Offset Crash Elements for Electric Vehicle Battery Protection
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Solution Overview
Problem
Electric vehicle batteries are vulnerable to damage in collisions, which can lead to explosions and fires due to their large size and the potential for impact forces to be directly applied to them, necessitating enhanced protection structures.
Innovation Solution
A crash elements structure comprising upper and lower shells with hexagonal apertures, a 'W' structure that channels energy away from the battery, and additional 'S' structures to distribute and absorb impact forces, made from materials like carbon fiber, positioned to reduce the impact on the battery during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crash elements structure is added to protect the battery, then safety is improved, but device complexity increases
Solution Approach 1:
The crash elements structure is divided into multiple discrete components including upper and lower offset elements, side elements, and triangular elements. Each segment is positioned at specific locations around the battery to provide targeted protection while maintaining manufacturing simplicity and assembly efficiency.
2Reliability
If the crash elements structure is positioned close to the battery, then protection effectiveness is improved, but the risk of direct impact transmission increases
Solution Approach 1:
The offset elements are designed with specific geometries and positioning that create a cushioning effect before impact forces reach the battery. The structure absorbs and dissipates energy through controlled deformation of the offset elements, reducing the peak forces transmitted to the battery while maintaining close proximity for effective protection.
Data Source
AI summary
A crash elements structure in an electric vehicle for reducing the damage to a vehicle battery caused by a vehicle collision. The crash elements structure may be situated near a corner of the vehicle battery, and may channel energy received by the vehicle away from the vehicle battery. The crash elements structure includes an upper structure positioned above and laterally offset from a lower structure, and a “W” structure that interfaces between the vehicle battery and the upper and lower structures. The upper and lower structures include several shells coupled together to form hexagonal apertures. The specific arrangement of the shells and the upper and lower structures influences the transfer of energy through the crash elements structure in the event of a collision.