EV Battery Case Side-Frame Structure for Side-Impact Durability
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Solution Overview
Problem
Existing electric vehicle battery cases lack sufficient durability against loads input from the side surface, particularly during collisions, which can compromise the integrity and security of the battery.
Innovation Solution
The battery case incorporates a pair of side frames with frame ribs, cross members, and side brackets with bracket ribs, all extending in the vehicle width direction, to enhance structural strength and distribute load input effectively, while also integrating a refrigerant passage within the side bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery case uses a simple frame structure without additional reinforcement, then the device complexity is low and manufacturing is easier, but the strength and durability against side loads are insufficient
Solution Approach 1:
The side frame is segmented into multiple components including the side frame body, frame ribs extending in the width direction, and bracket ribs in the side bracket. This segmentation allows each component to bear specific loads independently, improving overall structural strength against side impacts while maintaining manufacturing feasibility through modular construction
Solution Approach 2:
The frame ribs and bracket ribs are nested within the side frame and side bracket structures respectively. The ribs are integrated into the hollow cylindrical sides of these components, creating a nested configuration that enhances structural strength without significantly increasing external dimensions or complexity
2Strength
If the side frame and side bracket are designed with ribs extending in the vehicle width direction, then the strength against side surface loads is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The frame ribs and bracket ribs are designed to extend substantially in the vehicle width direction, creating equipotential load distribution paths. This orientation aligns the ribs with the primary direction of side loads, allowing uniform stress distribution across all rib structures and reducing sensitivity to minor alignment variations during manufacturing
Solution Approach 2:
The ribs are designed with specific dimensional parameters including length, thickness, and spacing that are optimized for strength while accommodating manufacturing tolerances. The hollow cylindrical configuration of the side frame and bracket provides a standardized geometric parameter that simplifies manufacturing while maintaining structural integrity
Data Source
AI summary
A battery case that accommodates a battery for an electric vehicle includes a pair of side frames that constitute left and right side walls of the battery case in a vehicle width direction and extend along a vehicle front-rear direction, a cross member that partitions an internal space of the battery case in the vehicle front-rear direction and extends from one of the side frames to the other side frame, and a side bracket that is fixed to an outer surface of the side frame and is configured to attach the battery case to a vehicle body. The side frame includes a frame rib extending in the vehicle width direction inside the side frame and the side bracket includes a bracket rib extending in the vehicle width direction inside the side bracket.