Battery Housing Cross-Member Layout for Side-Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery housings in electrically powered vehicles do not adequately protect battery cells and modules from damage during high-speed collisions and side impacts, particularly due to insufficient structural stability of the receiving trays.
Innovation Solution
A battery housing design featuring cross members attached to crash frame profiles on the outer wall of the receiving tray, with increased tensile strength or stiffness in the crossbeam end regions, allowing forces to be effectively absorbed and distributed across a larger area, and incorporating reinforcing ribs and multiple connection points for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional deformation elements are used in receiving trays, then the battery cells are protected from minor impacts, but the structural stability is insufficient for high-speed collisions and side impacts
Solution Approach 1:
The receiving tray is divided into multiple structural components: the base receiving tray itself, crash frame profiles attached to its side walls, and cross members connecting these profiles. This segmentation allows each component to perform its specific function - the tray holds batteries, the crash frames absorb impact forces, and the cross members provide structural reinforcement - thereby achieving both protection and structural stability.
Solution Approach 2:
The invention transitions from a two-dimensional flat receiving tray to a three-dimensional reinforced structure by adding crash frame profiles that extend outward from the side walls and cross members that connect these profiles. This dimensional enhancement creates a cage-like structure that provides superior collision protection and structural stability compared to the original flat tray design.
2Ease of manufacture
If cross members with uniform tensile strength are used, then manufacturing is simple, but force absorption during collision is not optimized
Solution Approach 1:
The cross members are designed with non-uniform tensile strength distribution: the end regions have higher tensile strength than the middle region. This local quality enhancement optimizes force absorption during collisions, as the higher strength end regions can better withstand and distribute impact forces, while the lower strength middle region allows for controlled deformation. This design balances manufacturing feasibility with optimized collision performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides robust collision protection, especially in side impacts, by effectively distributing and absorbing forces, reducing weight through optimized crossbeam dimensions, and ensuring stable connections, thus enhancing the structural integrity of the battery housing.
Implementation Method 1
crash frame profiles, which are arranged on at least two side wall sections of the outer wall of the receiving tray, and which are designed to absorb forces acting on the receiving tray by deformation
Implementation Method 2
the cross members have a greater tensile strength or stiffness in the cross member end regions compared to the cross member middle region
Data Source
Figure 1
Figure 2~2C
Figure 3~3B
AI summary
The present disclosure relates to a battery housing (100) for receiving a plurality of battery cells or battery modules, in particular in an electrically powered vehicle, with a one-piece and shaped receiving tray (101) for receiving the plurality of battery cells or battery modules, wherein the receiving tray (101) has a base plate (103) and an outer wall (105) which is arranged around the base plate (103), wherein the outer wall (105) defines an interior space (107) of the receiving tray (101), wherein a flange (109) is arranged around the outer wall (105) of the receiving tray (101), which extends at an angle to the outer wall (105) of the receiving tray (101);a plurality of crash frame profiles (111) arranged on at least two side wall sections (106) of the outer wall (105) of the receiving tray (101), and designed to absorb forces acting on the receiving tray (101) by deformation, wherein the crash frame profiles (111) have a plurality of coupling sections (113) for attaching the battery housing (100) to body longitudinal members, in particular vehicle sills; and a plurality of cross members (115) each connected to two crash frame profiles (111) of the plurality of crash frame profiles (111), wherein the cross members (115) are designed at least partially as profile bodies connected to the respective crash frame profile (111), and wherein the cross members (115) have a greater tensile strength or stiffness in the cross member end regions (125) compared to the cross member center region (123).