Ramp Sheet Metal Battery Support for EV Crash Intrusion Protection
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Solution Overview
Problem
Existing battery supports in electric vehicles are vulnerable to mechanical damage during crashes, posing risks of fire and requiring costly replacements, especially in vehicles with large batteries.
Innovation Solution
A battery support arrangement featuring a single-shell ramp sheet metal made of high-strength steel, designed to reinforce the front axle and battery support, deflecting obstacles away from the battery compartment during impacts, and incorporating a buffer element to dissipate crash energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery supports are used without additional protection, then the structure remains simple and production costs are low, but the battery support is vulnerable to mechanical damage during crashes
Solution Approach 1:
A ramp sheet metal is introduced as an intermediary protective element between the front axle support and the battery support. This ramp sheet metal absorbs and redirects impact forces during crashes, preventing direct mechanical damage to the battery support while maintaining a relatively simple overall structure.
Solution Approach 2:
The ramp sheet metal is positioned in advance to cushion and redirect potential impact forces before they can reach the battery support. By being pre-positioned in the impact path, it provides protective cushioning that prevents mechanical damage before it occurs to the battery support.
2Strength
If the ramp sheet metal is made from thicker or multiple sheet metal layers, then the protective function is improved, but the weight and production costs increase
Solution Approach 1:
The ramp sheet metal is made from ultra-high-strength steel with a tensile strength of at least 1500 MPa. This parameter change in material strength allows the use of thinner sheet metal (reducing weight) while maintaining or improving the protective function against mechanical damage during crashes.
Solution Approach 2:
The ramp sheet metal utilizes composite material properties by combining ultra-high-strength steel with an optimized geometric design featuring reinforcement beads and specific thickness variations. This composite approach achieves high strength and protective function while minimizing weight through material efficiency.
3Ease of manufacture
If a single-shell ramp sheet metal with ultra-high-strength steel is used, then weight and production costs are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The ramp sheet metal features local quality variations through strategically positioned reinforcement beads and varying sheet metal thickness in different regions. This allows the single-shell structure to achieve high protective function where needed while using thinner material elsewhere, reducing overall weight and manufacturing complexity while maintaining formability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents mechanical damage to the battery support, reduces weight and production costs, and enhances safety by minimizing intrusion and fire risks during crashes.
Implementation Method 1
The ramp sheet metal is designed as a hot molded and press hardened component with a tensile strength Rm of greater than 1200 MPa
Implementation Method 2
the ramp sheet metal prevents the ground obstacle from penetrating frontally into the battery support and damaging the battery support. The ramp sheet metal makes it possible for the ground obstacle to slide or deviate beneath the battery support
Data Source
AI summary
The present invention relates to a battery support arrangement of an electric motor vehicle, having a battery support which is arranged in the underfloor region of the electric motor vehicle, and a front axle support, and a single-shell ramp sheet metal extending in the motor vehicle longitudinal direction is arranged in the transition from the front axle support to the battery support, as a hot molded and press hardened component with a tensile strength Rm greater than 1200 MPa.