Wavelike Battery Protector Structure for Underfloor Impact Loads
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Solution Overview
Problem
Existing battery protectors for electric vehicles, particularly those under the vehicle floor, are inefficient in absorbing high punctual impact loads and consume excessive space, impacting vehicle parameters like ground clearance and height, and are not optimized for energy distribution during deformation.
Innovation Solution
A battery protector system comprising a top belt, bottom belt, and core made from materials like aluminum, steel, and fiber-reinforced composites, with a wavelike cross-section to efficiently distribute and absorb impact energy through elastic and/or plastic deformation, reducing the risk of damage to battery modules and minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal or composite protectors are used to absorb impact energy, then protection reliability is improved, but device volume and height increase significantly
Solution Approach 1:
The patent changes the material parameters by using foam material with specific density ranges (50-150 kg/m³) and optimizes geometric parameters including wavelength (0.05-0.2 times protector length), amplitude (0.02-0.1 times protector length), and wall thickness (0.01-0.05 times amplitude). These parameter optimizations enable the foam protector to achieve effective impact energy absorption with significantly reduced volume compared to traditional solid metal or composite protectors.
Solution Approach 2:
The patent employs composite structure by combining foam material with outer protective layers or coatings. The foam core provides energy absorption through cellular deformation, while outer layers provide structural integrity and surface protection. This composite approach achieves high protection reliability with compact dimensions.
2Reliability
If deformable cooling conduits are used for impact absorption, then protection reliability is improved, but ground clearance and vehicle height are reduced
Solution Approach 1:
The patent optimizes the foam protector geometry parameters including wavelength, amplitude, and overall height to achieve effective impact absorption with minimal height. The wavelength is set to 0.05-0.2 times the protector length and amplitude to 0.02-0.1 times the protector length, enabling compact design that preserves ground clearance while maintaining protection reliability.
Solution Approach 2:
The patent employs sinusoidal waveforms and curved geometries in the foam protector design. The wavy structure with optimized curvature radii enables progressive deformation during impact, absorbing energy efficiently within a compact height envelope, thereby maintaining adequate ground clearance.
3Strength
If rigid resistant structures are used for impact protection, then local stress resistance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent optimizes the foam material density parameters (50-150 kg/m³) and geometric parameters (wall thickness 0.01-0.05 times amplitude, cell structure characteristics) to achieve adequate local stress resistance. The foam's cellular structure provides progressive deformation under localized impact, distributing stresses effectively without requiring complex rigid structural elements.
Solution Approach 2:
The patent utilizes foam material with controlled porosity and cellular structure. The porous foam compresses progressively under impact loads, absorbing energy through cell collapse and material deformation. This porous structure provides effective local stress resistance while maintaining simple geometry and ease of manufacturing compared to rigid resistant structures.
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 system effectively reduces the risk of damage from high local stress impacts, such as from an immovable traffic bollard, by optimizing energy distribution and minimizing space requirements, while maintaining structural integrity and reducing the risk of external objects reaching the battery module.
Implementation Method 1
The protector according to the present disclosure offers optimized distribution of the occurring energy into the structure by a combination of elastic and/or plastic deformation
Implementation Method 2
The protector according to the present disclosure offers optimized distribution of the occurring energy into the structure by a combination of elastic and/or plastic deformation
Data Source
AI summary
The present disclosure relates to a battery structure for an electric vehicle. The battery structure comprises a battery case for at least one battery module and a protector interconnected to the battery case including a top belt, a bottom belt and a core arranged between and interconnecting the top belt and the bottom belt.