EV Battery Pack Crossmember Layout for Side-Collision Load Transfer
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Solution Overview
Problem
In electric vehicles with battery packs located below the floor panel, lateral collisions cause the floor panel to deform downward, applying loads to the battery stacks and potentially damaging them.
Innovation Solution
The implementation of a battery pack configuration with a bottom plate, battery crossmembers, end plates, and load transmitting components that distribute and mitigate the loads applied during floor panel deformation, ensuring the loads are received by the crossmembers and end plates rather than the battery stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack is located below the floor panel to increase vehicle rigidity, then lateral collision resistance is improved, but the battery stacks become vulnerable to damage from floor panel deformation
Solution Approach 1:
The patent introduces load transmitting components as intermediary elements between the floor panel and battery stacks. These components (including battery crossmembers and end plates) act as mediators that intercept and redirect collision loads, preventing direct transmission to the battery stacks while maintaining the floor panel's structural support function
Solution Approach 2:
The battery pack structure is segmented into distinct load-bearing elements (battery crossmembers, end plates, and load transmitting components) that are strategically positioned to distribute and redirect forces. This segmentation allows different parts to handle specific load paths, isolating the battery stacks from direct impact
2Reliability
If load transmitting components extend higher than battery stacks, then load transmission to battery stacks is reduced, but device complexity increases
Solution Approach 1:
The load transmitting components serve multiple functions: they transmit vertical loads from the floor panel, provide lateral support to battery stacks, and act as structural reinforcement during collision. This multi-functionality reduces the need for separate protective components, thereby limiting complexity increase
Solution Approach 2:
The patent merges the load transmitting function with the existing battery pack structural elements (crossmembers and end plates). Rather than adding separate protective components, these existing elements are designed to extend higher and perform both structural support and load transmission functions simultaneously
Data Source
AI summary
An electric vehicle may include: a floor panel; and a battery pack located below the floor panel. the battery pack may include: a bottom plate; a plurality of battery stacks distributed on the bottom plate along a longitudinal direction of the electric vehicle with an interval provided between the battery stacks; a battery crossmember located between the battery stacks; a plurality of end plates each of which is fixed to a side surface of corresponding one of the battery stacks; a first load transmitting component extending from the battery crossmember to a position located higher than upper surfaces of the battery stacks; and a second load transmitting component located outward of the first load transmitting component in the width direction. The second load transmitting component may be a component extending to a position higher than the upper surfaces of the battery stacks.