An integrated cell-to-pack design based on an origami sandwich structure to enhance cooling and mechanical performances of battery packs in electric vehicles

Abstract

The rapid growth in the energy density of batteries in electric vehicles has led to the need for complex structural components and cooling systems to ensure the safety of the battery pack. However, these inactive materials occupy a significant portion, accounting for at least 35% of the pack's volume. To enhance the volume utilization rate of the battery pack, this paper proposes a novel origami structure with its optimized geometry that enhances thermal and mechanical performances as well as crashworthiness performance. The simulation results of temperature evaluation show that the proposed origami channels for a battery pack can reduce the maximum temperature by more than 2.6 °C at a 5C discharging rate and by over 20 °C under internal short-circuit conditions compared with a flat cooling channel. The experimental results of a quasi-static punch compression test demonstrate the enhanced mechanical properties of the origami channels with a significant increase in peak crushing force and impact energy absorption compared with flat cooling channels.