Side Sill Reinforcement Layout for EV Battery Side-Impact Protection
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Solution Overview
Problem
Electric vehicle batteries are vulnerable to damage during side impacts, which can lead to chemical leakage, thermal runaway, and fires due to the absence of specific protection in unibody structures.
Innovation Solution
Incorporating side sill reinforcements with varying strengths and a vehicle crossmember to redirect impact energy away from the battery pack, enhancing the unibody structure's ability to absorb and distribute forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If unibody structure is used for weight reduction and safety, then vehicle weight decreases and ride quality improves, but battery pack vulnerability to side impact increases
Solution Approach 1:
The side sill reinforcement is divided into multiple segments with different strength levels along its length. The reinforcement members have varying cross-sectional areas and material properties, creating zones of different strength to selectively manage impact energy propagation and protect the battery pack while maintaining overall vehicle weight efficiency.
Solution Approach 2:
Different portions of the side sill reinforcement are designed with locally optimized properties. The reinforcement members have varying thickness, material composition, and geometric characteristics at different locations to provide enhanced protection specifically where the battery pack is most vulnerable, rather than uniformly strengthening the entire structure.
2Object-affected harmful factors
If side sill reinforcements with varying strengths are added to protect battery, then battery protection improves, but device complexity increases
Solution Approach 1:
The side sill reinforcement structure integrates multiple functions into a single component: it serves as both a structural element for the unibody construction and a dedicated impact protection system for the battery pack. The reinforcement members are combined with the side sill extrusion to form an integrated assembly that reduces the number of separate protective components needed.
Solution Approach 2:
The side sill reinforcement structure performs multiple functions simultaneously: it maintains the structural integrity of the unibody, manages impact energy during side collisions, and specifically protects the battery pack. This multi-functionality eliminates the need for separate protective systems and reduces overall structural complexity.
3Force
If reinforcement members with different strengths are used to direct impact energy, then impact energy distribution improves, but manufacturing precision requirements increase
Solution Approach 1:
The reinforcement members are designed with systematically varied parameters including cross-sectional area, wall thickness, and material grade that change along the length of the side sill. These parameter changes create the desired impact energy distribution while using standard manufacturing tolerances, as the variations follow predictable gradients rather than requiring precise individual customization of each component.
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 protects the battery pack from side impacts by dispersing energy through the side sill reinforcements and crossmember, reducing the risk of damage and ensuring safety.
Implementation Method 1
Strengths of the plurality of reinforcement members differ to direct impact energy around a portion of the vehicle running parallel to the side sill reinforcement when the outer wall is impacted
Implementation Method 2
The vehicle crossmember absorbs impact energy directed into the vehicle crossmember from at least one of the first side sill reinforcement and the second side sill reinforcement
Data Source
AI summary
The technology disclosed herein enables protection of an electric vehicle battery from side impact forces to the vehicle. In a particular example, an apparatus includes a side sill reinforcement, including an inner wall and an outer wall, and a plurality of reinforcement members running a length of the side sill reinforcement. Strengths of the plurality of reinforcement members differ to direct impact energy around a portion of the vehicle running parallel to the side sill reinforcement when the outer wall is impacted.