![]() The challenges that limit the application of cellular structures today include systematically designing pseudo-random cellular structures, assessing which cellular patterns are most suitable for a particular application, and mastery of manufacturing technology for efficient mass production of cellular structures. In the automotive sector, cellular structures have been used for structural applications and impact- absorbing modules, for example, for protecting the electric vehicle battery pack against impact loading. Various applications of cellular structures can be found in aviation, bioengineering, automotive, and other fields. Each type of structure has its characteristics. In addition, it highlights the importance of packaging space for EVs, particularly in low-floor electric buses, as weight distribution becomes a challenge in these applications.Ĭellular structures can be classified into foams, honeycombs, and lattice structures. This case study showcases the benefits of adopting modularity in the design of EVs. Lastly, mechanical design of the battery pack of the first fully electric bus designed and developed in Australia is presented. Several patented mechanical design solutions, developed with an aim to increase crashworthiness and vibration isolation in EV battery pack, are discussed. This chapter discusses design elements like thermal barrier and gas exhaust mechanism that can be integrated into battery packaging to mitigate the high safety risks associated with failure of an electric vehicle (EV) battery pack. ![]() Robust mechanical design and battery packaging can provide greater degree of protection against all of these. Current Li-ion battery packs are prone to failure due to reasons such as continuous transmission of mechanical vibrations, exposure to high impact forces and, thermal runaway. ![]() Safety and reliability are the two key challenges for large-scale electrification of road transport sector. ![]()
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