Battery Box Reinforcement Element for Side Impact Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery boxes in electric vehicles face challenges in effectively absorbing collision energy while minimizing weight and preventing crevice corrosion, particularly during side impacts, which can lead to damage to battery cells.

Innovation Solution

A battery box with a structural frame featuring partially hollow L-shaped profile segments and reinforcement elements composed of open cells, such as honeycomb chambers, that absorb crosswise forces and distribute impact energy, reducing the risk of crevice corrosion and enhancing energy absorption capacity without increasing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery box uses a frame with support structures to absorb collision energy, then the protection against side impacts is improved, but the installation space is reduced and the structure becomes more complex

Engineering Contradiction:

Improveprotection against side impactsVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The reinforcement element is nested inside the hollow profile segment of the frame, utilizing the existing hollow space without adding external structures. This nested arrangement provides crash energy absorption functionality while maintaining a compact overall structure and avoiding additional complex external components.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The reinforcement element employs a honeycomb structure with thin-walled cells that can deform flexibly during impact to absorb energy. This flexible cellular structure provides effective crash protection while maintaining a lightweight and space-efficient design compared to rigid bulk structures.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If the battery box uses a frame with support structures to absorb collision energy, then the protection against side impacts is improved, but the installation space is reduced

Engineering Contradiction:

Improveprotection against side impactsVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #7Nested doll (Nesting)

3Stability of the object's composition

If the battery box uses conventional connecting elements for mounting, then the battery cells are securely fixed, but crevice corrosion may occur at connection points

Engineering Contradiction:

Improvesecure fixation of battery cellsVSAvoidcrevice corrosion

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The connecting elements are extracted from the hollow profile segment and mounted on its outer surface. This extraction eliminates crevices between connecting elements and the profile wall, preventing crevice corrosion while maintaining secure fixation of battery cells through surface-mounted connections.

Inventive Principle:

Principle #2Taking out (Extraction)

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 solution effectively protects battery cells from side impacts by absorbing and dissipating collision energy through targeted deformation of the reinforcement elements, while minimizing the risk of crevice corrosion and maintaining a lightweight structure, thus enhancing the battery box's energy absorption capacity without damaging the cells.

Implementation Method 1

at least one reinforcement element (4) for absorbing impact energy in case of impact is arranged inside at least one of the profile segments (3)

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS11518227B2Battery box with reinforcement element

Publication Date: 2022.12.06 LINDE WIEMANN

AI summary

A battery box for a motor vehicle for receiving battery cells has a structural frame with at least two structural components joined to one another at the end face. Each structural component has at least one profile segment that is partially hollow and has a substantially L-shaped cross section. A reinforcement element for absorbing collision energy in the event of a collision is arranged within at least one of the profile segments. The reinforcement element is a molded part having a plurality of open cells, which are arranged adjacent to one another and with their longitudinal extent substantially parallel to one another. When the battery box is mounted in the motor vehicle, the open cells are oriented with their longitudinal extent substantially parallel to the transverse direction of the vehicle.