Battery Pack Longitudinal Beam Collapse for Lateral Impact Protection
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Solution Overview
Problem
Existing energy storage devices in electric vehicles face deformation issues under lateral force inputs, such as collisions, which can lead to excessive stress on the storage modules due to the lack of effective absorption of local forces.
Innovation Solution
The energy storage device incorporates longitudinal beams with laterally projecting chamber portions that include weakening devices, allowing for targeted local deformation and force reduction, thereby creating a damping space between the main beam and the storage housing to absorb forces without impairing the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the longitudinal beam is designed with a laterally projecting hollow chamber portion to stiffen the beam and provide screw connection, then the structural strength and fastening capability are improved, but the beam becomes susceptible to local deformation under lateral force that propagates to the storage module
Solution Approach 1:
The patent introduces weakening devices (such as grooves, holes, or reduced thickness sections) in the hollow chamber portion of the longitudinal beam before any collision occurs. These pre-designed weak points are strategically positioned to ensure that when lateral force is applied, the deformation occurs at the intended location rather than propagating to the storage module. This preliminary structuring of the beam allows controlled deformation behavior under impact conditions.
Solution Approach 2:
The patent converts the potentially harmful effect of lateral force deformation into a beneficial protective mechanism. By designing the hollow chamber portion with weakening devices, the deformation energy from collisions is absorbed and localized in the chamber portion itself, protecting the storage module from damage. The deformation that would otherwise be harmful is redirected to a safe zone, transforming the harm into a protective feature.
2Ease of manufacture
If the longitudinal beam is designed flat on the inner side to simplify manufacturing and assembly, then the manufacturing ease is improved, but the beam lacks sufficient stiffness and deformation absorption capability under lateral force
Solution Approach 1:
The patent segments the longitudinal beam into distinct functional zones: a flat inner side for simple manufacturing and assembly, and an outer side with a hollow chamber portion containing weakening devices for enhanced stiffness and controlled deformation. This segmentation allows each part of the beam to serve its specific function optimally while maintaining overall manufacturing simplicity.
Solution Approach 2:
The patent applies local quality by providing the hollow chamber portion with weakening devices only in specific locations where deformation absorption is needed, rather than uniformly modifying the entire beam. The weakening devices are strategically positioned in the hollow chamber portion to provide localized deformation capability while maintaining the overall structural integrity and manufacturing simplicity of the beam.
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
This design enhances the structural integrity of the energy storage device by enabling controlled deformation of the chamber portions under lateral forces, reducing the risk of deformation transmission to the storage modules and protecting the housing from excessive stress.
Implementation Method 1
the chamber portion is provided with one or more weakening devices which enable the chamber portion to collapse locally when the force is applied and thus to deform locally in a targeted manner, so that the force is reduced
Data Source
AI summary
An energy storage device with a housing and with at least one storage module accommodated therein, and a frame to which the housing is fastened by screw elements screwed at distinct fastening positions. The frame has at least two longitudinal beams, which are formed by metal hollow profile elements. Each hollow profile element has a main portion and at least one chamber portion which projects laterally therefrom towards the housing, into which the screw elements are screwed in. The chamber portion is provided with one or more weakening devices to facilitate collapse of the chamber portion in the event of a force acting with a horizontal force component.