Battery Array Bracket Layout for Secure EV Pack Mounting
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Solution Overview
Problem
Existing electrified vehicle battery packs face challenges in securely mounting and supporting battery arrays within the enclosure assembly, requiring robust and lightweight solutions to ensure stability and ease of assembly/disassembly.
Innovation Solution
The use of specifically designed brackets with multiple attachment points and fasteners that connect to both the enclosure assembly and the support structure of the battery array, providing vertical attachment points for secure mounting and facilitating simple assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust mounting structures are used to securely mount battery arrays, then structural integrity and stability are improved, but device complexity and weight increase
Solution Approach 1:
The mounting structure is divided into separate brackets that attach to the enclosure assembly and support the battery array. Each bracket is an independent component that can be manufactured and assembled separately, reducing overall system complexity while maintaining structural integrity.
Solution Approach 2:
The bracket acts as an intermediary component between the enclosure assembly and the battery array support structure. It mediates the connection by providing attachment points that interface with both the enclosure and the battery support, simplifying the overall mounting system.
2Reliability
If multiple fasteners and attachment points are used to secure battery arrays, then mounting reliability is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The mounting system uses discrete fasteners at specific attachment points rather than a continuous complex fastening mechanism. This segmentation allows for straightforward assembly by simply inserting fasteners at predefined locations.
Solution Approach 2:
The bracket is pre-configured with attachment points and fastener holes in specific locations before assembly. This preliminary arrangement of mounting features enables quick and easy assembly without requiring complex alignment procedures during installation.
3Weight of moving object
If lightweight bracket design is used to reduce weight, then weight is reduced, but strength and structural integrity worsen
Solution Approach 1:
The bracket design incorporates local reinforcement at critical stress points such as fastener holes and attachment areas, while keeping other portions of the bracket lightweight. This localized strengthening maintains overall structural integrity without significantly increasing weight.
Solution Approach 2:
The bracket may utilize composite material construction or hybrid material approaches that combine lightweight materials with localized strengthening features, achieving an optimal balance between weight reduction and maintaining sufficient strength for battery array support.
Data Source
AI summary
Exemplary battery pack designs for use in electrified vehicles may include an enclosure assembly that houses one or more battery internal components. One or more brackets may be used to mount each of the battery internal components within the enclosure assembly. Each bracket may include at least one attachment point for securing the bracket to the enclosure assembly and at least two attachment points for securing the bracket to a support structure of the battery internal component. Fasteners may be received through the brackets and then into either the enclosure assembly or the support structure in order to mount the battery internal component inside the battery packs.