Underfloor Reinforcing Element for EV Battery Housing
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Solution Overview
Problem
The underfloor stretchers in hybrid or electric vehicles limit the installation of large batteries due to the need to span them, which compromises the structural strength during frontal impacts, such as in 'small overlap' collisions, where the base's resistance is compromised.
Innovation Solution
Incorporating short underfloor stretchers with transverse reinforcing elements, such as square-shaped brackets or metal profiles, fixed directly to the floor, to stiffen the structure and maintain resistance during frontal impacts without interfering with battery installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If underfloor stretchers are cut to accommodate large batteries, then battery size increases, but base strength during frontal impacts degrades
Solution Approach 1:
The underfloor stretcher is divided into two separate elements: a first underfloor stretcher element positioned forward of the battery and a second underfloor stretcher element positioned rearward of the battery. This segmentation allows the stretchers to be shortened to accommodate large batteries while maintaining structural strength through distributed load paths and reinforced connection points.
2Volume of moving object
If short underfloor stretchers are used to accommodate large batteries, then battery installation space increases, but bending instability and buckling risk increase during frontal impacts
Solution Approach 1:
The first and second underfloor stretcher elements are connected to the vehicle floor at multiple reinforced connection points, merging their structural function with the floor assembly. This creates a unified load-bearing system that prevents bending instability and buckling in the shortened stretcher elements during frontal impacts.
Solution Approach 2:
Reinforced connection points serve as intermediary elements between the shortened underfloor stretcher elements and the vehicle floor. These intermediaries transfer and distribute loads, providing the necessary structural support and stability to the short stretchers during impact events.
3Ease of manufacture
If underfloor stretchers are shortened to face battery ends, then battery modules can be installed without spanning, but additional reinforcing elements are required to maintain floor stiffness
Solution Approach 1:
The first and second underfloor stretcher elements serve multiple functions: they provide structural support for the vehicle floor, transfer impact loads, and define mounting points for the battery modules. This multi-functionality reduces the need for additional dedicated reinforcing elements while maintaining floor stiffness and simplifying battery installation.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a hybrid or electric vehicle (1) which has a floor (3), rocker panel side members (5) which extend along the two lateral sides of the floor (3), underfloor bottom runners (7) between said rocker panel side members (5), and at least one drive battery (9) that is arranged under the floor (3) between the rocker panel side members (5). The vehicle (1) is characterised in that one of the ends of at least one underfloor bottom runner (7) is positioned facing one of the faces of one, or the, drive battery (9), and in that the vehicle (1) additionally comprises at least one reinforcing element (15) that is secured under said floor (3) and extends transversely from one of the underfloor bottom runners (7).