Battery Array Bracket Fastener for Impact Load Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack enclosures face challenges in securely fastening high-voltage battery arrays, particularly under side impact loads, which can lead to localized stress concentrations and potential detachment of battery arrays from surrounding structures.
Innovation Solution
A battery pack attachment assembly that includes a bracket and bracket fastener system, where the bracket fastener has a stem extending longitudinally from a radially enlarged head, captured between the bracket and the enclosure surface, and secured using mechanical fasteners that threadably engage the bracket fastener, distributing loads across multiple arrays to reduce peak stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used to secure battery arrays, then the battery arrays can be held in place, but localized stress concentrations occur under side impact loads leading to potential detachment
Solution Approach 1:
The bracket is divided into multiple segments or sections, each capable of independently fastening to the enclosure. This segmentation distributes the impact loads across multiple attachment points rather than concentrating stress at single fastening locations, thereby preventing localized stress concentrations while maintaining reliable battery array security
Solution Approach 2:
The bracket incorporates locally optimized features such as reinforced attachment zones, distributed fastening points, and strategically positioned structural elements. These local quality enhancements ensure that stress is evenly distributed across the bracket-enclosure interface, preventing stress concentrations at critical fastening locations while maintaining overall structural integrity
2Strength
If multiple fasteners are used to secure battery arrays, then the structural integrity is improved, but the device complexity increases
Solution Approach 1:
The bracket is designed as a multi-functional component that simultaneously provides structural support, load distribution, and multiple fastening points for securing battery arrays. By integrating these functions into a single bracket structure rather than using separate components, the system achieves high structural integrity while minimizing device complexity
Solution Approach 2:
Multiple fastening functions are merged into a single integrated bracket structure. The bracket combines multiple attachment points, support surfaces, and load-pathways into one unified component, eliminating the need for separate fasteners and brackets for each battery array, thereby reducing overall system complexity while maintaining strength
Data Source
AI summary
A battery pack assembly includes, among other things, an enclosure providing an interior area that houses one or more battery arrays, a bracket secured relative to the enclosure, and a bracket fastener having a stem extending longitudinally from a head along a longitudinal axis of the bracket fastener. The head is enlarged radially relative to the stem. The head is captured between the bracket and a surface of the enclosure. A battery pack securing method includes, among other things, securing a bracket relative to an enclosure of a battery pack to capture a head of a bracket fastener between the bracket and a surface of an enclosure. The bracket fastener has a stem that extends longitudinally from the head of the bracket fastener.