Power Storage Module Case Reinforcement Against Side-Impact Bending
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Solution Overview
Problem
Power storage devices in vehicles face a high risk of cell unit damage due to deformation of module cases during a side impact, which can occur when a vehicle is subjected to such an event.
Innovation Solution
The power storage device incorporates a case with reinforcing portions that protrude from the side wall and align with connection portions of the power storage modules, preventing the module cases from bending and thereby protecting the cell units from damage during a side impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple module cases are arranged side by side to increase energy capacity, then the energy capacity is improved, but the risk of cell unit damage during side impact increases due to module case deformation
Solution Approach 1:
The case is designed with non-uniform thickness, featuring a thinner first case wall portion and a thicker second case wall portion. The thicker portion is strategically positioned to provide enhanced protection at locations requiring greater strength during side impact, while the thinner portion reduces overall weight. This local variation in quality optimizes both protection and energy capacity.
Solution Approach 2:
The case structure parameters are changed by varying the thickness of different case wall portions. The first case wall portion has a smaller thickness than the second case wall portion, creating a gradient structure that adapts to different protection requirements at different locations, thereby reducing cell unit damage risk while maintaining energy capacity.
2Weight of moving object
If the case wall is made thinner to reduce weight, then the weight is reduced, but the protection against side impact is weakened
Solution Approach 1:
The case implements local quality variation with different wall thicknesses at different locations. The first case wall portion is thinner to reduce weight, while the second case wall portion is thicker to maintain side impact resistance. This localized differentiation allows the case to be lightweight overall while providing sufficient protection where needed.
Solution Approach 2:
The case wall thickness parameter is changed across different portions of the case. By setting the first case wall portion thickness to be smaller than the second case wall portion thickness, the design optimizes the weight-strength trade-off, achieving reduced weight without compromising side impact resistance at critical locations.
3Strength
If the case wall is made thicker to improve side impact resistance, then the protection is improved, but the weight increases
Solution Approach 1:
Rather than uniformly thickening the entire case wall, the design applies local quality enhancement by making only the second case wall portion thicker while keeping the first case wall portion thinner. This localized thickening provides improved side impact resistance at critical locations without the weight penalty of a uniformly thick case.
Solution Approach 2:
The case wall thickness parameter is selectively changed across different portions. The second case wall portion has a greater thickness to improve side impact resistance, while the first case wall portion maintains a smaller thickness to control weight, achieving an optimized balance between protection and weight.
4Strength
If reinforcing portions are added to the case to prevent module case bending, then the side impact resistance is improved, but the device complexity increases
Solution Approach 1:
The reinforcing portions are merged with the case structure itself, forming an integrated design where the reinforcing portions and case walls are part of a unified structure. This integration reduces the number of separate components and simplifies manufacturing, thereby improving side impact resistance without significantly increasing device complexity.
Solution Approach 2:
The case is designed as a composite structure with different wall thicknesses in different portions, creating a composite material distribution that optimizes strength-to-weight ratio. This composite approach provides enhanced side impact resistance through strategic material distribution rather than adding complex external reinforcements.
Data Source
AI summary
In a power storage device, a plurality of power storage modules is arranged side by side in a vehicle left-right direction. A plurality of cell units is arranged side by side in a vehicle front-rear direction. A connection portion connects cell units on both sides thereof. A module case accommodates the cell units and the connection portion. The connection portions of the power storage modules are arranged side by side in the left-right direction. The side wall portion is located on one side in the left-right direction of the power storage modules. A reinforcing portion protrudes from the side wall portion toward the power storage modules in the left-right direction. The reinforcing portion is further aligned in the left-right direction with the connection portion of each of the power storage modules arranged side by side in the left-right direction.