Battery Tray Impact-Absorbing Structure for Side Collision Loads
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Solution Overview
Problem
Conventional vehicle-mounted battery packs struggle to protect the battery module from side collisions effectively, as the buffer cavity is inadequate in absorbing side collision loads, leading to potential deformation and damage, and reinforcing the floor part increases vehicle weight.
Innovation Solution
A vehicle-mounted battery pack design featuring a battery tray with a thinner side frame and an impact-absorbing region on the outer side, including an easily deformable portion, which absorbs side collision loads by deforming downward and crushing, minimizing deformation and protecting the battery module while reducing vehicle weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the floor part is reinforced to protect the battery module from side collision loads, then the protection capability is improved, but the vehicle weight increases
Solution Approach 1:
The floor part is divided into different regions with different thicknesses: a first region above the battery module with greater thickness for protection, and a second region away from the battery module with smaller thickness to reduce weight. This segmentation allows the structure to provide protection only where needed while minimizing overall weight.
Solution Approach 2:
The floor part has non-uniform thickness distribution, with the first region having greater thickness specifically positioned above the battery module to provide localized protection against side collision loads, while other regions have reduced thickness to minimize weight addition.
2Device complexity
If the buffer cavity is used to protect the battery module, then the structure is simple, but it cannot effectively absorb side collision loads
Solution Approach 1:
The invention transitions from a simple buffer cavity design to a three-dimensional thickness-varied floor part structure, where the thickness varies in the vertical dimension to provide both protection and weight reduction while maintaining structural simplicity.
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
The design effectively absorbs side collision energy, protects the battery module, and reduces the need for excessive reinforcement, thereby minimizing weight and enhancing impact energy absorption.
Implementation Method 1
the impact-absorbing region includes an easily deformable portion, which is formed of at least one of an inclined portion and a thin portion, at a lower portion thereof... the impact energy can be favorably absorbed by deforming the impact-absorbing region downward
Implementation Method 2
the impact energy can be favorably absorbed by deforming the impact-absorbing region downward and crushing (compressing) the side frames using the side collision load input
Data Source
AI summary
A vehicle-mounted battery pack includes a battery tray including a floor part, a right frame, and a left frame. The battery tray includes a battery disposition region, a right impact-absorbing region, and a left impact-absorbing region. A battery module is placed in a battery disposition region. The left and right impact-absorbing regions are provided on outer sides of the battery disposition region in the vehicle width direction. The right frame and the left frame are formed to be thinner than the right and left impact-absorbing regions. Further, an easily deformable portion is formed at a lower portion of the right and left impact-absorbing regions.