Analysis of the Impact of Threshold Beam on Battery Protection Based on Side Impact Characteristics

In 2022, the production and sales share of new energy vehicles in China exceeded 25%, but only in the first quarter, there were as many as 640 new energy vehicle fire accidents. The proportion of battery pack fires caused by side collisions was about 5%. In response to this safety hazard, through in-depth analysis of finite element analysis models, it was found that the threshold beam structure is an important energy absorption component for side collision conditions, playing a decisive role in battery pack protection. By analyzing the impact performance of threshold beams with different cross-sectional shapes and material types on the extrusion pressure and module invasion of battery pack molds during side impact, combined with weight and cost, the final selection of aluminum extruded profile threshold beams significantly reduced module extrusion pressure.