Comprehensive Optimization and Design of an Electric Vehicle Battery Box Side Profile for Lightweight and Crashworthiness Using a Novel Hybrid Structure

Lightweighting is a critical focus in the transportation sector, directly enhancing efficiency and significantly reducing costs. In electric vehicle (EV) design, the body surrounding the battery must effectively absorb impact, especially during crashes. This study aims to improve the crash performance of the side profiles in the battery box of an M1 category vehicle. It is based on the crash test in Annex 8D of the ECE R100 regulation. In this study, the safe displacement at which the battery will not deform is set as 20 mm, and the maximum force and energy absorption at this displacement are compared. In total, 33 different electric and hybrid vehicle models were benchmarked in this study. L-shaped geometry and aluminum materials are generally preferred; this study focuses on using glass-fiber-reinforced polymer (GFRP) pultruded profiles to make batteries more durable and lighter. The GF800 material was selected for its superior mechanical strength among glass fiber composites. A virtual tensile test verified its properties. A unique hybrid model combining honeycomb and auxetic geometries was developed, showing a crash performance improvement of ~360% over honeycomb structures and ~88% over auxetic structures. Through multi-objective optimization using artificial neural networks (ANNs), 27 models were analyzed, leading to an optimized design. The final design resulted in the battery box side profile being 23.9% lighter and 38.6% cheaper, and exhibiting a performance 3% higher. This study demonstrates significant advancements in EV safety and cost efficiency, highlighting the practical benefits of innovative material and design approaches.