Battery Pack Support Structure for Side-Collision Load Transfer
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Solution Overview
Problem
In vehicles with battery packs mounted below the floor, the support structure can move towards the battery pack during a side collision, leading to potential damage and instability.
Innovation Solution
A support structure comprising a battery frame with lateral beams and a connection bracket forming a crank shape, along with a bracing member at the corner, which is reinforced by a longitudinal plate, effectively transferring collision loads and suppressing movement towards the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support structure is provided to mount the battery pack below the floor, then the battery pack can be securely positioned, but during a side collision the support structure moves toward the battery pack causing deformation and potential damage
Solution Approach 1:
The support structure is divided into multiple components: lateral beams, connection brackets, and bracing members. Each component has a specific function in distributing and resisting collision forces, preventing any single point from bearing the full impact load that would cause movement toward the battery pack
Solution Approach 2:
The connection bracket is designed with a crank shape that extends in the lateral direction, adding a dimensional element perpendicular to the collision direction. This lateral extension allows the structure to absorb and distribute collision forces across multiple dimensions, reducing the direct inward movement toward the battery pack
2Volume of moving object
If the connection bracket is positioned at the side of the battery pack for compact mounting, then space is efficiently utilized, but during side collision this portion moves toward the battery pack causing deformation
Solution Approach 1:
The bracing member is pre-installed at the corner portion of the crank-shaped connection bracket before collision occurs. This pre-positioned bracing element creates structural reinforcement that prevents deformation during side collision, addressing the vulnerability of the compactly positioned connection bracket before the harmful event occurs
Solution Approach 2:
The bracing member is specifically placed at the corner portion of the connection bracket, which is the critical area most susceptible to collision forces. This localized reinforcement provides targeted strength exactly where needed, preventing deformation at the vulnerable corner while maintaining overall structural efficiency
Data Source
AI summary
A battery pack is placed on a battery frame. The battery frame has a lateral frame which extends in a lateral direction. A connection bracket for connecting the battery frame and a floor of a vehicle is joined to an end of the lateral frame. With the joining of the end of the lateral frame with the connection bracket, a crank shape is formed in the lateral direction. A reinforcement plate functioning as a brace is placed at a corner portion of the crank shape.