Battery Pack Protection Structure for EV Lateral Impact Loads
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Solution Overview
Problem
The increasing size of battery packs in electric vehicles to enhance cruising range complicates the task of securing adequate space for protecting battery cells against vehicle collisions, particularly lateral impacts.
Innovation Solution
A structural design incorporating a body cross member, shock-absorbing member, and battery side frame, along with anti-rotation brackets and reinforcement members, forms a robust protection system that absorbs and distributes lateral impacts, ensuring effective protection of battery packs despite variations in size and specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the battery pack size is increased to extend cruising range, then the energy storage capacity is improved, but the space available for protecting battery cells against collision is reduced
Solution Approach 1:
The protection system is divided into multiple functional components: shock-absorbing members positioned at front and rear, side protection members for lateral impacts, and upper/lower protection members. This segmentation allows each component to specialize in protecting against specific impact directions, maximizing protection effectiveness within limited space.
Solution Approach 2:
The protection structure extends in multiple spatial dimensions - longitudinal (front to rear), lateral (side to side), and vertical (upper to lower). By utilizing all three dimensions, the system creates a comprehensive protective envelope around the battery pack without requiring excessive space in any single dimension.
2Use of energy by moving object
If the battery pack size is increased to extend cruising range, then the energy storage capacity is improved, but the structural space for impact protection is reduced
Solution Approach 1:
The protection members are strategically positioned to nest around the battery pack structure. The shock-absorbing members are placed in gaps between the battery pack and vehicle body, utilizing otherwise wasted space. This nesting approach provides comprehensive protection without adding external bulk.
Solution Approach 2:
Different regions of the vehicle body are equipped with protection members tailored to the specific impact risks in those areas. Front and rear areas receive shock-absorbing members for longitudinal impacts, while side areas receive side protection members. This localized approach optimizes space utilization by providing protection only where needed.
3Reliability
If shock-absorbing members are positioned to protect against lateral impact, then the lateral impact protection is improved, but the alignment with body cross member becomes misaligned
Solution Approach 1:
The side protection members are designed with configurable positioning systems that allow adjustment of their location and orientation. This dynamic adaptability enables the protection members to be optimally positioned for lateral impact protection while maintaining proper alignment with the body cross member through adjustable mounting mechanisms.
Solution Approach 2:
The side protection members are designed to serve multiple functions: they provide lateral impact protection, maintain structural alignment with the body cross member, and can be configured to accommodate different battery pack arrangements. This multi-functionality resolves the contradiction between protection effectiveness and structural alignment.
Data Source
AI summary
A structure for protecting a battery pack of a vehicle, includes: a body cross member provided in a transverse direction of a vehicle body for connection between side sills provided at opposite sides of the vehicle body; a shock-absorbing member formed in backward and forward directions of the vehicle, provided inside the side sills, and aligned with the body cross member, and a battery side frame coupled to a lower side of the side sill and spaced from the shock-absorbing member.