EV Battery Array Wall Structure for Impact Load Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery structures in electric vehicles face challenges in efficiently securing and supporting large battery arrays, particularly in maintaining structural integrity during impact events, while optimizing space utilization and minimizing interference with passenger or cargo space.
Innovation Solution
A battery structure for electric vehicles comprising a first and second battery array with secured walls forming unitized structures, connected by flange portions and fasteners, and supported by cross beams, secured to a battery tray using various fasteners, allowing for efficient load transfer and space optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery arrays are secured using traditional mounting methods, then assembly is simple, but structural integrity during impact events is insufficient
Solution Approach 1:
The patent combines multiple structural elements (battery arrays, walls, cross beams, and mounting structures) into an integrated unitized structure where the second wall of each battery array serves dual purposes as both a containment boundary and a mounting surface for attachment to cross beams, eliminating separate mounting brackets and improving structural integrity
Solution Approach 2:
The battery structure is divided into modular battery arrays, each with its own unitized wall structure that can be independently assembled and secured to the vehicle floor, allowing for distributed load bearing and simplified assembly while maintaining overall structural integrity
2Strength
If battery arrays are supported close to passenger or cargo space, then load transfer is efficient, but space utilization is reduced
Solution Approach 1:
The patent utilizes the vertical dimension by extending cross beams upward from the vehicle floor to engage with the battery array walls, allowing load transfer without occupying horizontal passenger or cargo space, thus resolving the conflict between structural support and space utilization
3Area of stationary object
If walls of battery arrays are spaced closely together, then space is optimized, but structural stability is compromised
Solution Approach 1:
The patent employs composite wall structures combining vertical portions, horizontal flange portions, and connecting members to create unitized structures that achieve both compact spacing and enhanced structural stability through integrated load distribution pathways
Data Source
AI summary
A battery structure for an electric vehicle includes first and second battery arrays. The first battery array includes first walls that are secured to each other to form a first unitized structure that is configured to house first battery cells. One first wall of the plurality of first walls extends in a transverse direction relative to a longitudinal direction of the electric vehicle. The second battery array is adjacent to the first battery array and includes second walls that are secured to each other to form a second unitized structure that is configured to house second battery cells. One second wall of the plurality of second walls is secured to the first wall of the first battery array and includes a first vertical portion, a second vertical portion spaced apart from the first vertical portion and connecting members connecting the first vertical portion and the second vertical portion.