Polymeric Side-Impact Reinforcement for Battery Case Protection
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Solution Overview
Problem
Battery cases in vehicles require improved impact-resistance, particularly against side impacts, to prevent fire hazards.
Innovation Solution
A reinforcement member comprising interconnected reinforcement elements with plates and layers of hollow cells, connected by material bonds and/or form/force-fits, designed to absorb and dissipate energy during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional reinforcement structures are used, then the structure provides basic strength, but the impact resistance particularly against side impacts is insufficient
Solution Approach 1:
The reinforcement member is divided into multiple reinforcement elements (first, second, third elements) with distinct functions: energy absorption through hollow cells, structural strength through plates, and connectivity through interconnection. This segmentation allows each element to specialize in specific protective functions, significantly improving impact resistance compared to conventional unified structures.
Solution Approach 2:
The reinforcement member combines different material properties within a single structure: hollow cells for energy absorption, plates for structural integrity, and polymeric materials for flexibility and weight reduction. This composite approach creates a multi-functional reinforcement system that simultaneously achieves high impact resistance, fire protection, and weight efficiency.
2Strength
If thicker plates are used to improve strength, then the impact resistance increases, but the weight of the reinforcement member increases
Solution Approach 1:
The reinforcement elements incorporate hollow cells with controlled porosity that provide exceptional strength-to-weight ratio. The hollow structure absorbs impact energy through controlled deformation while maintaining low weight, replacing the need for thick solid plates and achieving both high impact resistance and weight reduction.
Solution Approach 2:
The reinforcement member is divided into multiple elements with specialized functions, allowing the use of thinner individual plates that collectively provide superior protection. The segmentation enables optimization of each element's thickness and material properties, reducing overall weight while maintaining or improving impact resistance.
3Strength
If a solid monolithic reinforcement structure is used, then the structure provides uniform strength, but the energy absorption capability during impact is limited
Solution Approach 1:
The reinforcement member is segmented into multiple elements where specific elements (with hollow cells) are dedicated to energy absorption while others provide structural integrity. This functional segmentation allows the structure to simultaneously absorb impact energy and maintain structural strength, overcoming the limitations of monolithic designs.
Solution Approach 2:
The combination of hollow cell structures and solid plates creates a composite reinforcement system where different material configurations perform different functions: hollow cells absorb energy through controlled collapse, while plates maintain structural integrity. This composite approach achieves both high energy absorption and structural strength.
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 reinforcement member effectively absorbs and dissipates energy during impacts, protecting the battery case by rotating and twisting, thereby maintaining its integrity and preventing damage.
Implementation Method 1
designed to absorb and dissipate energy during impacts
Implementation Method 2
The reinforcement member effectively absorbs and dissipates energy during impacts, protecting the battery case by rotating and twisting
Implementation Method 3
protecting the battery case by rotating and twisting, thereby maintaining its integrity and preventing damage
Data Source
AI summary
The present invention relates to a reinforcement member made from a polymeric material. The present invention further relates to a vehicle comprising the reinforcement member, a method to absorb an impact on vehicle and a method to produce the reinforcement member.