Embossed Battery Housing Base for Outward Crash Deformation
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Solution Overview
Problem
Conventional battery housings for electromotive vehicles are prone to damage and potential fire during accidents due to uncontrolled bulging of the base under lateral impact forces, which can cause damage to high-voltage battery modules.
Innovation Solution
The battery housing incorporates embossments in its base that are offset into the trough interior, with a transition section that bridges the connection between the embossment and the base, allowing forces to be transmitted in a way that causes the base to bulge outward rather than inward, thereby protecting the battery modules from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the base is made with a large flat extension to accommodate battery modules, then the battery volume requirement is met, but the base becomes prone to uncontrolled inward bulging under lateral impact forces
Solution Approach 1:
The embossment introduces a vertical dimension (offset into the trough interior) to the otherwise flat base structure. This third dimension creates a stepped configuration that redirects lateral forces through the transition section, preventing uncontrolled inward bulging while preserving the large flat area needed for battery module accommodation.
Solution Approach 2:
The base is segmented into distinct functional zones: a flat area for battery module placement and an embossed area with transition section for force management. This segmentation allows each zone to perform its specific function optimally without compromising the other.
2Device complexity
If the frame structure is connected directly to the base edge, then the structure is simple, but lateral impact forces are directly transmitted to the base causing inward bulging and battery damage
Solution Approach 1:
The transition section acts as an intermediary element between the frame structure connection point and the flat base area. It mediates the force transmission by providing a geometric transition that redirects lateral forces, preventing direct transmission to the battery module support area while adding minimal structural complexity.
3Ease of manufacture
If conventional flat base design is used, then manufacturing is simple, but crash performance is insufficient due to uncontrolled base deformation
Solution Approach 1:
The embossment is pre-formed into the base structure before final assembly, creating a permanent geometric feature that passively manages force distribution during crashes. This preliminary structural preparation ensures reliable crash performance without requiring active control systems or complex manufacturing processes.
Data Source
AI summary
A battery housing for a vehicle comprising a trough with a base and with side walls connected to the base, and comprising a frame structure. In its edge area, the base has at least one embossment, which is offset into the trough interior and follows the course of the adjacent side wall, with a connection section, which is offset with respect to the base and to which the frame structure is connected, and with a transition section arranged between the connection section and the base. The transition section has an offset amount with respect to the base that corresponds at least to the material thickness of the base.