Collapsible Side Beam Structure for Battery Pack Impact Protection
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Solution Overview
Problem
Traditional battery packs are expensive and susceptible to failure due to inadequate protection from external forces, which can damage the battery cells.
Innovation Solution
The battery pack incorporates a side beam with interconnected elements forming a web that collapses in response to excessive force, providing energy absorption and protection to the battery cells, using ductile materials like aluminum or steel that can sustain significant plastic deformation before fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional componentry is used to protect battery cells from external forces, then protection is provided, but cost increases and susceptibility to failure remains
Solution Approach 1:
The side beam integrates structural support function with energy absorption function into a single component. The web structure merges the protective enclosure function with the crashworthiness function, eliminating the need for separate protective componentry while reducing cost and failure susceptibility.
Solution Approach 2:
The side beam is designed to utilize the harmful external force by allowing controlled collapse of the web structure. This converts the harmful impact energy into beneficial plastic deformation of the ductile material, protecting the battery cells while reducing the need for expensive protective componentry.
2Reliability
If rigid protective structures are used, then protection is improved, but weight increases
Solution Approach 1:
The side beam transitions from a static rigid structure to a dynamic structure that adapts its stiffness based on applied load. During normal operation, the web structure provides sufficient rigidity for protection. During impact, the structure dynamically collapses to absorb energy, reducing weight compared to continuously rigid protective structures.
Solution Approach 2:
The effective stiffness parameter of the side beam changes during impact through controlled plastic deformation. The ductile material allows the structure to transition from a high-stiffness protective state to a low-stiffness energy-absorbing state, providing protection while minimizing weight compared to permanently rigid structures.
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 effectively absorbs and mitigates mechanical loads, reducing the risk of damage to battery cells and potentially lowering the overall weight of the battery pack compared to traditional systems.
Implementation Method 1
using ductile materials like aluminum or steel that can sustain significant plastic deformation before fracture
Data Source
AI summary
A battery pack includes an enclosure defining an enclosure interior, a stack of battery cells disposed in the enclosure interior between a first wall of the enclosure and a second wall of the enclosure, and a side beam extending from the first wall to the second wall and adjacent to the stack of battery cells. The side beam includes a plurality of interconnected elements forming a web, where a portion of the web is configured to collapse in response to a force against a side of the battery pack exceeding a threshold force.