Method and apparatus for attaching a crushable carbon fiber reinforced polymer structure to the outer surface of a battery enclosure
A battery housing for a traction motor battery of a vehicle is disclosed that includes a plurality of elongated impact absorbing carbon fiber reinforced polymer members attached to the walls of the enclosure. The impact absorbing members may be corrugated members that have ridges and furrows connected by ramp surfaces that define trapezoidal spaces relative to the sides of the enclosure. The ridges are designed to be deformed into the trapezoidal space in the event of an impact to absorb impact forces and protect the battery. The impact absorbing members may be retained by T-shaped guides on the outer surface of the walls of the enclosure or may be adhesively attached to the sides of the enclosure.
1. A method of providing an impact absorbing battery enclosure for a battery of a vehicle having a battery powered traction motor comprising:
providing a plurality of sides and a top side and a bottom side;
assembling all of the sides together about the battery;
assembling a plurality of impact absorbing carbon fiber reinforced polymer members to the plurality of sides to form an impact absorbing assembly that encloses the battery enclosure, wherein the impact absorbing carbon fiber reinforced polymer members are corrugated and have at least one ridge, a pair of adjacent of furrows, and a first ramp surface and a second ramp surface that each extend from the at least one ridge to the furrows on opposite sides of the at least one ridge and toward the side of the enclosure at an angle that define a trapezoidal space between the impact absorbing members and the sides of the enclosure;
providing an attachment flange on a first side and a second side of the impact absorbing carbon fiber reinforced polymer members that extend parallel to one of the sides of the enclosure;
connecting the attachment flange on the first side and on the second side to one of the sides of the enclosure;
providing a plurality of T-shaped guides on one of the sides of the enclosure that define receptacles for the impact absorbing carbon fiber reinforced polymer members between two T-shaped guides that extend parallel to each other; and
inserting each of the attachment flanges of the impact absorbing carbon fiber reinforced polymer members between one of the T-shaped guides and one of the sides of the enclosure.
2. The method of claim 1 wherein the impact absorbing members are adhesively attached to one of the sides of the enclosure.