Sandwich Structure Design of a Cooling Fin for Battery Modules Against Impact Loads
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Sandwich Structure Design of a Cooling Fin for Battery Modules Against Impact Loads Zitong Shi1,2 · Guanhua Chen1 · Lingxiao Zhu1 · Jie Li2 · Yong Xia1,2 Received: 25 March 2020 / Accepted: 1 July 2020 © China Society of Automotive Engineers (China SAE) 2020
Abstract Lithium-ion batteries (LIBs) are widely employed in electric vehicles owing to their high power density, long cycle life, and environmental friendliness. However, LIBs are hazardous in the event of a crash, leading to thermal runaway. In this study, the basic structure of a battery module is analyzed to improve the crashworthiness of LIBs. A simplified finite element model of the battery module structure, which is a battery unit composed of two pouch cells and a cooling fin, is set up and verified by conducting module-level simulations. The simulation results reveal that the cooling fin in the battery module has the potential to absorb energy. Six sandwich configurations are introduced to modify the cooling fin. With a unidirectionally stiffened double hull USDH structure serving as an example, a parametric analysis is conducted, demonstrating that the sandwich height does not influence the areal density; a small height of 3 mm can make the material work sufficiently while avoiding early buckling of the structure. Further, the crashworthiness of different sandwich configurations with the same areal density and height is compared, leading to three deformation modes. USDH and circular core structures are found to be able to effectively reduce the peak force and improve the energy absorption ability. Keywords Lithium-ion battery · Impact protection · Sandwich configuration · Cooling fin Abbreviations BRAS Blast-resistant adaptive sandwich LIB Lithium-ion batteries USDH Unidirectionally stiffened double hull
1 Introduction The lithium-ion batteries (LIBs) used in electric vehicles have high power density and are prone to thermal runaway. To avoid explosions and fire accidents in the event of collision, it is vital to design a safe and lightweight battery protection structure. The mechanical response of LIBs has been widely studied in the design of battery protection structures [1, 2]. Sahraei et al. [3, 4] and Greve and Fehrenbach [5] carried out quasi-static tests on cylindrical and pouch cells under different loading and constraint conditions and * Yong Xia [email protected] 1
State Key Laboratory of Automotive Safety and Energy, Tsinghua University, Beijing 100084, China
State Key Laboratory of Vehicle NVH and Safety Technology, Chongqing 401120, China
2
obtained the relationship between short circuit and mechanical response. Sahraei et al. [3, 6, 7] established a homogenized model of a jellyroll and a finite element model of a battery cell. Greve and Fehrenbach [5] introduced the Mohr–Coulomb failure criterion into the battery model and verified it. Lai et al. [8–10] established a representative volume element model to analyze the deformation mode of batteries under in-plane compression. Xu et al. [11, 12] and Wang et al. [13, 14
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