EV Battery Case Corrugated Side Structure for Impact Energy Absorption
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Solution Overview
Problem
Existing battery cases for electric vehicles lack sufficient energy absorption performance, particularly due to the presence of side blocks that do not contribute to improved energy absorption and the absence of effective flange portions for connecting with vehicle body structural members.
Innovation Solution
A battery case design featuring a battery tray with cross frame parts and an impact absorbing member having a corrugated portion that extends beyond the interval between cross frame parts, enhancing energy absorption by distributing collision loads and inhibiting out-of-plane deformation through its corrugated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If side blocks are arranged at intervals on side edge support members, then the structure is simplified and easier to manufacture, but energy absorption performance is insufficient because some side blocks do not contribute to energy absorption depending on collision point
Solution Approach 1:
The impact absorbing member is divided into multiple convex portions along the longitudinal direction, with each convex portion acting as an independent energy absorption unit. This segmentation allows the structure to effectively absorb energy regardless of where the collision occurs along the side portion.
Solution Approach 2:
The corrugated portion with convex portions provides localized energy absorption capabilities at specific intervals along the side portion. Each convex portion is strategically positioned to handle collision loads from different locations, ensuring comprehensive energy absorption coverage.
2Reliability
If a closed cross-section region is formed by joining upper and lower plates, then energy absorption performance is improved, but the structure becomes more complex and heavier
Solution Approach 1:
The corrugated portion features convex portions with curved surfaces that efficiently absorb collision energy through controlled deformation. The curved geometry provides superior energy absorption compared to flat structures while maintaining a simpler single-plate configuration.
Solution Approach 2:
The impact absorbing member uses a thin-walled corrugated structure that flexes and deforms during collision to absorb energy. This flexible shell structure achieves high energy absorption performance without requiring heavy or complex multi-plate assemblies.
3Strength
If iron side blocks are fixed on upper sides of side edge support members, then impact resistance is improved, but the overall energy absorption performance has room for improvement
Solution Approach 1:
The impact absorbing member combines the corrugated metal structure with the plastic battery tray through integrated design and joining mechanisms. This composite approach leverages the high strength of metal for impact resistance while maintaining the energy absorption capabilities through controlled deformation of the corrugated structure.
Solution Approach 2:
The impact absorbing member transitions from a rigid static structure to a dynamic system that deforms controllably during collision. The corrugated structure is designed to undergo progressive crushing and deformation, dynamically absorbing energy throughout the collision process rather than simply resisting it statically.
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 design significantly improves energy absorption performance by distributing collision loads and increasing deformation resistance, allowing for greater plastic deformation and improved rigidity, thus enhancing the battery case's ability to absorb collision energy effectively.
Implementation Method 1
the corrugated portion has a plurality of bottom surfaces and a plurality of convex portions... allowing for greater plastic deformation
Implementation Method 2
the corrugated portion is formed in at least a longer range than an interval between the two cross frame parts; the corrugated portion has a plurality of bottom surfaces and a plurality of convex portions
Data Source
AI summary
A battery case includes: a battery tray; a plurality of cross frame parts; and an impact absorbing member, wherein the impact absorbing member includes a corrugated portion, wherein the corrugated portion has a plurality of bottom surfaces and a plurality of convex portions; the bottom surfaces of the corrugated portion are each between the convex portions; the convex portion has a top surface, two side surfaces, and two ridge lines; the two side surfaces of the convex portion face each other; the two ridge lines of the convex portion are ridge lines connecting the top surface of the convex portion and the two side surfaces of the convex portion; and the two ridge lines of the convex portion extend in a direction from a second side portion toward a first side portion of the battery tray.