Battery Support Extrusions for Impact Energy Absorption
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Solution Overview
Problem
Existing battery support structures for high voltage battery packs in electric vehicles lack effective energy absorption capabilities, particularly in new vehicle configurations with varying packaging spaces.
Innovation Solution
A battery support structure comprising a first extrusion along the longitudinal sides and a second extrusion connected to the first, featuring discrete energy absorption structures and hollow chambers, which absorb impact loads and facilitate load path management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery support structures are used, then manufacturing cost is reduced, but energy absorption capability during impact loads is insufficient
Solution Approach 1:
The support structure is divided into multiple extrusions (first extrusion along longitudinal sides, second extrusion along lateral sides) with discrete energy absorption structures spaced apart along each extrusion. This segmentation allows the structure to absorb impact loads through controlled deformation of individual segments while maintaining overall structural integrity and managing complexity through modular design.
Solution Approach 2:
The support structure combines different geometric configurations (hollow chambers, curved walls, straight walls) within the extrusions to create a composite structural system. The first and second extrusions work together as a composite system, where each extrusion contributes different structural characteristics to achieve optimal energy absorption while managing overall complexity.
2Reliability
If existing battery support structures are used, then structural simplicity is maintained, but protection of battery internals during impact events is inadequate
Solution Approach 1:
The discrete energy absorption structures are pre-configured within the first and second extrusions to absorb impact loads before they reach the battery cells. The hollow chambers and curved wall configurations are designed in advance to deform controllably during impact events, providing predetermined cushioning protection for the battery internals while maintaining a relatively simple overall support structure.
Solution Approach 2:
Energy absorption capabilities are concentrated at specific locations where the discrete energy absorption structures are positioned along the extrusions. The curved wall portions are strategically placed to provide enhanced local protection, while straight wall portions maintain structural simplicity in areas requiring less energy absorption, thus protecting battery internals without requiring complex structures throughout the entire support system.
3Adaptability or versatility
If battery support structures are designed for specific vehicle configurations, then packaging space optimization is achieved, but adaptability to wider vehicle platform configurations is limited
Solution Approach 1:
The first and second extrusions are designed with universal applicability across different vehicle platform configurations. The discrete energy absorption structures can be spaced at various intervals along the extrusions to accommodate different packaging spaces, and the curved or straight wall configurations can be selected based on specific vehicle requirements. This multi-functional design allows the same basic support structure to be adapted to wider or narrower vehicle platforms without requiring complete redesign, maintaining ease of manufacture through standardized components.
Solution Approach 2:
The support structure incorporates design flexibility that allows it to adapt dynamically to different vehicle configurations. The spacing of discrete energy absorption structures, the selection of curved versus straight wall portions, and the arrangement of hollow chambers can be adjusted based on the specific packaging constraints of different vehicle platforms. This dynamic adaptability enables integration across wider vehicle families while maintaining cost-effectiveness through modular design principles.
Data Source
AI summary
An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery support structure to support a plurality of battery cells, wherein the battery support structure includes opposing longitudinal sides and opposing lateral sides. A first extrusion is positioned to extend along at least one of the opposing longitudinal and lateral sides. A second extrusion is connected to the first extrusion such that the first extrusion is located between the plurality of battery cells and the second extrusion.