Body Side Structure With U-Shaped Battery Impact Absorber
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Solution Overview
Problem
Existing battery pack protection structures in battery-powered vehicles are either too complex and heavy, or they fail to reliably absorb collision energy, risking damage to the battery pack during side collisions.
Innovation Solution
A U-shaped collision energy absorptive part made of a thin steel sheet with specific tensile strength and thickness is integrated into the vehicle's side structure to absorb collision energy, reducing load transfer to the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed cross section structure is used for the impact absorption part, then collision energy absorption capability is improved, but device complexity and weight increase
Solution Approach 1:
The impact absorption part is divided into multiple crushable cells arranged in series along the vehicle width direction. Each cell independently absorbs collision energy through controlled deformation, achieving effective energy absorption without requiring a complex closed cross-section structure. This segmentation allows the system to absorb collision energy while maintaining structural simplicity and reducing overall weight.
2Reliability
If aluminum alloy is used for the impact absorption part, then collision energy absorption is improved, but manufacturing cost increases
Solution Approach 1:
The material parameters are optimized by selecting specific steel grades (tensile strength 270-340 MPa) and plate thickness (1.0-1.4 mm) that provide adequate collision energy absorption capability while maintaining cost-effectiveness. This parameter optimization allows the use of conventional steel materials instead of expensive aluminum alloys, achieving reliable protection without increasing manufacturing cost.
3Strength
If the impact absorption part is made robust, then structural strength is improved, but battery pack safety deteriorates due to excessive load transfer
Solution Approach 1:
The impact absorption part is designed with controlled deformation characteristics through its crushable cell structure. During collision, the cells deform progressively in a controlled manner, absorbing collision energy dynamically rather than transferring it rigidly to the battery pack. This dynamic deformation behavior ensures that the structure provides adequate strength for energy absorption while preventing excessive load transfer that could damage the battery pack.
4Object-affected harmful factors
If the battery pack is detached from the floor side member during side collision, then load transfer is reduced, but the battery pack may fall off and be damaged
Solution Approach 1:
The impact absorption part serves as an intermediary element positioned between the side sill and the battery pack. During collision, this intermediary structure absorbs the collision load through controlled deformation of its crushable cells, preventing direct load transfer to the battery pack while maintaining the battery pack's fixed position. This mediator approach reduces collision load transfer without compromising battery pack stability.
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 solution effectively absorbs collision energy, preventing battery pack deformation and ensuring vehicle safety by minimizing load transfer during side collisions.
Implementation Method 1
the collision energy absorptive part is deformed to absorb collision energy to reduce a load transferred to the battery pack
Data Source
AI summary
An automotive body side structure includes: a side sill extending in a vehicle length direction; a battery pack disposed vehicle inside in a vehicle width direction relative to the side sill; and a collision energy absorptive part having a substantially U-shaped cross section, the substantially U-shaped cross section including: a bottom portion substantially parallel to a vehicle height direction; and a pair of side wall portions continuous from an upper end and a lower end of the bottom portion. The collision energy absorptive part is provided in a protruding shape toward vehicle outside in the vehicle width direction on an outer peripheral side in the vehicle width direction of the battery pack facing the side sill. The collision energy absorptive part is made of a steel sheet having a tensile strength of 270 MPa-class to 340 MPa-class and a plate thickness of 1.0 mm to 1.4 mm.