Optimal design of honeycomb battery pack enclosure for electric vehicle

A lithium-ion battery pack enclosure which consists of batteries is the prime source of energy for battery electric vehicles, BEV. While electric vehicle is in running condition, the battery enclosure comes across the worst scenarios like the vibrations coming from the road and impact because of road surface variations. These will cause structural stresses and variations in deformations for the enclosure structure. Electric vehicle safety wholly depends on how safe its battery pack assembly for its mechanical properties, like ability to resist deformation under static loading, vibration, and shock loading. Battery pack enclosure should meet all mechanical properties requirements. In parallel, the battery pack enclosure should be lighter in weight because it will help to improve the vehicle range and increase the battery pack life cycles. In the current study, a design of honeycomb battery pack enclosure is proposed based on mechanical parameters like mass of enclosure, natural frequency, and deformation for generic gravity loading. Baseline battery pack design was validated through physically tested data from literature and further comparative study performed on baseline battery pack enclosure and honeycomb battery pack enclosure for mass, vibrational performance, and static deformation.