Battery Case Fixing Structure with Collapsible Linking Wall
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Solution Overview
Problem
Conventional battery case structures for electric vehicles fail to effectively absorb collision energy during side collisions, potentially leaving the drive battery unprotected.
Innovation Solution
A battery case fixing structure with outward-projecting fixing portions and a planar linking wall, formed integrally with the case, which absorbs collision energy by collapsing the space surrounded by these features, while reducing component count and enhancing stiffness through metal die-casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional crank-shaped section is used for fixing the battery case, then the structure is simple and easy to manufacture, but the side collision resistance is insufficient and collision energy cannot be absorbed effectively
Solution Approach 1:
The fixing structure is divided into multiple functional segments: at least two fixing portions for attachment to the vehicle body, a linking wall connecting these portions, and a case side wall. This segmentation allows each component to perform its specific function - the fixing portions provide attachment points, the linking wall creates a collapsible space for energy absorption, and the case side wall protects the battery, collectively improving side collision resistance without excessive complexity.
Solution Approach 2:
The patent converts the harmful collision energy into a beneficial energy absorption mechanism by designing a collapsible space between the fixing portions and the case side wall. During side collision, this space is intended to collapse and deform, transforming the harmful kinetic energy into deformation energy, thereby protecting the battery from direct impact while the fixing structure remains integrated and manufacturable.
2Strength
If multiple separate components are used for the fixing structure, then adjustability and adaptability are improved, but the number of components increases and stiffness is reduced
Solution Approach 1:
The fixing portions, linking wall, and case side wall are formed as a single integrated structure through metal die-casting, merging multiple functional components into one piece. This integration eliminates the need for separate fasteners and joints, thereby increasing the overall stiffness and strength of the fixing structure while reducing the total number of components and simplifying the assembly process.
Solution Approach 2:
The patent employs metal die-casting to create the integrated fixing structure, utilizing the composite properties of metal materials to achieve both high stiffness and complex geometric shapes in a single manufacturing process. This allows the structure to maintain structural integrity and rigidity while incorporating the necessary fixing portions and linking walls.
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 structure effectively absorbs side collision energy, enhances side collision resistance, and minimizes damage to the battery case by preferentially supporting collision loads with the vehicle's floor frame, while maintaining reduced weight and component count.
Implementation Method 1
when the collision load of a side collision is inputted into the battery case, due to collapsing of the space surrounded by the two fixing portions, the linking wall, and the case side wall, the collision energy can be absorbed effectively
Data Source
AI summary
In a battery case fixing structure, a case side wall, facing outward in a vehicle width direction, of a battery case includes at least two fixing portions that project outward in the vehicle width direction and are fixed to a vehicle body, and a linking wall that is formed as a planar shape opposing the case side wall and links the at least two fixing portions in a fore-and-aft direction, the fixing portions and the linking wall being formed integrally with the battery case. Accordingly, it is possible to enhance the side collision resistance performance by increasing the strength of a battery case of an electric vehicle.