Sandwich Panel Composite Based Light-Weight Structure Design for Reserved Energy Storage System (RESS) Protection

The research in the electric vehicle requires a safe Reserved Energy Storage System (RESS) that is durable and crashworthy to withstand a harsh environment, especially ground impact from stone debris on the road. RESS, which typically uses lithium-ion type battery, is posed to the danger of thermal runaway as an aftermath of intrusion into the battery cell structures. Thermal runaway might happen because the separators between the anode and cathode damage and fail that result in a short circuit. Nowadays, metallic structures have been applied underneath the cells to protect RESS. However, the protection cannot hold high-speed impact properly. This research focuses on a composite-based protective layer by using sandwich panel constructions to achieve a stiffer structure. The design and analysis of the sandwich composite structure was conducted using non-linear finite element analysis. The study involves multiple design variables to take into account variations such as layer thickness, topology, and fiber orientation. This research only uses plain weave Carbon Fiber Reinforced Polymer (CFRP). The variables that are set as performance indicators are mainly cell deformation and energy absorbed. Among the two topologies tested, Navy Truss (NavTruss) model is proven to have better performance compared to the Blast Resistant Adaptive Sandwich (BRAS) model. This due to the NavTruss structure absorbs energy by undergoing progressive crushing, while BRAS structure collapse within the supports. In the NavTruss itself, various orientations are tested, and it is found that the most effective orientation is [(0/90)2/[(±45)/(0/90)]3]s. The optimum NavTruss composite structure configuration appears to be more superior with 36 percent mass saving compared to the metallic structure.