Battery Housing Projections for Crash Force Distribution
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Solution Overview
Problem
Existing battery structures for motor vehicles face challenges in ensuring safety during crashes due to additional space and weight requirements of crash control elements, as well as high production costs and potential coolant leakage leading to insulation defects.
Innovation Solution
A battery structure with a heat sink between opposing inner surfaces of the battery housing shell, featuring projections that distribute external forces during deformation, ensuring the heat sink transfers forces effectively while maintaining coolant integrity and preventing damage to the cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crash control element is added to ensure safety during crashes, then safety is improved, but additional space and weight are required
Solution Approach 1:
The patent combines the crash control function with the existing battery housing shell structure by integrating protrusions directly into the housing. This merging eliminates the need for separate crash control elements, achieving safety functionality without additional weight or space requirements.
Solution Approach 2:
The battery housing shell is designed to serve multiple functions: it provides structural containment for battery modules and simultaneously acts as a crash control element through integrated protrusions. This multi-functionality allows the housing to absorb and distribute crash forces without requiring dedicated safety components.
2Reliability
If a crash control element is added to ensure safety during crashes, then safety is improved, but production cost increases
Solution Approach 1:
The crash control functionality is merged into the battery housing shell manufacturing process. The protrusions are formed as integral parts of the housing during molding or fabrication, eliminating separate production steps and reducing overall manufacturing complexity and cost.
Solution Approach 2:
The housing shell serves dual purposes as both a structural container and a crash control element. This eliminates the need to manufacture and assemble separate safety components, simplifying the production process and reducing costs associated with multiple parts and assembly operations.
3Force
If the battery housing shell deforms during a crash, then force transmission is achieved, but coolant distributors may be damaged
Solution Approach 1:
The housing shell features localized protrusions at specific positions that concentrate force transmission away from the coolant distributor area. This local structural differentiation ensures that crash forces are directed through designated load paths while protecting the coolant distributor from damage.
Solution Approach 2:
The protrusions act as intermediary elements that mediate between the external crash force and the internal components. They provide a controlled interface for force transmission, directing loads through the housing structure while shielding the coolant distributor from direct impact forces.
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 design enhances safety by distributing crash forces effectively, preventing coolant leakage, and maintaining cooling functionality without significant weight increase, thus improving the safety and reliability of battery structures in motor vehicles.
Implementation Method 1
a force acting from the outside on the battery housing shell acts on the at least one heat sink when the battery housing shell deforms is transferrable, and is transferrable from the heat sink to an opposite second inner surface of the battery case shell
Implementation Method 2
at least one battery module having a heat sink on which the at least one battery cell is arranged
Data Source
Figure 1~2
Figure 3~4
AI summary
Battery assembly for a motor vehicle, comprising at least one battery module arranged in a battery housing shell, wherein the battery module comprises at least one battery cell storing electrical energy, wherein the at least one battery module comprises a heat sink on which the at least one battery cell is arranged, wherein the at least one heat sink is arranged between two opposing inner surfaces of the battery housing shell, wherein at least one first projection is formed on a first inner surface of the battery housing shell at the level of the heat sink, such that a force acting from the outside on the battery housing shell can be transferred to the at least one heat sink when the battery housing shell is deformed, and can be transferred from the heat sink to an opposing second inner surface of the battery housing shell.