Battery System Bracket Force Transmission
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Solution Overview
Problem
Existing battery systems for electric and hybrid vehicles face challenges in providing adequate protection against external mechanical loads while maintaining a lightweight and cost-effective design.
Innovation Solution
The battery system incorporates an auxiliary frame connected to the housing shell via a bracket that extends between cell carriers, allowing force transmission along the width of the system, enhancing protection and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery housing is made extremely solid to dissipate forces to the ladder frame, then the protection of battery modules against mechanical loads is improved, but the weight and production cost increase
Solution Approach 1:
The patent applies local quality by providing brackets only at specific locations where force transmission is most critical - namely at the upper half of the battery system where housing walls are subjected to severe bending loads. This localized reinforcement provides necessary strength protection where needed while avoiding unnecessary weight and cost throughout the entire housing structure.
Solution Approach 2:
The patent segments the force transmission function by introducing brackets as separate structural elements that connect the auxiliary frame to the housing shell. These brackets divide the load path into discrete segments, allowing force to be transmitted from the housing shell through the brackets to the auxiliary frame and then to the cell carriers, rather than requiring the entire housing to be uniformly solid.
2Strength
If the battery housing is made extremely solid to dissipate forces to the ladder frame, then the protection of battery modules against mechanical loads is improved, but the production cost increases
Solution Approach 1:
The patent segments the force transmission function by introducing brackets as separate structural elements that connect the auxiliary frame to the housing shell. These brackets divide the load path into discrete segments, allowing force to be transmitted from the housing shell through the brackets to the auxiliary frame and then to the cell carriers, rather than requiring the entire housing to be uniformly solid.
Solution Approach 2:
The patent applies local quality by providing brackets only at specific locations where force transmission is most critical - namely at the upper half of the battery system where housing walls are subjected to severe bending loads. This localized reinforcement provides necessary strength protection where needed while avoiding unnecessary weight and cost throughout the entire housing structure.
3Strength
If brackets extend beyond the outermost cell supports, then the protection of protruding cells from mechanical stress is improved, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing the brackets to serve multiple functions: they provide structural support for the auxiliary frame, transmit forces from the housing shell, protect protruding cells from mechanical stress, and contribute to the overall structural integrity of the battery system. This multi-functionality reduces the need for additional specialized components.
Solution Approach 2:
The brackets are designed in advance to extend beyond the outermost cell supports, proactively protecting cells that protrude outward along the width of the housing shell before mechanical stress can reach them. This preliminary structural arrangement ensures protection is already in place before any accident or mechanical load occurs.
Data Source
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AI summary
A battery system for installation in a motor vehicle comprising a housing consisting of a housing shell (1) and a housing cover, at least two battery modules (2, 3) arranged in the housing, each comprising a cell carrier (4) and cells (5) arranged on the cell carrier (4), and an auxiliary frame (6), wherein the cells (5) are connected to the auxiliary frame (6) via the cell carrier (4) and wherein the auxiliary frame (6) is connected to the housing shell (1), wherein the auxiliary frame (6) is connected to the housing shell (1) via a bracket (7), wherein the bracket (7) extends at least from one cell carrier (4) to an adjacent cell carrier (4).