Vehicle Battery Mounting Structure for Collision Energy Absorption

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Solution Overview

Problem

Existing battery unit mounting structures in vehicles face challenges in efficiently absorbing collision energy while minimizing battery case deformation and manufacturing costs, particularly with larger battery capacities, leading to increased weight and cost.

Innovation Solution

A battery unit mounting structure that includes left and right rear frames with protruding portions and reinforcing plates, fixed to the frames with multiple fastening points, allowing for efficient energy absorption and reduced deformation by distributing collision forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the battery unit size is increased to accommodate larger battery capacity, then the battery capacity increases, but the vehicle body stroke amount at the time of collision is reduced

Engineering Contradiction:

Improvebattery capacityVSAvoidcollision energy input to battery case

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The battery frame is divided into multiple segments including left and right protruding portions that can independently deform during collision. This segmentation allows different parts of the battery frame to absorb collision energy through controlled deformation, reducing the overall impact on the battery case while maintaining large battery capacity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery frame acts as an intermediary component between the vehicle body frame and the battery case. The frame's protruding portions are designed to deform and absorb collision energy before it reaches the battery case, serving as a protective mediator that reduces harmful energy transmission to the battery

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the battery case strength is increased to prevent deformation under collision, then the collision energy absorption improves, but the weight and manufacturing cost increase

Engineering Contradiction:

Improvebattery case strengthVSAvoidbattery case weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The battery frame's protruding portions are designed in advance to deform and absorb collision energy before it reaches the battery case. This beforehand cushioning mechanism protects the battery case from direct impact, allowing the case to be made with lighter materials while still maintaining adequate protection

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The battery frame is designed to convert harmful collision energy into beneficial controlled deformation of the protruding portions. The frame's structural design allows it to absorb impact energy through planned deformation, transforming the harmful collision force into a protective mechanism that reduces the need for heavy battery case reinforcement

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If the battery case strength is increased to avoid deformation, then the battery protection improves, but the manufacturing cost increases

Engineering Contradiction:

Improvebattery case strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The battery frame is segmented into multiple functional portions including left and right protruding portions that can independently deform during collision. This segmentation allows the frame to absorb collision energy through controlled deformation, reducing the need for expensive heavy-duty battery case materials and simplifying manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery frame serves as an intermediary protective structure between external collision forces and the battery case. By designing the frame to absorb impact energy, the battery case can be manufactured with standard materials rather than requiring expensive high-strength materials, thereby reducing manufacturing costs

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12397628B2Battery unit mounting structure for vehicle

Publication Date: 2025.08.26 SUBARU CORP

AI summary

A battery unit mounting structure for a vehicle includes: left and right rear frames extending along a front-rear direction; a battery unit including a housing in which a battery is housed and which is disposed between the rear frames, and a battery frame provided with protruding portions extending in a vehicle width direction and protruding in the vehicle width direction beyond a space between the rear frames; and reinforcing plates provided permanently with the rear frames respectively in regions in which the rear frames and the protruding portions are respectively fixed to each other. Each of the reinforcing plates extends in the front-rear direction of the vehicle in a corresponding one of the regions in which the rear frames and the protruding portions are respectively fixed to each other. The battery frame and each of the rear frames are fixed to each other at first and second fastening portions.