step HeightAdjustment of the casting mold for different cab heights
Cover MaterialChoice between ABS or PC based on impact requirements
FastenersStandard vs. stainless steel bolts for corrosion resistance
Wiring PortsNumber and location of grommet holes for harnesses

Things to plan for (US market)

  • FMVSS / SAE Standards: Ensure the boarding step meets slip-resistance and load-bearing requirements for commercial vehicles.
  • SAE J1455: Environmental testing for electronic/electrical components under hood or exterior exposure.
  • RoHS / REACH: Compliance for plastics and adhesives if exporting to regions with strict chemical regulations.
  • DOT Regulations: General safety compliance for vehicle components installed on public roads.

How a project runs

  1. Inquiry - Specify chassis model, battery dimensions, and quantity.
  2. Design - CAD modeling of the frame stamping dies and injection molds.
  3. Prototype - 3D-printed fit checks and soft-tooling samples.
  4. Pilot Run - Assembly of stamped frames and molded covers; vibration testing.
  5. Production - Mass stamping, molding, and final assembly line integration.

Quantities & timeline

Tooling for the main frame requires progressive stamping dies. The covers require injection molds. The boarding step requires casting dies. Lead times depend on mold complexity. Send us your specifications, estimated quantity, and target price and we will reply with options.

Production notes

Tooling and process

The main frame typically requires aluminum machining for the L-shaped profile. Injection molding is used for the covers, likely employing ABS or PC resins. The boarding step is usually cast zinc for strength-to-weight ratio.

Cost drivers

Tooling complexity is typically the primary cost factor, especially for the machined frame fixtures. Heat-resistant material grade for the plastics adds cost but is necessary for engine bay proximity. Packaging for oversized frames also impacts logistics expenses.

Prototyping path

Initial prototypes involve 3D-printed fit checks in a vehicle mockup. Functional samples of the machined frame are typically produced using soft tooling. Adhesive trials may be conducted if bonding replaces riveting in custom variants.

What we would change before tooling

We would verify thread engagement depth on the fixed blocks to ensure fastener torque consistency. Wall thickness and joint design of the molded covers should be reviewed to prevent deformation in cabin heat.

Common failure points

Rattle at joints is a risk if tolerance fits are loose. Edge hardness and wear on the boarding step must be monitored. Battery compartment security relies on proper latch alignment; poor fit at gaps can compromise protection.

Patent drawings

Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 1
Fig. 1 - Overall assembly view of the battery box.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 2
Fig. 2 - Main frame and side panel structure.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 3
Fig. 3 - Battery securing mechanism detail.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 4
Fig. 4 - Upper and lower cover installation.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 5
Fig. 5 - Boarding step attachment.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 6
Fig. 6 - Wiring harness routing.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 7
Fig. 7 - Internal battery tray layout.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 8
Fig. 8 - Pressure plate hook adjustment.
Lightweight Double-Layer Battery Box with Integrated Boarding Step for Commercial Vehicles - Patent Fig. 9
Fig. 9 - Chassis mounting interface.

Drawings reproduced from the public patent document for reference.

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  1. ✓ Patent vetted China-only family and legal status checked
  2. 2 Product brief · now How it works, uses and options written up
  3. 3 Prototype First samples for buyers to review
  4. 4 Pilot run Small first batch for launch customers
  5. 5 Volume production Repeat orders at scale

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This page is based on the public patent document CN112896076B, assigned to China National Heavy Duty Truck Group Jinan Power Co Ltd. IP2M is an independent manufacturing service and is not affiliated with, endorsed by or licensed by the patent owner. Images marked as concept renderings are illustrations, not photos of an existing product. Patent status information is provided for reference only and is not legal advice; confirm freedom to operate for your market before production. Full disclaimer.