Vehicle Battery Case Load Path for Side-Collision Protection
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Solution Overview
Problem
Existing vehicle battery cases fail to effectively distribute loads during a side collision, leading to potential malfunction or damage of battery cells, which are crucial for electric vehicles with high capacity.
Innovation Solution
A vehicle battery case design featuring a battery cross member and side members that distribute loads through a structured arrangement, including reinforcing ribs and a load path, to protect battery cells during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a simple battery case structure is used, then manufacturing cost and device complexity are reduced, but load distribution during side collision is insufficient causing battery cell damage
Solution Approach 1:
The battery case is segmented into multiple functional components: side members, cross members, reinforcing ribs, and flange parts. Each segment serves a specific structural role in load distribution, transforming a simple monolithic structure into a complex load-bearing system that effectively manages collision forces while protecting battery cells.
Solution Approach 2:
The patent introduces a three-dimensional load path through vertical flange parts extending from the side members and horizontal cross members, creating a multi-dimensional load distribution network. This spatial arrangement allows forces to be distributed across multiple dimensions rather than concentrated in a single plane, enhancing protective capability while maintaining structural efficiency.
2Weight of moving object
If aluminum material is used for weight reduction, then vehicle weight is reduced, but structural strength and load distribution capability during collision are compromised
Solution Approach 1:
The patent employs aluminum alloy materials with optimized compositional ratios (specific ranges of alloying elements) to create a composite-like structure that combines lightweight properties with enhanced strength. The material composition is engineered to provide both weight reduction and sufficient structural integrity for load distribution during collisions.
Solution Approach 2:
Different regions of the battery case are designed with locally optimized material properties and structural characteristics. The flange parts, cross members, and reinforcing ribs have specific geometric features and material distributions tailored to their local stress conditions, ensuring optimal strength-to-weight ratio in each critical area while maintaining overall lightweight design.
Data Source
AI summary
A vehicle battery case includes: a lower panel disposed on a bottom of a vehicle and configured to support a battery from below; a battery cross member disposed on the lower panel and extending in the width direction of the vehicle; and battery side members which are disposed on both sides of the lower panel in the longitudinal direction of the vehicle and in contact with both ends of the battery cross member. Each battery side member has a flange part which extends from the lower end thereof to the outside of the vehicle and is connected to a side sill, and a load applied to the side sill of the vehicle during a vehicle side collision is sequentially transferred from the battery side member to the battery cross member.