Battery Enclosure with Cylindrical Impact Absorbers
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Solution Overview
Problem
There is a need for an efficient and lightweight structure to absorb collision energy and minimize deformation of electric vehicle battery enclosures while maintaining limited package space and avoiding weight addition, which affects fuel economy and vehicle design.
Innovation Solution
The use of cylindrical tubular impact absorbing members with internal reinforcing walls, attached between inner and outer walls of the battery enclosure, which can collapse and absorb impact by adjusting stiffness and orientation, and can be formed in a single extrusion or welded separately to the enclosure sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If beams and cross members are added to the battery enclosure for impact protection, then the structural strength and impact absorption capability are improved, but the vehicle weight increases and additional packaging space is required
Solution Approach 1:
The impact absorbing members are nested within the battery enclosure structure, positioned between the inner and outer walls. This integration allows the impact protection function to be embedded within the existing enclosure volume rather than adding external beams and cross members, achieving impact absorption without proportionally increasing vehicle weight or requiring additional packaging space.
Solution Approach 2:
The impact absorbing members are combined with the battery enclosure structure by attaching them between the inner and outer walls. This merging of functions allows the enclosure to simultaneously provide structural containment and impact absorption, eliminating the need for separate external reinforcement elements that would increase weight and space requirements.
2Strength
If beams and cross members are added to the battery enclosure for impact protection, then the structural strength and impact absorption capability are improved, but the packaging space requirements increase
Solution Approach 1:
The impact absorbing members are nested within the battery enclosure structure, positioned between the inner and outer walls. This integration allows the impact protection function to be embedded within the existing enclosure volume rather than adding external beams and cross members, achieving impact absorption without proportionally increasing vehicle weight or requiring additional packaging space.
3Quantity of substance
If the battery enclosure is tightly packed with battery cells, then the space utilization is improved, but the crush space available for impact absorption is reduced
Solution Approach 1:
The impact absorbing members are nested within the battery enclosure structure, positioned between the inner and outer walls. This integration allows the impact protection function to be embedded within the existing enclosure volume rather than adding external beams and cross members, achieving impact absorption without proportionally increasing vehicle weight or requiring additional packaging space.
Solution Approach 2:
The impact absorbing members utilize the vertical dimension between the inner and outer walls of the enclosure, rather than requiring horizontal crush space. By positioning members in this third dimension, the design allows tight packing of battery cells in the horizontal plane while still providing impact absorption capability through the vertical space available in the enclosure structure.
4Quantity of substance
If the battery enclosure is tightly packed with battery cells, then the space utilization is improved, but the available space for reinforcement structures is reduced
Solution Approach 1:
The impact absorbing members utilize the vertical dimension between the inner and outer walls of the enclosure, rather than requiring horizontal crush space. By positioning members in this third dimension, the design allows tight packing of battery cells in the horizontal plane while still providing impact absorption capability through the vertical space available in the enclosure structure.
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
This solution effectively reduces battery enclosure deformation during impacts, maintaining structural integrity and weight efficiency, as demonstrated by simulation tests comparing deformation times and springback of steel and aluminum cases with and without the impact absorbing members.
Implementation Method 1
cylindrical tubular impact absorbing members attached to each other about the sides of the battery... The impact absorbing members are spaced from adjacent impact absorbing members to provide clearance for the impact absorbing members to collapse toward the inner wall
Data Source
AI summary
A battery enclosure for the battery of an electric vehicle is disclosed that is provided with cylindrical impact absorbing tubular members. The tubular members are arrayed about the battery enclosure between an inner wall and an outer wall in a spaced relationship. The tubular members are spaced from each other and include internal reinforcing walls that stiffen the battery enclosure and absorb impact loads. The reinforcing walls may be in an X-shaped, Y-shaped or parallel and may be oriented to absorb impact loads to a greater or lesser extent.