Corrugated EV Battery Case Structure for Impact Energy Absorption
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Solution Overview
Problem
Existing battery cases in electric vehicles lack effective energy absorption performance, particularly due to the presence of side blocks that do not contribute to impact resistance and the occurrence of out-of-plane deformations during collisions.
Innovation Solution
A battery case design featuring a battery tray with cross frame parts and an impact absorbing member with a corrugated portion that extends along the side frames, enhancing energy absorption through controlled deformation modes and reducing out-of-plane deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If side blocks are fixed on upper sides of side edge support members at intervals, then the structure is simplified and easier to manufacture, but energy absorption performance is insufficient because some side blocks do not contribute to impact resistance
Solution Approach 1:
The side edge support member is divided into multiple convex portions along its length, with each convex portion acting as an independent impact absorption unit. This segmentation allows the structure to effectively utilize multiple cross frame parts during collision, maximizing energy absorption while maintaining manufacturing simplicity.
Solution Approach 2:
The side edge support member integrates multiple functions: it serves as both a structural support element and an impact absorption mechanism. The convex portions are formed as integral parts of the side edge support member, combining the support function with energy absorption capability in a single component.
2Strength
If a closed cross-section region is formed by joining upper plate and lower plate, then energy absorption performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The battery case is divided into a battery tray and a cover, with the battery tray containing integrated side edge support members. This segmentation allows the complex energy absorption structure to be incorporated into a single tray component rather than requiring multiple joined plates, simplifying the overall assembly process.
Solution Approach 2:
The side edge support member is formed as an integral part of the battery tray, combining the tray structure with the impact absorption mechanism. This eliminates the need for separate joining operations between upper and lower plates, reducing device complexity while maintaining energy absorption performance.
3Ease of manufacture
If cross frame parts are arranged at intervals along the longitudinal direction, then manufacturing is simplified, but out-of-plane deformations occur during collision reducing structural rigidity
Solution Approach 1:
The corrugated portion is pre-formed in the side edge support member with a specific waveform structure before collision occurs. This preliminary structural configuration is designed to control the deformation mode during impact, guiding the deformation to occur within the plane of the cross frame parts and preventing out-of-plane buckling.
Solution Approach 2:
The corrugated waveform introduces controlled curvature into the side edge support member. This curvature enhances the structural rigidity by creating a more complex load path that resists out-of-plane deformations, while the waveform pattern is designed to accommodate the interval arrangement of cross frame parts for ease of manufacture.
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 improves energy absorption performance by increasing plastic deformation areas and restraining out-of-plane deformations, leading to enhanced collision resistance and structural rigidity.
Implementation Method 1
the corrugated portion has a plurality of bottom surfaces and a plurality of convex portions... the convex portion has a top surface, two side surfaces, and two ridge lines... improves energy absorption performance by increasing plastic deformation areas
Data Source
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AI summary
A battery case includes: a battery tray; a plurality of cross frame parts; and an impact absorbing member, wherein the impact absorbing member includes a corrugated portion, wherein the corrugated portion has a plurality of bottom surfaces and a plurality of convex portions; the bottom surfaces of the corrugated portion are each between the convex portions; the convex portion has a top surface, two side surfaces, and two ridge lines; the two side surfaces of the convex portion face each other; the two ridge lines of the convex portion are ridge lines connecting the top surface of the convex portion and the two side surfaces of the convex portion; and the two ridge lines of the convex portion extend in a direction from a second side portion toward a first side portion of the battery tray.