Stepped Battery Case Structure for EV Side-Impact Energy Absorption
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Solution Overview
Problem
Existing battery pack structures in electric vehicles do not efficiently absorb collision energy during lateral accidents, leading to potential damage to battery cells and limiting the number of cells that can be accommodated, thus restricting the vehicle's driving range.
Innovation Solution
A battery case design featuring a battery side member with a side wall portion, a first-step protrusion, and a second-step protrusion, along with a transverse member and additional side wall, which absorb collision energy and allow for increased battery cell accommodation by optimizing the use of space for conduits and cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional battery case structure is used, then the structure is simple and easy to manufacture, but collision energy is not efficiently absorbed and battery cells are vulnerable to damage
Solution Approach 1:
The battery side member is segmented into multiple functional regions: a side wall portion for basic enclosure, a first-step protrusion with deformation absorption space for energy dissipation, and a second-step protrusion for enhanced protection. This segmentation allows each region to perform its specific function optimally while collectively providing comprehensive collision energy absorption and battery cell protection.
2Quantity of substance
If the battery case structure is expanded to accommodate more battery cells, then the driving range increases, but the space for conduits and cables becomes limited
Solution Approach 1:
The battery side member utilizes vertical dimensionality with multi-level protrusions extending upward from the side wall. The first-step and second-step protrusions create vertically stacked functional zones that absorb collision energy without encroaching on the horizontal space required for battery cell arrangement and conduit routing, thus resolving the spatial conflict between protection functions and accommodation capacity.
3Reliability
If the battery side member includes multi-step protrusions for collision energy absorption, then battery cell protection improves, but manufacturing complexity increases
Solution Approach 1:
The multi-step protrusions are integrated into a single monolithic battery side member structure rather than being separate components. This merging of multiple protective functions into one unified component maintains structural integrity while simplifying assembly processes, as the entire collision energy absorption system is formed as one piece during manufacturing.
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 design effectively absorbs collision energy, protects battery cells, and increases the number of cells that can be accommodated, thereby enhancing the vehicle's driving range and safety.
Implementation Method 1
a first-step protrusion protruding outwards from an upper portion of the side wall portion... efficiently absorbing collision energy generated when a lateral collision accident of the vehicle or the like occurs
Data Source
AI summary
In a battery case and an electric vehicle structure including the same, the battery case includes a battery side member surrounding a side portion of a battery accommodation space formed by a lower case. The battery side member includes a side wall portion surrounding the side portion of the battery accommodation space, a first-step protrusion protruding outwards from an upper portion of the side wall portion, and a second-step protrusion protruding outwards from an upper portion of the first-step protrusion.