Vehicle Battery Housing Multi-Rib Cross Members for Impact Loads
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Solution Overview
Problem
Existing battery units for vehicles face challenges in efficiently absorbing impact loads without increasing the size and weight of the battery housing case, which compromises energy efficiency.
Innovation Solution
A battery unit design featuring a battery module housed in a housing case with frame members and cross members, including a multi-rib structure and single rib sections, distributes impact loads efficiently through a cover wall without increasing the number or size of cross members, utilizing a widened portion and reinforcing ribs to stabilize load transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of frame members or their size is increased to protect battery cells from impact load, then the protection reliability is improved, but the battery housing case becomes larger and heavier
Solution Approach 1:
The cross member is segmented into multiple ribs (first rib, second rib, third rib, fourth rib) that branch from a common base. This segmentation distributes the impact load across multiple structural elements rather than requiring a single large frame member, achieving reliable protection while maintaining lighter weight and smaller size.
Solution Approach 2:
The invention transitions from a two-dimensional flat cross member to a three-dimensional multi-rib structure that extends in multiple directions from a common base. This dimensional change allows the structure to absorb and distribute impact loads more effectively in various directions, improving protection reliability without increasing overall size or weight proportionally.
2Reliability
If the number of frame members or their size is increased to protect battery cells from impact load, then the protection reliability is improved, but the battery housing case size increases
Solution Approach 1:
The cross member is segmented into multiple ribs (first rib, second rib, third rib, fourth rib) that branch from a common base. This segmentation distributes the impact load across multiple structural elements rather than requiring a single large frame member, achieving reliable protection while maintaining lighter weight and smaller size.
Solution Approach 2:
The multi-rib structure nests multiple structural functions within a compact configuration. The first, second, third, and fourth ribs are nested within the space defined by the cross member's length and width, creating a space-efficient structure that provides comprehensive impact protection without increasing the external dimensions of the battery housing case.
3Use of energy by moving object
If a multi-rib structure is introduced to distribute impact load, then the energy efficiency is improved, but the structural complexity increases
Solution Approach 1:
Multiple ribs (first rib, second rib, third rib, fourth rib) are merged into a single integrated cross member structure that shares a common base. This merging approach achieves the energy efficiency benefits of a multi-rib structure for impact load distribution while avoiding the complexity of assembling multiple separate components, as the ribs form a unified structural element.
Solution Approach 2:
The multi-rib structure introduces localized complexity only where needed for impact load distribution, while the rest of the battery housing case maintains a simple design. The ribs are concentrated in the cross member region that requires impact protection, allowing the overall structure to remain simple and easy to manufacture despite the localized structural complexity.
Data Source
AI summary
A battery unit includes battery module and battery housing case. The battery housing case includes a pair of frame members and a plurality of cross members. Both ends of the cross member in extending direction is connected to the pair of frame members. The module case includes cover wall connected to each of two adjacent cross members. At least one of the cross members includes multi-rib structure and single rib. The multi-rib structure branches into a plurality of ribs from one end side to the other end side and then rejoining the plurality of ribs to one rib. The end of single rib portion in the extending direction are connected to the multiple rib structure portion. The end of the cover wall is connected to a vicinity of a portion of the multi-rib structure portion where a number of ribs changes from a plurality of ribs to one rib.