Automotive Body Shear Structures for RESS Protection
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Solution Overview
Problem
Rechargeable energy storage systems (RESS) packaged under the floorboard of vehicles face space constraints and risk of damage from external objects, necessitating a body structure that maximizes energy density while minimizing surrounding structure size and protecting the power source.
Innovation Solution
A body structure featuring upper and lower shear structure assemblies with trapezoidal sections attached to cross-members and rockers, constructed as metallic foam sandwiches or lattices, to dissipate external loads and protect the power source, allowing for efficient energy storage and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the RESS system is packaged under the floorboard to maximize energy density, then the energy storage capacity is improved, but the power source becomes vulnerable to damage from external objects
Solution Approach 1:
The body structure is divided into multiple segments including upper and lower shear structure assemblies, front and rear shear structure assemblies, and intermediate shear structure assemblies. These segmented structures work together to distribute and dissipate external loads, protecting the RESS while maintaining compact packaging under the floorboard.
Solution Approach 2:
The shear structure assemblies are designed with energy-absorbing capabilities to provide beforehand cushioning against external impacts. The structures include features such as folded plates, corrugated sections, and controlled deformation zones that absorb impact energy before it reaches the power source, preventing damage from external objects.
2Volume of moving object
If the surrounding body structure is minimized to maximize RESS size, then the space utilization is improved, but the structural protection capability deteriorates
Solution Approach 1:
The body structure employs local quality by concentrating structural reinforcement only in critical areas where external impacts are most likely to occur. The shear structure assemblies are strategically positioned at the periphery of the RESS enclosure, providing localized protection without adding unnecessary material throughout the entire structure, thus maintaining compact dimensions while ensuring adequate protection.
Solution Approach 2:
The shear structure assemblies utilize composite construction combining multiple materials and structural features including metallic foams, corrugated plates, and layered configurations. These composite structures provide high strength-to-weight ratios, enabling effective protection of the RESS while minimizing the overall volume of the surrounding body structure.
3Reliability
If shear structure assemblies are added to protect the power source, then the protection capability is improved, but the device complexity increases
Solution Approach 1:
The shear structure assemblies are designed to perform multiple functions simultaneously: they provide impact protection, dissipate external loads, maintain structural integrity, and serve as part of the overall body structure framework. This multi-functionality reduces the need for separate protective components, thereby limiting the increase in device complexity while achieving improved protection capability.
Solution Approach 2:
The protective shear structure assemblies are merged with the existing body structure framework rather than being added as separate components. The upper, lower, front, rear, and intermediate shear structures are integrated into the overall enclosure design, sharing structural elements and fastening systems with the main body, thus minimizing the increase in complexity while providing comprehensive protection.
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 body structure effectively dissipates external loads, enhancing protection for the RESS and maximizing energy density by distributing load energy efficiently, thus ensuring the power source's safety and optimal performance.
Implementation Method 1
Each of the upper and lower shear structure assemblies may define a respective plane wherein each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure
Implementation Method 2
At least one of the upper and lower shear structure assemblies may be constructed as at least one of a metallic foam sandwich and a lattice of interconnected structural members
Data Source
AI summary
A body structure for an automotive vehicle includes an enclosure for a power source, an upper shear structure assembly and a lower shear structure assembly. The enclosure includes a front cross-member, a rear cross-member, a left rocker and a right rocker. The upper and lower shear structure assemblies are disposed across the top and bottom of the enclosure, respectively, and are fastened to respective top and bottom surfaces of the cross-members and rockers. The upper and lower shear structure assemblies may include respective front and rear generally trapezoidal sections configured for attachment to respective front and rear box structures. Each of the shear structure assemblies is effective to dissipate in-plane a portion of an external load imposed upon the enclosure.