Pneumatic Impact Element for Vehicle Battery Protection

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Solution Overview

Problem

Existing solutions for protecting traction batteries in motor vehicles during impacts, such as rigid cages and fluid-filled deformation elements, either increase the vehicle's weight or are inadequate in absorbing deformation energy, posing risks to occupants due to voltage surges.

Innovation Solution

A gas-tight impact element with compressed air chambers and safety openings, integrated into the vehicle's supporting frame, which absorbs impact energy uniformly and directs compressed air for controlled release, enhancing stability and safety without significant weight increase.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid cage is used to protect the traction battery, then the protection reliability is improved, but the vehicle weight increases significantly

Engineering Contradiction:

Improveprotection reliabilityVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent uses a pneumatic cushioning system with compressible gas chambers instead of a rigid cage. The gas chambers can be compressed during impact to absorb energy, providing protection while maintaining low weight. The system includes gas supply devices that can inflate the chambers before impact to maximize cushioning effect.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent changes the physical state and compressibility parameters of the protective structure. By using gas-filled chambers with variable pressure and compressibility, the system provides rigid protection when inflated and compliant cushioning during impact, resolving the contradiction between protection reliability and weight.

Inventive Principle:

Principle #35Parameter changes

2Loss of energy

If a fluid-filled deformation element is used, then the deformation energy absorption is improved, but the vehicle weight increases

Engineering Contradiction:

Improvedeformation energy absorptionVSAvoidvehicle weight

Core Design Contradiction:

Loss of energyVSWeight of moving object

Solution Approach 1:

The patent replaces heavy liquid fluids with compressible gas in the deformation elements. The gas chambers can be compressed to absorb deformation energy while being significantly lighter than fluid-filled alternatives. The system maintains energy absorption capability through gas compression rather than fluid displacement.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent uses composite structures combining rigid housing with compressible gas-filled chambers. This composite approach provides both the structural integrity needed for protection and the energy absorption capability through gas compression, while minimizing weight compared to solid or fluid-filled alternatives.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If a rigid structure is used for impact protection, then the stability is improved, but the deformation energy absorption capability deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoiddeformation energy absorption

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The patent transforms the static rigid structure into a dynamic system with compressible gas chambers. The chambers can adapt their compression level based on impact force, providing structural stability during normal operation and energy absorption during impact. The system transitions from rigid to compliant state during deformation events.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent pre-inflates gas chambers before impact to create a cushioning effect. The compressed gas is stored in advance and ready to absorb impact energy when needed, providing both structural stability during normal use and deformation energy absorption during impact events.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The solution effectively absorbs deformation energy and protects traction batteries from damage, improving passive safety by distributing impact forces and ensuring controlled air release, thus reducing the risk of voltage surges and maintaining low vehicle weight.

Implementation Method 1

A gas-tight impact element with compressed air chambers and safety openings, integrated into the vehicle's supporting frame

Methodology Applied

Scientific EffectCompressed air storage: Compression

Implementation Method 2

The solution effectively absorbs deformation energy and protects traction batteries from damage, improving passive safety by distributing impact forces

Methodology Applied

Scientific EffectImpact energy absorption: Impact Force

Implementation Method 3

The chamber may have at least one safety opening that designed to conduct away the compressed air if the chamber has been damaged

Methodology Applied

Scientific EffectControlled air release: Pressure Gradient

Data Source

PatentUS9254873B2Impact element and supporting frame for a motor vehicle

Publication Date: 2016.02.09 DR ING H C F PORSCHE AG

AI summary

An impact element (10) for a motor vehicle (70) has a flat basic body (12) formed from a rigid material and has connecting sections (16) on one side (50) to fix the basic body (12) to a supporting frame (72) of the motor vehicle (70). The basic body (12) has a gas-tight chamber (24) in which at least one opening (26) is formed to fill the chamber (24) with compressed air.