EV Battery Reinforcement Structure for Collision Rigidity
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Solution Overview
Problem
Existing electric vehicle body structures face challenges in securing safety performance and body rigidity while increasing battery capacity to achieve longer cruising distances, as the space under the body is predominantly occupied by the battery, making it difficult to construct main members and reinforcement materials.
Innovation Solution
A vehicle body design incorporating internal side members, battery cross members, and coupling structures that intersect and connect with the center floor and battery case, along with additional cross members and connecting elements, to enhance rigidity and distribute collision loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery volume is increased by 1.5 times or more to secure cruising distance of 200 miles or more, then the battery capacity is improved, but the space under the body is fully occupied making it difficult to construct main members and reinforcement material
Solution Approach 1:
The battery case is merged with the body structure by directly coupling it to the center floor, and the battery cross member is integrated to connect both the battery case and the center floor, creating a unified structural system that serves both battery mounting and structural reinforcement functions
Solution Approach 2:
The battery case serves multiple functions: it contains the battery, acts as a structural component coupled to the center floor, and provides mounting points for the battery cross member. The battery cross member simultaneously supports the battery case and reinforces the center floor structure
2Quantity of substance
If the battery volume is increased by 1.5 times or more to secure cruising distance of 200 miles or more, then the battery capacity is improved, but the body rigidity and safety performance according to collision cannot be secured
Solution Approach 1:
The battery cross member is pre-installed to connect the battery case to the center floor before final assembly, establishing structural reinforcement pathways in advance to prevent deformation during collision
Solution Approach 2:
The body structure employs composite construction combining the battery case, battery cross member, and center floor into an integrated load-bearing system that distributes collision forces across multiple components rather than relying on a single structural element
3Quantity of substance
If the battery volume is increased by 1.5 times or more to secure cruising distance of 200 miles or more, then the battery capacity is improved, but it is difficult to construct main member and reinforcement material under the body
Solution Approach 1:
The body structure is segmented into modular components including the battery case, battery cross member, and center floor sections, allowing independent manufacturing and assembly of each component to simplify the overall construction process
Solution Approach 2:
The battery cross member is positioned within the spatial envelope defined by the battery case and center floor, nesting structural reinforcement elements within the existing battery mounting space rather than requiring additional external space
Data Source
AI summary
A body for a vehicle configured for securing safety performance and vehicle rigidity according to a vehicle collision while increasing a battery capacity mounted in the vehicle, may include an internal side member mounted on a center floor in a longitudinal direction of the body; a battery cross member mounted in a width direction of the body inside a battery case provided at a lower end portion of the center floor while intersecting the internal side member; and a coupling structure coupled to the battery case, the battery cross member, and the center floor.