Reinforced Battery Case Structure for EV Side-Collision Intrusion
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Solution Overview
Problem
Battery cases in electric vehicles face significant deformation and potential intrusion during side collisions due to limited energy absorption in the lateral direction, posing a risk of fire and explosion, and existing reinforcing structures are inefficient in transferring load directly to the reinforcing material.
Innovation Solution
A battery case design featuring a case body with a bottom plate, side frames, and reinforcing materials with both ends inserted through the side frames, allowing for effective distribution of collision energy and minimizing deformation by utilizing high-strength materials like 1470 MART steel and a hat-shaped cross-sectional reinforcing material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the reinforcing material is joined to the inner surface of the sidewall, then the battery case structure is simplified, but the load transfer efficiency deteriorates and intrusion protection is insufficient
Solution Approach 1:
The reinforcing material is merged with the side frame by inserting it into the side frame's hollow portion, creating an integrated load-bearing structure. This combination allows the reinforcing material to directly receive and distribute collision loads through the side frame, preventing sidewall deformation while maintaining structural simplicity.
Solution Approach 2:
The reinforcing material transitions from a two-dimensional surface attachment (joined to inner surface) to a three-dimensional insertion structure (inserted into hollow portion). This dimensional change enables the reinforcing material to span across the sidewall thickness, creating direct load transfer paths that prevent intrusion while maintaining structural efficiency.
2Stability of the object's composition
If the sidewall forms a closed cross-section, then structural integrity is maintained, but the reinforcing material cannot function until considerable deformation occurs
Solution Approach 1:
The reinforcing material is pre-positioned inside the side frame's hollow portion before collision occurs. This preliminary positioning ensures that when collision happens, the load is immediately transferred to the reinforcing material through the side frame, preventing deformation before it can compromise battery protection, rather than waiting for the sidewall to deform considerably.
3Strength
If high-strength reinforcing material is used, then collision energy absorption is improved, but manufacturing complexity increases
Solution Approach 1:
The battery case is segmented into distinct functional components: the side frame with its hollow portion and the separate reinforcing material. This segmentation allows each component to be manufactured independently using standard processes, then assembled through simple insertion, maintaining ease of manufacture while enabling the use of high-strength materials for optimal collision protection.
Data Source
AI summary
The present invention relates to a battery case capable of minimizing the deformation of a battery by effectively coping with side collisions of an electric vehicle and the like, the battery case comprising: a case body for accommodating a battery cell; and a cover coupled to the case body, wherein the case body comprises: a bottom plate; side frames which are coupled to the bottom plate to surround the battery cell, and which include inner sidewalls and outer sidewalls; a mounting frame coupled to the outer sidewalls of the side frames; and at least one reinforcing material, which is arranged on the bottom plate and has longitudinal both-end portions inserted into the side frames, wherein the end portions of the reinforcing material may come in contact with the mounting frame by penetrating the inner sidewalls and the outer sidewalls of the side frames.