EV Battery Case Floor Structure for Frontal Collision Load Transfer
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Solution Overview
Problem
In existing vehicle designs where the battery case functions as a floor panel, excessive loads from occupants during frontal-impact collisions are not effectively distributed, potentially damaging the battery and other housed components due to the absence of a traditional floor panel or cross-members to absorb these loads.
Innovation Solution
A vehicle lower structure design where the battery case upper face serves as a floor panel, supported by a cover and reinforced with front- and rear-side cross-members extending in the vehicle width direction, which transmit collision loads efficiently through the cross-members to inhibit input into protected objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery case upper face is made to function as a floor panel to eliminate the floor panel and expand cabin space, then the number of components is reduced and space is expanded, but the structure cannot effectively distribute collision loads from occupants, causing excessive load input into housed components
Solution Approach 1:
The battery case is divided into a main body portion and a raised portion with different functions. The main body portion serves as the floor panel to expand cabin space, while the raised portion houses large-sized battery modules and provides structural support for load distribution during collisions.
Solution Approach 2:
Different portions of the battery case are given different structural properties. The main body portion is designed for space expansion as a floor panel, while the raised portion is designed with enhanced structural strength to handle collision loads and protect battery modules.
2Device complexity
If the battery case serves as both floor panel and housing without additional cross-members, then device complexity is reduced, but the structure cannot effectively transmit collision loads in the width direction, leading to potential damage to housed components
Solution Approach 1:
The battery case is merged with the floor panel function, eliminating the need for a separate floor panel. The battery case itself serves dual purposes: housing battery modules and providing the cabin floor surface, thereby reducing component count while maintaining structural integrity through its integrated design.
Solution Approach 2:
The battery case performs multiple functions simultaneously: it houses battery modules, provides the cabin floor panel, and acts as a structural element for load distribution. This multi-functionality reduces the need for additional components like separate cross-members.
Data Source
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AI summary
A vehicle lower structure includes: a battery case (12) that is provided at a lower part of a vehicle and houses a battery, and of which an upper face constitutes a vehicle cabin floor; a cover (32) that covers a protection target provided on a vehicle upper side of the battery case (12) and supports a seat cushion (35) of a vehicle seat (VS) from a vehicle lower side; and a reinforcing cross-member (40) that is provided on a vehicle front side of the cover (32) and extends in a vehicle width direction, and in which a support part (40A) that supports the cover (32) from the lower side is provided at an upper end portion.