Optimization of Lateral Impact Resistance of Battery Pack with Honeycomb Sandwich Panel Structure Based on Lightweight Design

ZHANG Desheng; LIAO Jieguo; SUN Zhenxin

doi:10.19554/j.cnki.1001-3563.2025.21.031

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Packaging Engineering ›› 2025, Vol. 46 ›› Issue (21) : 286-295. DOI: 10.19554/j.cnki.1001-3563.2025.21.031

Optimization of Lateral Impact Resistance of Battery Pack with Honeycomb Sandwich Panel Structure Based on Lightweight Design

ZHANG Desheng^1,2*, LIAO Jieguo¹, SUN Zhenxin²

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Abstract

The work aims to replace the traditional aluminum-alloy frame of the battery pack with honeycomb sandwich panels, to examine the effects of various parameters on the mass and intrusion of the battery pack under lateral impact. An orthogonal experimental design was adopted to identify the optimal energy-absorbing combination of face-sheet materials and honeycomb cores, on which a finite element model of the battery pack was established. Using LS-DYNA, the influences of three honeycomb parameters (height, thickness, and cell size), four face-sheet parameters (ply thicknesses at 0°, ±45°, and 90°), and three enclosure thickness parameters on the dynamic response under lateral impact were analyzed. Furthermore, three surrogate models—RBF, Kriging, and RSM—were constructed with the objectives of minimizing mass and intrusion, and the NSGA-Ⅱ algorithm was employed to obtain the optimal solution. Quasi-static compression analysis showed that the combination of a hexagonal honeycomb and CFRP face sheets provided the best energy absorption performance. Results from the RBF model with the highest fitting accuracy indicated that increasing honeycomb height and thickness led to higher mass and crushing force, while specific energy absorption and intrusion decreased. After multi-objective optimization, the mass of the battery pack enclosure decreased by 47.21%, specific energy absorption increased by 34.43%, and crushing force decreased by 22.52% while still meeting the design requirements; Although intrusion increased slightly, a safety margin of 5.29 mm remained between the battery and the enclosure. Replacing the aluminum-alloy frame with honeycomb sandwich panels thus improves the lateral impact resistance of the battery pack and provides a technical pathway that balances safety protection and lightweight design.

Key words

honeycomb sandwich panel / lateral impact / surrogate model / NSGA-Ⅱ algorithm / lightweight design

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ZHANG Desheng, LIAO Jieguo, SUN Zhenxin. Optimization of Lateral Impact Resistance of Battery Pack with Honeycomb Sandwich Panel Structure Based on Lightweight Design[J]. Packaging Engineering. 2025, 46(21): 286-295 https://doi.org/10.19554/j.cnki.1001-3563.2025.21.031

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