Battery Case Structure With Overlapping Cross Members for Crash Loads
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Solution Overview
Problem
Existing battery cases for electric vehicles face challenges in efficiently responding to collision loads and improving production efficiency, particularly in reducing component changes and easily adjusting the size of the battery case.
Innovation Solution
A battery case design that includes a side frame with a longitudinal member and a width-direction member, featuring first and second lower width-direction units that overlap in the height direction, and a cooling panel on the upper side of the first lower width-direction unit to cool the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing structure with multiple width-direction members is added to effectively prevent collision loads, then the collision resistance is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The width-direction member is divided into multiple units (first lower width-direction unit and second lower width-direction unit) that are disposed to overlap each other in the height direction. This segmentation allows the structure to effectively respond to collision loads from different directions while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The patent introduces a height direction dimension by overlapping width-direction units vertically, transforming a two-dimensional planar structure into a three-dimensional layered structure. This enables the battery case to resist collision loads more effectively without significantly increasing overall structural complexity.
2Strength
If the battery case structure is reinforced to absorb collision energy in a narrow space, then the collision energy absorption is improved, but the device complexity increases
Solution Approach 1:
The first lower width-direction unit and second lower width-direction unit are nested in the height direction, with one unit positioned above the other. This nesting arrangement allows the structure to absorb collision energy from multiple directions within a compact space, improving energy absorption without proportionally increasing structural complexity.
3Strength
If welding is used to connect longitudinal members and width-direction members for effective collision load prevention, then the collision resistance is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The width-direction member is segmented into multiple units that can be manufactured separately and then assembled through overlap connection. This segmentation simplifies manufacturing by allowing each unit to be produced independently and connected through simpler means rather than requiring complex welding of entire assemblies.
4Strength
If a dedicated platform with reinforced underbody is designed to absorb collision energy, then the collision energy absorption is improved, but the production efficiency decreases due to component changes
Solution Approach 1:
The battery case structure is divided into modular units (longitudinal members, width-direction units) that can be manufactured separately and assembled. This modular segmentation improves production efficiency by allowing parallel manufacturing of components while maintaining the reinforced structure needed for collision energy absorption.
Solution Approach 2:
The overlapping width-direction units serve multiple functions: they provide structural reinforcement for collision energy absorption, create compartment divisions for battery modules, and enable simplified assembly through overlap connection. This multi-functionality reduces the number of separate components needed, improving production efficiency.
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 effectively responds to collision loads, improves production efficiency by reducing component changes, and allows for easy size adjustments of the battery case, enhancing its structural integrity and manufacturing flexibility.
Implementation Method 1
a cooling panel disposed on an upper side of the first lower width-direction unit and cooling the battery module
Implementation Method 2
a cooling panel disposed on an upper side of the first lower width-direction unit and cooling the battery module
Data Source
AI summary
The present invention provides a battery case comprising: a side frame; longitudinal members which are arranged in the side frame and extend in the longitudinal direction; width-direction members which are arranged in the side frame and extend in the width-direction so as to be connected crosswise with the longitudinal members, and which each include a first lower width-direction unit and a second lower width-direction unit that are arranged overlapping in the height direction; and a cooling panel which is arranged above the first lower width-direction units and cools a battery module.