Battery Pack Deformation Elements Energy Absorption
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Solution Overview
Problem
Conventional battery packs in vehicles are prone to destruction in accidents, leading to the escape of hazardous substances and inadequate absorption of accident energy, which compromises safety and increases the risk to occupants.
Innovation Solution
A battery pack design featuring deformation elements, such as hollow profiles or foamed bodies, strategically arranged between battery cells to absorb energy by deforming under external forces, thereby reducing the destructive impact on battery elements and preventing substance escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid battery housing is used to protect battery elements from destruction, then protection against substance escape is improved, but weight increases and accident energy absorption is reduced
Solution Approach 1:
The battery pack is segmented into modular units with individual battery elements arranged in series and parallel configurations. This segmentation allows the system to maintain protection while reducing overall weight compared to a single massive housing, as each module can use lighter protective structures.
Solution Approach 2:
The housing material and structural parameters are optimized to provide adequate protection without excessive weight. The design transitions from overly rigid massiveness to a balanced structure that provides necessary protection while maintaining vehicle efficiency.
2Reliability
If a rigid battery housing is used to protect battery elements, then protection against substance escape is improved, but accident energy absorption is reduced
Solution Approach 1:
Deformation elements are pre-installed within the battery pack structure to absorb accident energy before it reaches the battery elements. These elements are designed to deform in a controlled manner during collisions, cushioning the impact and preventing direct transmission of forces to the battery cells.
Solution Approach 2:
The housing and internal structure are designed with optimized stiffness and deformation characteristics. Rather than being uniformly rigid, the structure allows controlled deformation in specific zones to absorb energy while maintaining integrity where needed to prevent substance escape.
3Loss of energy
If deformation elements are added between battery elements, then accident energy absorption is improved, but device complexity increases
Solution Approach 1:
The deformation elements serve multiple functions: they absorb accident energy, provide structural support, and facilitate thermal management. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving energy absorption goals.
Solution Approach 2:
Foamed deformation elements are used, which provide effective energy absorption through their cellular structure. These porous materials achieve high energy absorption capacity without adding excessive weight or complexity to the overall battery pack design.
4Quantity of substance
If battery elements are arranged in multiple layers, then capacity is improved, but heat dissipation becomes more difficult
Solution Approach 1:
Fluid-carrying channels are integrated into the battery pack structure to enable active thermal management. Coolant flows through these channels to remove heat from the battery elements, allowing multiple layers to be arranged for high capacity while maintaining effective heat dissipation.
Solution Approach 2:
Thermal interface materials and heat-conductive structures are used between battery elements and cooling channels to improve heat transfer efficiency, enabling dense multi-layer arrangements without compromising thermal management.
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 battery pack effectively absorbs accident energy through deformation elements, minimizing damage to battery cells and preventing hazardous substance release, enhancing safety and reducing the risk to vehicle occupants.
Implementation Method 1
deformation elements, such as hollow profiles or foamed bodies, strategically arranged between battery cells to absorb energy by deforming under external forces
Implementation Method 2
the at least one deformation element is formed either as a hollow profile, the inner volume of which can be collapsed during deformation
Implementation Method 3
or as a foamed body is formed, which forms in its entire volume a plurality of cavities which are collapsible under the action of a force
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a battery pack comprising a plurality of battery elements (1) which are packed next to each other in at least one packing layer, wherein at least one deformation element (2) is arranged at least partially within a packing layer between at least two adjacent battery elements (1), in particular wherein the battery elements (1) are displaceable under an external force by deformation of deformation elements (2).