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DE-102024137199-A1 - Accident energy absorption arrangement for an electric vehicle and method thereof

DE102024137199A1DE 102024137199 A1DE102024137199 A1DE 102024137199A1DE-102024137199-A1

Abstract

The present disclosure provides a crash energy absorption arrangement and a method for reducing the transmission of impact forces to one or more battery cells (104) of an electric vehicle during an accident. The crash energy absorption arrangement (100) comprises a battery housing (102) suitable for mounting one or more battery cells (104) of the electric vehicle and at least one crash element (108) rigidly coupled to a lateral surface of the battery housing (102) to reduce the transmission of impact forces to the one or more battery cells (104) when the electric vehicle is subjected to an impact. A plurality of bending beams (110) is coupled to the at least one crash element (108) such that the plurality of bending beams (110) are spaced apart from one another to allow progressive absorption of the impact forces.

Inventors

  • Sunil Amberkar
  • Meenakumari Lakshman Singh
  • Anil Bodaindala

Assignees

  • Mercedes-Benz Group AG

Dates

Publication Date
20260513
Application Date
20241211
Priority Date
20241111

Claims (10)

  1. Crash energy absorption arrangement (100) for an electric vehicle, comprising: a battery housing (102) suitable for mounting one or more battery cells (104) of the electric vehicle; at least one crash element (108) rigidly coupled to a lateral surface () of the battery housing (102) to reduce the transmission of impact forces to the one or more battery cells (104) when the electric vehicle is subjected to a crash; and a plurality of bending beams (110) coupled to the at least one crash element (108) such that the plurality of bending beams (110) are spaced apart to allow progressive absorption of the impact forces.
  2. Accident energy absorption arrangement (100) according to Claim 1 , wherein the at least one accident element (108) has a side wall with a plurality of wave projections (204) facing the lateral surface () of the battery housing (102).
  3. Accident energy absorption arrangement (100) according to Claim 1 , wherein the at least one accident element (108) comprises a support element (202) connected to a load-bearing structure of the electric vehicle.
  4. Accident energy absorption arrangement (100) according to Claim 1 , wherein each of the multiple bending beams (110) comprises multiple bending plates (302), wherein at least two adjacent bending plates (302) of the multiple bending plates (302) are connected to each other by a bent bending plate (304) at a predetermined distance.
  5. Accident energy absorption arrangement (100) according to Claim 4 , wherein the predetermined spacing for the curved bending plates (304) of the plurality of bending beams (110) is selected on the basis of the impact forces to be absorbed by the plurality of bending beams (110) when the electric vehicle is subjected to impact.
  6. Arrangement (100) for accident energy absorption according to Claim 1 , wherein each of the multiple bending beams (110) is designed to deform and absorb the impact forces applied to it when the electric vehicle is subjected to an accident, in order to enable the at least one accident element (108) to reduce the transmission of the impact forces to the one or more battery cells (104).
  7. Accident energy absorption arrangement (100) according to Claim 1 , wherein the multiple bending beams (110) are fitted into a cavity (206) which is formed in the at least one accident element (108).
  8. Method (400) for reducing the transmission of impact forces to one or more battery cells (104) of an electric vehicle, comprising the following steps: fastening the one or more battery cells (104) in a battery housing (102); fastening at least one crash element (108) to a lateral surface () of the battery housing (102) to prevent the impact forces from being transmitted to the one or more battery cells (104) when the electric vehicle is subjected to a crash; and coupling a plurality of bending beams (110) to the at least one crash element (108) such that the plurality of bending beams (110) are spaced apart to allow progressive absorption of the impact forces.
  9. Procedure (400) according to Claim 8 , wherein: each of the multiple bending beams (110) comprises multiple bending plates (302), wherein at least two adjacent bending plates (302) of the multiple bending plates (302) are connected to each other by a curved bending plate (304) at a predetermined distance, and the coupling step comprises selecting the predetermined spacing for the curved bending plates (304) of the plurality of bending beams (110) based on the impact forces to be absorbed by the plurality of bending beams (110) when the electric vehicle is subjected to the accident.
  10. Procedure (400) according to Claim 8 , which further includes the fact that the multiple bending beams (110) absorb the impact forces supplied to them when the electric vehicle is subjected to an accident by deformation of the multiple bending beams (110) in order to enable the at least one bending beam (108) to reduce the transmission of the impact forces to the one or more battery cells (104).

Description

TECHNICAL AREA The present disclosure relates to electric vehicles. In particular, the present disclosure relates to a crash energy absorption arrangement configured to improve the safety and structural integrity of battery packs installed in electric vehicles during collision events, and to a method for reducing the transmission of impact forces to the battery packs. BACKGROUND With the increasing shift of the automotive industry to electric vehicles (EVs), the importance of effective safety measures is growing. A key aspect of EV safety is the protection of the battery pack, which is typically located beneath the vehicle floor or chassis. This battery pack serves as the primary power source and also plays a vital structural role. In the event of a collision, the integrity of the battery pack is crucial for both the safety of the occupants and the overall performance of the vehicle. Conventional vehicles are often equipped with various energy absorption systems to reduce the forces generated in a crash. These systems typically include crumple zones, reinforced frames, and other structural enhancements to manage energy transfer and minimize occupant injuries. However, these existing solutions may not be able to address the specific challenges associated with the unique design and placement of battery packs in electric vehicles. Furthermore, the increasing weight and complexity of battery systems in electric vehicles present new crash safety challenges. There is an urgent need for an effective crash energy absorption approach that does not compromise vehicle performance, battery integrity, or safety standards. Existing energy absorption technologies typically rely on passive structural modifications that may not provide optimal protection for the battery pack during severe impacts. Furthermore, many designs fail to adequately consider the specific geometry and location of the battery pack, increasing the risk of battery housing failure or even thermal runaway in severe collisions. Additionally, many existing solutions are heavy or complex, which can negatively impact the vehicle's range and efficiency. Furthermore, high-voltage batteries for electric vehicles are increasingly designed as structural components, which contributes to weight reduction and increased energy density. However, these structural and load-bearing batteries must also absorb forces in a crash, resulting in additional stress on the battery cells. Internal specifications require minimal cell deformation to avoid critical issues such as cell outgassing and subsequent thermal runaway. In current designs with cylindrical cells or cells of other form factors arranged in varying patterns, the structural components often direct the forces of a side impact to one side of the cells, leading to excessive deformation in a crash. In the patent specification US11541935B2 A vehicle frame for an electric vehicle is described, comprising a pair of longitudinal members spaced apart to create a compartment for the battery. A side impact attenuator is attached to one of these longitudinal members. The first component of the side impact attenuator is attached to the outer side wall of the first longitudinal member and forms a primary load path for absorbing impact forces directed at the longitudinal member. This first component has a corrugated shape and extends outward from the outer side wall to the outer end of the side impact attenuator. A second component of the side impact attenuator is attached to the outer side wall of the first longitudinal member and is positioned higher than its center. This second component forms a secondary load path for absorbing impact forces from the outer end of the side impact attenuator back to the first longitudinal member. However, as is clearly evident from the aforementioned patent specification, the side impact damper only acts as a damper for the impact force transferred to it in an accident and is inefficient when it comes to reducing the impact forces transferred to a battery pack installed under the floor or chassis of the electric vehicle. Given the challenges described above, there is an urgent need for a reliable solution to improve the structural integrity of battery packs in electric vehicles, addressing the shortcomings and disadvantages of conventional technologies. This solution should not only protect the battery pack in a collision but also maintain the overall efficiency and performance of the electric vehicle. Furthermore, the The structural integrity of the battery pack must be maintained to ensure its safety and reliability. SUBJECT OF THE PRESENT DISCLOSURE A general objective of the present disclosure is to provide an accident energy absorption arrangement for maintaining the structural integrity of a battery pack installed in an electric vehicle, as well as a method for reducing the transmission of impact forces to the battery pack. One objective of this disclosure is to provide a reliable solutio