Battery Lower Casing Impact Resistance Design
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Solution Overview
Problem
New energy vehicle battery systems face safety challenges due to potential damage, high voltage leakage, short circuits, and explosions during accidents, which hinder their development and pose risks to personal safety and property.
Innovation Solution
A battery lower casing design featuring a supporting bracket with a base plate, limiting portions, and a cross beam that absorbs and scatters impact forces, enhancing impact resistance and preventing deformation, thereby improving the safety and reliability of the battery system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a simple battery lower casing structure is used, then manufacturing cost and complexity are reduced, but impact resistance and safety are insufficient
Solution Approach 1:
The battery lower casing is divided into multiple functional components: bottom plate, fixing beams, cross beams, and supporting brackets. Each component serves a specific structural purpose, allowing the complex impact resistance function to be achieved through modular assembly rather than a single monolithic structure.
Solution Approach 2:
The patent employs composite structural design combining different structural elements (plates, beams, brackets) that work together to provide enhanced impact resistance. The supporting bracket with base plate and limiting portions creates a composite structure that distributes and absorbs impact forces more effectively than simple single-material designs.
2Ease of manufacture
If the battery lower casing structure is simplified for easy manufacture, then production efficiency increases, but the ability to scatter and attenuate impact force decreases
Solution Approach 1:
The structure is segmented into standardized components (bottom plate, fixing beams, cross beams, supporting brackets) that can be manufactured separately and assembled. This segmentation allows each part to be optimized for manufacturing while the assembled structure provides complex impact scattering capabilities.
Solution Approach 2:
The supporting bracket introduces a vertical dimension with the base plate positioned below the cross beam, creating a three-dimensional structure that scatters impact forces in multiple directions (horizontal and vertical) rather than just along a single plane, enhancing energy dissipation while maintaining manufacturability.
3Reliability
If conventional battery casing structures are used, then design and production are straightforward, but safety against spontaneous combustion and electrical leakage during accidents is insufficient
Solution Approach 1:
The supporting bracket with base plate and limiting portions is pre-installed to provide structural support and constraint before accidents occur. This preliminary structural preparation ensures that when impacts occur, the force distribution pathways are already in place to prevent battery module displacement, short circuits, and thermal runaway.
Solution Approach 2:
The base plate acts as an intermediary element between the fixing beam and the limiting portions, creating a force distribution interface that mediates impact forces. This intermediary structure prevents direct transmission of impact forces to battery modules, thereby reducing the risk of electrical leakage and spontaneous combustion.
Data Source
AI summary
The disclosure relates to a battery lower casing and a battery system. The battery lower casing includes: a bottom plate; a plurality of fixing beams sequentially connected end to end and fixed to the bottom plate; a cross beam disposed between the oppositely disposed fixing beams; and a supporting bracket including a base plate and limiting portions, wherein the limiting portions are connected to the base plate and disposed opposite to each other, the base plate and the oppositely disposed limiting portions enclose and form a recess, the base plate is connected to the fixing beam and an end portion of the cross beam adjacent to the fixing beam is embedded in the recess such that the cross beam is connected to the fixing beam.