Deployable Battery Enclosure Wing for EV Side-Impact Protection
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Solution Overview
Problem
The large and heavy motive battery in electric vehicles, typically positioned below the passenger compartment, poses a challenge in managing impact forces and lateral intrusion during collisions, necessitating a protective mechanism that can effectively distribute energy and prevent intrusion.
Innovation Solution
A vehicle battery enclosure with a rotatable wing mechanism, actuated by a pyrotechnic actuator, that deploys to contact the ground during impacts, distributing energy away from the battery compartment and preventing lateral intrusion, accompanied by an airbag system for additional protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery is positioned below the passenger compartment to manage packaging space, then the vehicle can accommodate the large and heavy motive battery, but the battery becomes vulnerable to impact forces during vehicle collisions
Solution Approach 1:
The patent employs a deployable wing structure that transitions from a stowed position during normal operation to a deployed position during impact events. This dynamic reconfiguration allows the enclosure to adapt its protective characteristics based on operational conditions, providing enhanced impact resistance when needed while maintaining packaging efficiency during normal use.
Solution Approach 2:
The wing structure is pre-positioned in a stowed configuration during normal vehicle operation, occupying minimal space. Upon detection of an impact event, the wing rapidly deploys to an extended position before the full force of the impact reaches the battery compartment, providing preliminary protection against incoming impact forces.
2Strength
If a rigid enclosure structure is used to protect the battery compartment, then impact resistance improves, but the device complexity and weight increase
Solution Approach 1:
The protective enclosure is divided into a stationary battery compartment and a separate deployable wing structure. This segmentation allows the majority of the enclosure to remain simple and lightweight, while only the necessary protective elements (the wing) are made complex and movable. The wing can be constructed from lighter materials since it only needs to provide protection during impact events, not continuous support.
Solution Approach 2:
Instead of using a permanently rigid structure throughout, the patent employs a dynamic wing that transitions between stowed and deployed states. This dynamic approach allows the enclosure to provide high impact resistance only when needed, reducing overall structural weight and complexity compared to a fully rigid enclosure that would be required to protect against impacts at all times.
3Reliability
If energy dissipation mechanisms are added to protect the battery during impacts, then safety improves, but the device complexity increases
Solution Approach 1:
The deployable wing structure is designed to interact with the ground during impact events, converting the harmful impact energy into beneficial ground contact forces. The wing's deployment creates a controlled energy dissipation path where impact forces are transferred to the ground through the wing's legs, protecting the battery compartment from direct exposure to these forces while using relatively simple mechanical components.
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 wing mechanism effectively dissipates impact forces to the ground, reducing the risk of battery compartment damage and lateral intrusion, while the airbag provides supplemental protection, enhancing the safety and integrity of the vehicle's battery system.
Implementation Method 1
a pyrotechnic actuator operatively coupled to the wing to rotate the wing to the deployed position
Implementation Method 2
an airbag supported by the wing and rotatable with the wing relative to the first member from the stowed position to the deployed position
Data Source
AI summary
A vehicle battery enclosure includes a first member elongated along an axis and a second member spaced from the first member. The vehicle battery enclosure includes a battery compartment between the first member and the second member. A wing is rotatably connected to the first member and is rotatable relative to the first member from a stowed position (FIGS. 1, 4A, 4B) to a deployed position (FIGS. 2, 3, 5A, 8, and 9). The wing is aligned with the battery enclosure along the axis in the deployed position. A pyrotechnic actuator is operatively coupled to the wing to rotate the wing to the deployed position.