EV Battery Support Structure for Crash Loads and Cell Swelling
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Solution Overview
Problem
Existing energy storage devices in electrically powered vehicles face challenges in crash safety due to the transmission of external forces to the battery cell stack through tensioning or clamping elements, which can damage the cells, and age-related expansion (cell swelling) affects their service life.
Innovation Solution
A support device comprising a first and second support element with wedge-shaped cross-sections is used to absorb external forces and swelling pressures, directing them away from the battery cell stack, integrated with a stiffening strut to enhance crash safety and extend the battery's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If tensioning or clamping elements are used to counteract cell swelling, then the service life of battery cells is extended, but crash safety deteriorates because external forces are transmitted to the battery cell stack
Solution Approach 1:
The patent introduces support elements as intermediary components between the battery cell stack and the battery housing. These support elements act as mediators that absorb and distribute external forces during crashes, preventing direct force transmission to the battery cells while also providing support against cell swelling, thus resolving the contradiction between crash safety and service life extension
Solution Approach 2:
The support elements are pre-installed between the battery cell stack and the battery housing to provide beforehand cushioning. During a crash, these elements absorb impact forces before they can reach the battery cells, and during normal operation, they provide continuous support against cell swelling, thereby simultaneously improving crash safety and extending service life
2Ease of manufacture
If cell swelling is allowed to occur naturally, then manufacturing simplicity is maintained, but service life deteriorates due to detrimental effects of expansion on battery cells
Solution Approach 1:
The support elements serve as intermediary components that provide mechanical support to the battery cell stack, counteracting the detrimental effects of cell swelling without requiring complex manufacturing processes. The elements are simply positioned between the battery housing and the battery cell stack, maintaining manufacturing simplicity while extending service life
Solution Approach 2:
The support elements modify the mechanical parameter landscape by providing distributed support forces that counteract cell swelling. This allows the battery system to maintain simple manufacturing processes while achieving extended service life through controlled mechanical parameter changes in the support structure
3Quantity of substance
If the battery cell stack is directly integrated into the battery housing, then energy density increases and part count is reduced, but crash safety worsens because there is no protection against external forces
Solution Approach 1:
The support elements are introduced as intermediary components between the battery cell stack and the battery housing. These elements maintain the direct integration approach for high energy density while simultaneously providing crash protection by absorbing and distributing external forces, thus resolving the contradiction between energy density and crash safety
Solution Approach 2:
The support elements provide beforehand cushioning in the integrated battery design, absorbing crash forces before they reach the battery cells. This allows the system to maintain the space-efficient direct integration approach while adding crash protection, thereby simultaneously achieving high energy density and improved crash safety
Data Source
AI summary
The invention relates, inter alia, to an energy storage device (10) for an electrically powered motor vehicle. A first support element (18) is arranged between one end (20) of a stiffening strut (16) and a battery housing (14).The first support element (18) supports the stiffening strut (16) on the battery housing (14), wherein a cross-section of the first support element (18) increases from the end (20) of the stiffening strut (16) towards the battery housing (14).A second support element (26) is arranged between a battery cell stack end side (13) and the battery housing (14). The second support element (26) supports the battery cell stack (12) on the battery housing (14), wherein a cross-section of the second support element (26) decreases from the battery cell stack end side (13) towards the battery housing (14).