Integrated Side Fairing and Crash Protection System for High Voltage EV Battery Safety

The paper presents a well-engineered and novel structural solution for side impact protection of high-voltage battery packs in electric trucks. While electric vehicles offer benefits like zero emissions and independence from fossil fuels, in turn present challenges in meeting crashworthiness standards and safety regulations. The device addresses the critical need for effective battery protection & styling of battery electric vehicles. The integration of a hybrid corrugated panel system with plastic side fairings is innovative, combining crashworthiness with aerodynamic and aesthetic benefits. The crash protection features two hat-section steel channels at the top and bottom and corrugated steel sheet with alternating ridges is attached to these channels. Corrugated panels are enforced with help of backing strips. This assembly is mounted on shear plates at both ends, secured to the vehicle's frame rail. During a side impact event, the plastic side fairings absorb the initial impact, crumpling easily. If the impact energy is substantial, impact progresses to the steel corrugated panel structure, which acts as a barrier to prevent intruding objects from striking the battery surface & crumples to absorb energy. Next the impact energy is absorbed by the bending of the steel channels & finally passing to frames. Ultimately, this energy absorption in a staged manner minimizes the energy transferred to the battery. The effectiveness of this structure is evaluated through a full-vehicle crash simulation, where a 1.36-ton moving barrier at 54 km/h with 27° tire rotation impacts the side of the vehicle. System performance is assessed based on permanent deformation of the battery housing and peak acceleration values at various locations within the battery housing & mountings. The proposed structure provides robust protection against impact forces, ensuring minimal permanent deformation and maintaining peak acceleration values within safe limits.