Battery Pack Side Energy Absorber Layout for Lateral Impact Protection

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Solution Overview

Problem

Existing vehicles lack effective mechanisms to enhance collision energy absorption during lateral collisions, particularly in protecting the battery pack from deformation.

Innovation Solution

The vehicle design incorporates a cover plate and energy absorber configuration with an inner and outer part, where the outer part protrudes downward, and fasteners are positioned higher than the lower surface of the outer part to enhance energy absorption and prevent contact with foreign objects, while being supported by a bracket and cover plate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the energy absorber is fixed only at the upper part to the battery pack, then the structure is simple, but the collision energy absorption capability is insufficient

Engineering Contradiction:

Improvecollision energy absorption capabilityVSAvoidfastening structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The energy absorber is divided into an inner part and an outer part, with different fastening strategies applied to each segment. The inner part is fixed to the battery pack at its upper end, while the outer part extends downward without direct fastening, allowing it to deform freely during collision to absorb energy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The energy absorber extends in the vertical dimension beyond the battery pack's lower surface. The outer part protrudes downward below the cover plate, creating a three-dimensional structure that increases the deformation path and energy absorption volume without adding complex fastening mechanisms.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the energy absorber is enlarged downward to increase energy absorption, then the collision energy absorption improves, but the fasteners may contact foreign objects

Engineering Contradiction:

Improvecollision energy absorptionVSAvoidfastener protection from foreign objects

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The energy absorber is segmented into an inner part (fastened to battery pack) and an outer part (extending downward). This segmentation allows the fasteners to be positioned only on the inner part, protecting them from foreign objects while the outer part provides extended energy absorption capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover plate acts as an intermediary element that covers the lower surface of the battery pack. The fasteners are positioned on the inner part above the cover plate, while the outer part extends below the cover plate, using the cover plate as a protective barrier between fasteners and potential foreign objects.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If the energy absorber is supported from the inner side by the cover plate, then the structural integrity improves, but the manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The cover plate serves multiple functions simultaneously: it covers the lower surface of the battery pack for protection, provides structural support to the energy absorber's inner part, and acts as a barrier protecting fasteners from foreign objects. This merging of functions reduces the need for additional components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover plate is designed as a multi-functional component that performs protection, support, and fastener shielding functions. By making the cover plate universal in its functionality, the overall structure achieves improved structural integrity without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration improves collision energy absorption, enhances rigidity, and prevents fastener contact with foreign objects, ensuring robust protection for the battery pack during lateral impacts.

Implementation Method 1

when collision load is applied on the energy absorber from a vehicle lateral side, the energy absorber is supported by the cover plate from a vehicle inner side

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

an amount of collision energy thereby absorbed upon deformation of the energy absorber is relatively larger than the inner part

Methodology Applied

Scientific EffectEnergy absorption: Absorption (physical)

Data Source

PatentUS12600414B2Vehicle

Publication Date: 2026.04.14 TOYOTA JIDOSHA KK

AI summary

A vehicle may include a battery pack located below the floor panel; an energy absorber extending along a side surface of the battery pack in the front-rear direction and facing the side sill from below; and a cover plate covering a lower surface of the battery pack from below. The energy absorber may include an inner part facing the side surface of the battery pack and an outer part located outside in a left-right direction of the vehicle with respect to the inner part. An end of the cover plate in the left-right direction may be fixed to a lower surface of the inner part of the energy absorber with a plurality of fasteners. A lower surface of the outer part may protrude downward relative to the lower surface of the inner part and is located lower than lower ends of the plurality of fasteners.