Door Closure Cross Member Layout for Side-Impact Battery Protection

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Solution Overview

Problem

The existing structure for mounting high capacity batteries in electric or hybrid electric vehicles is complex, leading to compromised collision response performance, particularly in side collisions, as it disrupts load transfer and increases the risk of battery damage from external shocks.

Innovation Solution

A cross member is strategically positioned under the vehicle body to support the door opening/closing device during side collisions, coupled with a battery bracket and side sill to absorb and redirect shock forces, preventing battery indentation and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the mounting structure occupies more space, then the battery can be securely fixed, but the risk of battery damage from external shocks increases due to increased load transfer cutoff

Engineering Contradiction:

Improvebattery fixation strengthVSAvoidbattery damage risk from external shocks

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The cross member is pre-positioned at the door opening/closing device location before any collision occurs. This preliminary placement ensures that when a side collision happens, the cross member is already in position to absorb and redirect the shock forces, preventing direct impact to the battery case and reducing damage risk.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cross member serves as a cushioning element positioned beforehand to absorb collision forces. By placing this protective structure in advance at the door opening/closing device location, the system prepares for potential external shocks, reducing the transmission of harmful forces to the battery case.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If a cross member is added to protect the battery, then collision response improves, but the device complexity increases

Engineering Contradiction:

Improvecollision response performanceVSAvoidmounting structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cross member positioned at the door opening/closing device location serves multiple functions: it maintains door mechanism functionality, provides structural support, and acts as a collision force absorber/redirector. This multi-functionality allows the same component to address multiple requirements without adding separate dedicated parts, thereby limiting complexity increase.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11850930B2Battery-equipped vehicle body and door closure systems

Publication Date: 2023.12.26 HYUNDAI MOTOR CO LTD

AI summary

Disclosed is a battery-equipped vehicle body including: a lower panel of a vehicle extending in a planar direction, and having a battery coupled to the upper portion or lower portion thereof; a door opening/closing device located on the side surface of the lower panel, and coupled so that a door of the vehicle is opened and closed; and a cross member extending in a direction parallel to the transverse direction of the vehicle, coupled to the upper portion or lower portion of the lower panel, and located to correspond to the door opening/closing device in the transverse direction.