Numerical Investigation of Horseshoe Lattice Structures for Crashworthiness Improvement of a Battery Frame
摘要
Lattice structures are increasingly being explored for their potential to improve the crashworthiness of battery frames in electric vehicles (EVs). They can be used in the design of battery housings to enhance protection against crashes, explosions, and fires. This study introduces a novel approach to enhance the crashworthiness and mechanical performance of an electric vehicle (EV) battery frame by integrating a metastructure based on horseshoe curved elements into a battery protection frame. These structures offer high strength and stiffness while maintaining a low mass, making them suitable for various applications, including shock absorption in automobiles. Using finite element method (FEM) simulations, a side-pole impact scenario was examined considering four different types of battery protection frames. The cross-section of a rectangular frame is reinforced in the first case with rectangular elements and in the next cases with horseshoe structures. The battery frame, constructed from aluminum, houses a representative volume of battery cells defined through a homogenization process derived from individual and pack cell crash tests. The crashworthiness was assessed by measuring the overall intrusion into the representative volume. Inspired by quilling techniques, the horseshoe metamaterial exhibits nonlinear mechanical responses and densification behavior before failure under static and impact conditions, contributing to the overall structural integrity and safety of the battery enclosure. This study demonstrates that this innovative design, based on bending-dominant metamaterials, reduces intrusion and improves the stiffness of the battery frame during static and dynamic events.