Meandering Battery Bracket Structure for Impact Load Distribution
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Solution Overview
Problem
Existing battery pack designs face challenges in geometry, production, and material properties, particularly in efficiently distributing impact forces and allowing for modular and cost-effective integration into vehicle chassis.
Innovation Solution
A battery bracket comprising an outer structure with a cavity and an inner structure that meanders within this cavity, providing contact areas for stabilization and allowing for fixation to the battery pack case, thereby enhancing load distribution and modular integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a battery bracket uses a single integrated structure, then manufacturing is simpler, but impact force distribution and structural stability are insufficient
Solution Approach 1:
The battery bracket is divided into two separate semi-products: an outer structure and an inner structure. This segmentation allows each component to be optimized independently for specific functions (outer structure for impact resistance, inner structure for modular integration) while collectively providing superior force distribution and stability compared to a single integrated bracket.
2Stability of the object's composition
If a battery bracket uses a complex integrated design for better load distribution, then structural integrity improves, but manufacturing cost and complexity increase
Solution Approach 1:
By segmenting the bracket into outer and inner structures that can be manufactured separately using different optimal processes, the design achieves high structural integrity through their combined interaction, while maintaining manufacturing efficiency by allowing each component to be produced independently and then assembled.
Solution Approach 2:
The inner structure is positioned within the outer structure, creating a nested configuration where the inner structure meanders between the lower and upper parts of the outer structure. This nesting provides enhanced load distribution and structural integrity while keeping the overall form factor compact and manufacturable.
3Reliability
If a battery bracket design prioritizes structural performance, then impact resistance improves, but modular integration and cost-effectiveness decrease
Solution Approach 1:
The segmented design with separate outer and inner structures enables modular integration, where each semi-product can be independently manufactured, tested, and replaced. This segmentation maintains high impact resistance through their combined structural interaction while improving adaptability for different vehicle platforms and battery pack configurations.
Solution Approach 2:
The outer structure serves multiple functions: providing impact resistance, forming a cavity for the inner structure, and offering mounting surfaces. The inner structure similarly provides structural support and enables modular integration. This multi-functionality achieves reliable impact resistance while facilitating versatile modular integration across different applications.
Data Source
Figure 1
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Figure 4A~4B
AI summary
The present disclosure refers to battery a bracket for mounting a battery pack case (20) inside a vehicle, the battery bracket comprising: an outer structure (12) having a lower part (12a) and an upper part (12b) forming a cavity (C) between the lower part (12a) and the upper part (12b); an inner structure (14) arranged in the cavity (C); wherein the outer structure (12) is configured for being fixed to an outer side face (22) of the battery pack case (20); wherein the inner structure (14) meanders between the lower part (12a) and the upper part (12b) in that the inner structure (14) comprises one or more lower contact areas (32, 34) and one or more upper contact areas (31, 33), wherein the inner structure (14) contacts the lower part (12a) in the lower contact areas (32, 34) and contacts the upper part (12b) in the upper contact areas (31, 33).