Battery Housing Crash Structure for Cell Deformation Protection
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Solution Overview
Problem
Existing electrical energy storage devices in vehicles suffer from deformation and damage during crashes due to sudden accelerations, leading to defects in storage cells and connections.
Innovation Solution
A crash structure with a high-strength, form-fitting design is integrated into the housing, preventing deformation by maintaining the storage device's position and reducing contact with the housing side wall, using materials like carbon fiber-reinforced plastic and thermoplastic, and incorporating support surfaces and detachable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the storage device is arranged in a housing with free space around it, then the storage device can be easily installed and maintained, but during a crash the storage device deforms and shifts from its normal position causing damage to cells and connections
Solution Approach 1:
The patent introduces a crash structure with support surfaces positioned in advance within the housing, which contacts the storage device during crashes to prevent deformation. This pre-positioned protective structure absorbs crash forces before they can damage the storage device, resolving the contradiction between easy installation (free space) and crash protection.
2Reliability
If a crash structure is added to prevent deformation during crashes, then the protection against crash damage is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The housing structure is designed to serve multiple functions: it provides mechanical support for the storage device during normal operation and simultaneously acts as a crash protection structure when equipped with the crash structure. This multi-functionality reduces overall device complexity by combining protective and structural roles into existing components.
Solution Approach 2:
The crash structure is implemented with support surfaces at specific critical locations where the storage device is most vulnerable during crashes, rather than providing uniform protection throughout the entire housing. This localized approach reduces manufacturing complexity while maintaining effective crash protection where it is most needed.
3Strength
If the housing side wall has an uneven contour for structural reasons, then the structural integrity is improved, but the available space for storage device arrangement is reduced
Solution Approach 1:
The housing structure is segmented into different functional zones: areas with uneven contours provide structural strength where needed, while adjacent areas maintain smooth surfaces to maximize available space for the storage device. This segmentation allows the housing to simultaneously achieve structural integrity and optimize space utilization.
Data Source
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Figure 3(a)~3(c)
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AI summary
The invention relates to an electrical energy storage device (100) for an electrically powered motor vehicle, in particular a commercial vehicle. The electrical energy storage device (100) comprises an electrical energy storage device (80) arranged in a housing (50). The electrical energy storage device (100) further comprises a crash structure (10) arranged in a region between an inner surface (52A) of a housing side wall (52) and the storage device (80). A side (12) of the crash structure (10) facing the housing side wall (52) has an outer contour that is formed, at least in sections, to conform to an uneven contour of the housing side wall (52).