Waveform Battery Protecting Member for EV Impact Absorption
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Solution Overview
Problem
Existing battery protection systems for electric vehicles require significant space and are complex, often made from metal or composite materials that are less effective for high punctual impact loads, and necessitate additional ballistic shields, complicating manufacturing and vehicle design.
Innovation Solution
A protecting member comprising a top belt with a waveform, a bottom belt, and a core made from a fiber-reinforced polyurethane foam, which absorbs impact energy through elastic and plastic deformation, providing efficient energy absorption with a simpler construction and reduced vertical space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery structure for an electric vehicle is used, then the vehicle can operate electrically, but the battery may overheat or catch fire due to external impacts or internal defects
Solution Approach 1:
The patent applies beforehand cushioning by providing a protecting member that prevents external objects from directly impacting the battery pack. The protecting member is positioned between potential external hazards and the battery, cushioning against future impacts before they can cause thermal runaway or fire.
Solution Approach 2:
The protecting member serves as an intermediary element between external objects and the battery pack. It mediates the interaction by absorbing or deflecting impact forces, preventing direct contact between harmful external objects and the battery cells, thereby eliminating the fire hazard without modifying the battery structure itself.
2Reliability
If the battery pack structure is reinforced to prevent impact, then safety improves, but the weight and complexity of the vehicle increase
Solution Approach 1:
The patent applies segmentation by separating the protection function from the battery pack structure itself. The protecting member is a distinct, independent component that provides impact resistance without requiring the battery pack housing to be heavier or more complex. This modular approach allows protection to be added without increasing overall vehicle weight significantly.
Solution Approach 2:
The protection function is extracted from the battery pack structure and implemented as a separate protecting member. This extraction allows the battery pack to maintain its original lightweight design while still gaining impact resistance through the dedicated protecting member, avoiding the need to reinforce the entire battery structure.
3Reliability
If a protecting member is added to prevent external objects from impacting the battery, then safety improves, but the device complexity increases
Solution Approach 1:
The protecting member is designed with universality, serving multiple functions simultaneously: it prevents external object impact, maintains proper spacing between the battery and external environment, and can be integrated with existing vehicle structures. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The protecting member is implemented as a relatively simple structural component that can be made from thin, lightweight materials. This approach provides effective protection without adding significant complexity to the battery structure, as the protecting member can be designed as a simple overlay or attachment rather than a complex multi-component system.
Data Source
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AI summary
The invention relates to a protecting member (1) for a battery structure (2) of an electric vehicle. The protecting member (1) comprises a top belt (3) having a wave form, a bottom belt (4) and a core (5) arranged between and interconnecting the top belt (3) and the bottom belt (4). The core (5) is at least partially made from a first core material comprising a lose network of fibers embedded in a foam.