Topologically Interlocked Battery Enclosure for Impact Resistance

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Solution Overview

Problem

Conventional battery pack enclosures for electric vehicles are bulky, add weight, and provide inadequate protection against impact forces in multiple directions, potentially endangering vehicle occupants during collisions.

Innovation Solution

The development of enclosure arrangement systems featuring kinetic energy absorbing elements, high-shear battery enclosures, and topologically interlocked materials to distribute and dissipate impact forces effectively, protecting battery cells and occupants by converting kinetic energy into frictional and strain energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional enclosures are used to protect battery cells during collision, then battery pack protection is improved, but vehicle occupant safety deteriorates due to increased acceleration

Engineering Contradiction:

Improvebattery pack protectionVSAvoidoccupant acceleration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The battery pack enclosure is divided into modular units, each containing a subset of battery cells surrounded by kinetic energy absorbing elements. This segmentation allows the impact force to be distributed across multiple independent modules rather than transmitted as a single concentrated force to the vehicle structure, thereby protecting both the battery pack and reducing occupant acceleration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Kinetic energy absorbing elements are introduced as intermediary components between the battery cells and the external impact environment. These elements serve as a buffer that absorbs impact energy through deformation, preventing direct transmission of collision forces to both the battery pack and vehicle occupants.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If heavy enclosures are added to protect the battery pack, then crashworthiness is improved, but vehicle range deteriorates due to increased weight

Engineering Contradiction:

ImprovecrashworthinessVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The kinetic energy absorbing elements utilize material parameter optimization and geometric design to achieve high energy absorption efficiency at reduced mass. By changing the physical parameters of the absorbing elements (such as density, elasticity, and structural configuration), the system achieves effective impact protection without the excessive weight of conventional enclosures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The enclosure system employs composite material structures combining different materials with complementary properties. The kinetic energy absorbing elements are made from materials optimized for energy dissipation, while the frame uses structurally efficient materials, creating a lightweight yet highly effective protective system that does not compromise crashworthiness.

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional enclosures are designed for single-direction protection, then protection in that direction is improved, but multi-directional protection deteriorates

Engineering Contradiction:

Improvedirectional protectionVSAvoidmulti-directional protection

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The kinetic energy absorbing elements are designed with multi-functional capabilities, serving as both impact absorbers and structural connectors. Each element is configured to effectively absorb kinetic energy from impacts arriving from multiple directions, enabling the battery pack to achieve comprehensive protection without requiring separate directional shielding systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The enclosure system incorporates dynamic response characteristics where the kinetic energy absorbing elements can adapt their deformation behavior based on the direction and magnitude of applied impact forces. This dynamic flexibility allows the structure to effectively mitigate impacts from various directions while maintaining overall structural integrity.

Inventive Principle:

Principle #15Dynamics

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

These systems enhance crashworthiness by reducing vehicle acceleration and improving occupant safety during collisions, while minimizing weight and maintaining battery performance.

Implementation Method 1

converting kinetic energy into frictional and strain energy

Methodology Applied

Scientific EffectKinetic energy absorption: Friction

Implementation Method 2

converting kinetic energy into frictional and strain energy

Methodology Applied

Scientific EffectStrain energy: Deformation

Implementation Method 3

high-shear battery enclosures, and topologically interlocked materials to distribute and dissipate impact forces effectively

Methodology Applied

Scientific EffectShear deformation: Shear Stress

Data Source

PatentUS11050114B2Impact resistant battery enclosure systems

Publication Date: 2021.06.29 PURDUE RES FOUND

AI summary

Battery enclosure arrangements for a vehicular battery system. The arrangements, capable of impact resistance include plurality of battery cells and a plurality of kinetic energy absorbing elements. The arrangements further include a frame configured to encase the plurality of the kinetic energy absorbing elements and the battery cells. In some arrangements the frame and/or the kinetic energy absorbing elements can be made of topologically interlocked materials.