Abstract
The battery pack integrated with the vehicle chassis addresses two critical challenges: impact resistance and thermal management. In response, this paper proposes a novel battery pack featuring 3D star-shaped negative Poisson’s ratio (NPR) structures. Compared to the conventional battery pack, the 3D star-shaped NPR structural battery pack has impact resistance and heat dissipation capabilities. Furthermore, a new L1-DUCO uncertainty-based multidisciplinary optimization is applied to further improve the overall performance of the battery pack. The results indicate that after the L1-DUCO uncertainty-based multidisciplinary optimization, the peak collision force of the battery pack is reduced by 6.96 kN, and the energy loss of the cooling water passing through the NPR condenser decreases by 42.12%. Additionally, the material cost of the NPR condenser is reduced by 56.42%. Most importantly, all constraint functions meet the 6-Sigma robustness design requirements following the L1-DUCO optimization. It can provide both theoretical and practical guidance for the integrated design of battery pack.
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