Rocker Insert Reinforcement for Electric Vehicle Battery Packaging
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Solution Overview
Problem
The integration of electric vehicle batteries on the lower portion of a vehicle body reduces the structural rigidity and resistance to bending, as it compromises the reinforcing features typically found in this area, making the vehicle more susceptible to side impacts and deformation.
Innovation Solution
A rocker insert with an elongated bar and internal reinforcing web features is mounted to the side rocker areas of the lower vehicle body portion, providing additional structural support and resistance to bending, and is attached using spacers, rivets, and an external cover to maintain anti-corrosive coating integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If batteries are mounted on the lower portion of the vehicle body, then package space is optimized, but structural rigidity and resistance to bending are reduced
Solution Approach 1:
The vehicle body structure is segmented into the lower portion and separate rocker inserts. The rocker inserts are discrete structural components that can be independently designed and attached to the lower portion, allowing the lower portion to maintain its simplified geometry for battery mounting while the inserts provide the necessary structural reinforcement.
Solution Approach 2:
The rocker inserts are constructed as composite structures with an outer skin and internal web features forming a hollow cross-section. This composite geometry provides high structural rigidity and bending resistance while maintaining a relatively compact profile that preserves package space for battery placement.
2Strength
If rocker inserts are added to reinforce the lower portion, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The rocker inserts are pre-formed as complete structural components with integrated mounting features, fastener receiving features, and web patterns. This preliminary fabrication allows the inserts to be manufactured independently and then attached to the lower portion in a single assembly operation, rather than requiring complex in-situ construction.
Solution Approach 2:
Spacers are introduced as intermediary components between the rocker inserts and the lower portion. These spacers simplify the attachment process by providing a standardized mounting interface and maintaining proper positioning, thereby reducing the overall assembly complexity despite adding an additional component.
3Object-affected harmful factors
If the lower portion is reinforced with traditional features, then resistance to side impacts is improved, but package space for batteries is reduced
Solution Approach 1:
The rocker inserts introduce structural reinforcement in the vertical dimension through their hollow cross-sectional geometry with web features. This vertical structuring provides bending resistance and impact strength without extending significantly in the horizontal plane, thereby preserving package space for battery placement in the lateral direction.
Solution Approach 2:
The rocker inserts provide localized structural reinforcement at the rocker areas of the lower portion, which are the specific zones susceptible to side impacts. This localized reinforcement targets the critical impact zones without requiring comprehensive thickening or additional features across the entire lower portion, thus preserving package space in non-critical areas.
Data Source
AI summary
An apparatus for a vehicle body including a rocker insert is provided. The apparatus includes a vehicle body including a plurality of metallic structure members and a lower portion operable to provide support to a floor surface within a passenger compartment of a vehicle and a rocker insert mounted to an in-vehicle side portion of the lower portion. The rocker insert includes an elongated bar portion including a hollow center portion including internal reinforcing web features. The rocker insert is oriented with respect to the vehicle body such that a longitudinal axis of the elongated bar portion of the rocker insert is parallel to an in-vehicle forward direction of the vehicle body.