Battery Mounting Structure With Angled Steel-Aluminum Crash Interface
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Solution Overview
Problem
Electric vehicle battery cases face challenges in absorbing collision energy effectively, leading to potential damage and fire, whether made of aluminum or steel, as they either deform excessively or inadequately absorb impact.
Innovation Solution
A battery mounting structure featuring a steel side case with an aluminum battery connection member, where the recess and insert portions are formed at an acute angle for surface contact, allowing the aluminum member to deform and absorb collision energy while the steel case provides additional protection, with chambers and a connection pipe for enhanced strength and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If aluminum extrusion type battery case is used, then collision energy absorption is improved, but excessive deformation during collision may cause battery damage and fire
Solution Approach 1:
The invention uses a composite structure combining aluminum extrusion type battery case with steel reinforcement members. The aluminum case absorbs collision energy through controlled deformation, while the steel members provide structural strength to prevent excessive deformation and battery damage, resolving the contradiction between energy absorption and battery protection.
Solution Approach 2:
The battery case is divided into multiple segments including the aluminum extrusion case body and separate steel reinforcement members (front/rear cross members, side members). This segmentation allows each component to perform its specific function: aluminum for energy absorption and steel for structural integrity, preventing the contradiction between deformation and protection.
2Stability of the object's composition
If steel battery case is used, then deformation during collision is reduced, but collision energy is not properly absorbed leading to battery damage and fire
Solution Approach 1:
The invention combines steel battery case with aluminum extrusion reinforcement members. The steel case provides deformation control and structural stability, while the aluminum members are designed to deform and absorb collision energy, resolving the contradiction between deformation control and energy absorption.
Solution Approach 2:
Different parts of the battery case have different material properties: steel is used where structural stability and low deformation are needed, while aluminum is used in areas designed for energy absorption through controlled deformation. This local differentiation resolves the contradiction between stability and energy absorption.
3Weight of moving object
If aluminum battery connection member is used, then weight is reduced, but strength may be insufficient compared to steel
Solution Approach 1:
The invention uses aluminum for the battery connection member to reduce weight, but incorporates steel reinforcement members and optimized structural design to compensate for the lower strength of aluminum, achieving both weight reduction and sufficient connection strength.
Solution Approach 2:
The aluminum connection member is designed with optimized geometric parameters (cross-sectional shape, thickness, reinforcement ribs) to enhance its strength-to-weight ratio, allowing it to provide sufficient connection strength while maintaining weight advantages over steel.
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 structure effectively absorbs collision energy, reducing the risk of battery damage and fire, with improved static deformation and plastic moment, enhancing occupant protection while optimizing material usage for reduced weight and cost.
Implementation Method 1
the battery connection member of aluminum material is deformed during a vehicle collision, and the battery may be protected by absorbing collision energy
Data Source
AI summary
A battery mounting structure of an electric vehicle is provided. The battery mounting structure includes a battery case including a side case portion in which a recess portion concave inwardly is formed and a battery connection member mounted in a vehicle body and having an insert portion inserted into the recess portion and connected to the side case portion.