Traction Battery Enclosure with Recessed Foam Pockets for Impact Energy Absorption
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Solution Overview
Problem
Conventional enclosures for traction batteries in electrified vehicles lack effective energy absorption features, leading to high peak forces during impact events, which can damage components within the enclosure.
Innovation Solution
A polymer-based enclosure with recessed pockets that deform upon impact, absorbing energy by crushing, bending, or severing, thereby extending the duration of force application and reducing peak force transmission to components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional enclosures without energy absorption features are used, then the structure is simple and manufacturing is easy, but peak forces during impact events are high which can damage components
Solution Approach 1:
The enclosure incorporates foam-filled pockets that utilize the energy-absorbing properties of porous foam materials. During impact events, the foam compresses and deforms, absorbing peak forces through cellular collapse and energy dissipation mechanisms, thereby protecting components without requiring complex additional structures
Solution Approach 2:
The enclosure integrates energy-absorbing foam pockets directly into the enclosure structure beforehand, creating built-in cushioning features that activate during impact events. This pre-positioned energy absorption capability protects components from peak forces without requiring separate cushioning systems or complex assemblies
2Object-affected harmful factors
If energy absorbing features are added to the enclosure, then peak force transmission is reduced, but the device complexity increases
Solution Approach 1:
The energy-absorbing foam pockets are merged with the enclosure structure itself, combining the protective enclosure function with the energy absorption function into a single integrated component. This eliminates the need for separate cushioning systems and reduces overall device complexity while effectively reducing peak force transmission to components
3Loss of energy
If the pocket floor is vertically aligned with the component, then energy absorption is optimized, but manufacturing precision requirements increase
Solution Approach 1:
The foam material properties are adjusted to provide energy absorption effectiveness across a range of compression distances, allowing the pocket floor alignment to vary within manufacturing tolerances without significantly compromising energy absorption efficiency. The foam's progressive collapse characteristics ensure effective energy dissipation regardless of precise alignment
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 deformation of the pockets within the enclosure effectively absorbs energy, reducing the peak magnitude of force transmitted to components, thereby enhancing the safety and durability of the battery pack during impact events.
Implementation Method 1
absorbing energy by deforming a pocket that is recessed within a vertically facing side of an enclosure. The pocket having a pocket floor that is vertically aligned with a portion of a traction battery component held within the enclosure
Implementation Method 2
The deformation of the pockets within the enclosure effectively absorbs energy, reducing the peak magnitude of force transmitted to components
Data Source
AI summary
An exemplary battery pack assembly includes an enclosure having a plurality of horizontally facing sides extending between a first and a second vertically facing side to provide an interior, a component within the interior, and a pocket of the first vertically facing side. The pocket is vertically recessed such that a pocket floor of the pocket is vertically aligned with a portion of the component.