EV Cell Pack Cross Member Layout for Side-Collision Load Paths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cell pack structures for electric vehicles are insufficient in dispersing and absorbing collision loads during side collisions, leading to inadequate protection of the vehicle body and potential damage to cell modules.
Innovation Solution
A cell pack structure featuring a cross member with a hollow shape and notches, along with reinforcements, that disperses collision loads through a load path structure, forming a crushable zone to reduce deformation and prevent damage to cell modules, while enhancing the rigidity of the cell pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a partitioning plate is disposed to partition a battery accommodation case into upper and lower parts, then the cell module is protected from rear collision, but the collision load cannot be effectively dispersed during side collision
Solution Approach 1:
The cross member is divided into multiple functional segments: upper structure wall, lower structure wall, and hollow body portion, each contributing to different aspects of collision resistance and load dispersion. The reinforcement members are also segmented and positioned at specific locations to optimize load distribution during side collisions.
Solution Approach 2:
The invention transitions from a simple partitioning plate (2D plane) to a three-dimensional cross member structure with upper and lower structure walls extending in the vertical dimension. This dimensional enhancement enables the structure to handle both rear collision (vertical protection) and side collision (horizontal load dispersion) simultaneously.
2Reliability
If crossing members are disposed inside the cell pack to protect the cell module during side collision, then the cell module is protected, but the vehicle body deformation is not sufficiently reduced
Solution Approach 1:
The invention merges the protection function and load dispersion function into a single integrated cross member structure. The upper structure wall, lower structure wall, and hollow body portion work together to simultaneously protect the cell module and disperse collision loads to the vehicle body, eliminating the need for separate protective structures.
Solution Approach 2:
The cross member employs a composite structure combining solid walls (upper and lower structure walls) with a hollow body portion, creating a composite material system that optimizes both protective strength and load dispersion characteristics. This composite design provides superior mechanical performance compared to solid or hollow structures alone.
3Reliability
If the cross member has a hollow shape, then the deformation mode can be adjusted for optimal protection, but the structural complexity increases
Solution Approach 1:
The hollow cross member features local quality variations through the upper structure wall, lower structure wall, and hollow body portion, allowing different regions to deform in controlled ways during collision. This local structural differentiation enables optimized deformation modes while maintaining manufacturing feasibility through standard extrusion or forming processes.
Data Source
AI summary
Cell modules (3) are aligned on front and rear sides and left and right sides in a tray (2), and a cross member (11) is disposed to cross inside of the tray (2) in a left-right direction between the front and rear cell modules (3). The cross member (11) is configured to have a hollow shape with a front wall (11e) and a rear wall (11f) coupled with four structure walls (11a to 11d). An upper notch (16) is formed at an upper edge of the cross member (11), and a lower notch (17) is formed at a lower edge, in a state where third and fourth structure walls (11c, 11d) are left. Reinforcements (18) are disposed on both left and right sides of the tray (2), and upper and lower flange portions (18b, 18c) of the left and right reinforcements (18) are joined to outside of side surfaces of the tray (2) on extension lines of the third and fourth structure walls (11c, 11d) of the cross member (11), respectively, in the up-down direction, thereby to form load path structures on left and right paths along the cross member (11).