Battery Case Floor Structure With Cross-Member Collision Load Path
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Solution Overview
Problem
In vehicle structures where the battery case functions as a floor panel, excessive loads from occupants during frontal-impact collisions are not effectively distributed, potentially damaging objects housed under the seat cushion.
Innovation Solution
A vehicle lower structure with a battery case that serves as a floor panel, incorporating a cover supported by front- and rear-side reinforcing cross-members extending in the vehicle width direction, which transmit collision loads to side members and rockers, inhibiting load 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 space, then the vehicle cabin space is expanded and component count is reduced, but the load from occupants cannot be effectively distributed during frontal-impact collisions, potentially damaging objects housed under the seat cushion
Solution Approach 1:
The floor structure is segmented into multiple functional layers: the battery case upper face serves as the cabin floor, while separately positioned front-side and rear-side reinforcing cross-members provide structural support and load distribution. This segmentation allows the floor panel to be eliminated for space expansion while maintaining collision protection through dedicated reinforcing elements.
Solution Approach 2:
The cover acts as an intermediary element between the seat cushion and the battery case. It transmits loads from the seat cushion to the front-side and rear-side reinforcing cross-members, preventing direct transmission of collision loads to objects housed under the seat cushion while maintaining the structural integrity of the floor system.
2Reliability
If reinforcing cross-members are added to distribute collision loads, then the protection of housed objects during collision is improved, but the device complexity and component count increase
Solution Approach 1:
The front-side and rear-side reinforcing cross-members serve multiple functions: they provide structural support for the cover, distribute collision loads in the vehicle width direction, and prevent direct load transmission to the battery case. This multi-functionality reduces the need for additional dedicated protection components, thereby limiting the increase in device complexity.
Solution Approach 2:
The reinforcing cross-members are integrated with the cover support structure, combining the functions of load distribution and structural support into unified components. This merging approach minimizes the number of separate parts needed while achieving both space expansion and collision protection goals.
Data Source
AI summary
A vehicle lower structure includes: a battery case 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 that covers a protection target provided on a vehicle upper side of the battery case and supports a seat cushion of a vehicle seat from a vehicle lower side; and a reinforcing cross-member that is provided on a vehicle front side of the cover and extends in a vehicle width direction, and in which a support part that supports the cover from the lower side is provided at an upper end portion.