Battery Pack Top Cover Spacer With Nonlinear Repulsive Force
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Solution Overview
Problem
Existing automotive battery pack mounting solutions face challenges in controlling repulsive spring force and movement limitation between the battery pack top cover and the car body underside, particularly due to variations in car and battery designs, which can lead to direct contact and structural instability.
Innovation Solution
A spacer system comprising a rigid support bracket and a solid elastomeric member with distinct deformation parts, generating initial and higher repulsive forces to control movement and prevent direct contact, featuring a non-linear force-distance characteristic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam spacer elements are used between the car body and battery pack top cover, then direct contact is prevented during driving, but the repulsive spring force cannot be controlled and structural instability occurs due to variations in car and battery designs
Solution Approach 1:
The spacer is divided into two distinct parts: a rigid support bracket portion and an elastomeric member portion. This segmentation allows each part to perform its specific function - the rigid bracket provides structural support and mounting attachment, while the elastomeric member provides controlled repulsive force and movement limitation, thereby resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The spacer combines two different materials with complementary properties: a rigid material (such as metal or rigid plastic) for the support bracket and an elastomeric material for the deformable member. This composite structure enables both structural stability from the rigid part and controlled elasticity from the elastomeric part, solving the reliability issue while maintaining manageable complexity.
2Ease of manufacture
If the top cover is attached directly to the car body underside, then assembly is simplified, but structural instability and direct contact during driving conditions occur
Solution Approach 1:
The spacer acts as an intermediary element between the top cover and the car body underside. It is attached to the top cover and protrudes towards the car body, providing a buffer that prevents direct contact while maintaining the attachment relationship. This intermediary structure simplifies assembly compared to complex mounting mechanisms while ensuring structural stability during driving.
3Manufacturing precision
If the spacer height is increased to accommodate larger tolerances, then movement limitation is improved, but the repulsive force control and space constraints are worsened
Solution Approach 1:
The elastomeric member's properties can be adjusted by changing parameters such as material composition, cross-sectional area, and length to achieve the desired repulsive force characteristic. This allows the spacer to accommodate larger tolerances in height while maintaining controlled repulsive force, as the elastomeric material can be formulated to provide appropriate stiffness and elasticity for different space constraints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The spacer system effectively limits vertical movements, absorbs vibrations, and provides thermal insulation, offering enhanced control and stability during assembly and operation, with adjustable design options to accommodate varying distances and loads.
Implementation Method 1
the first part of the elastomeric member is structured and arranged to be elastically deformed mainly by bending of the elastomeric material in response to external forces acting on the spacer for generating a first repulsive spring force; the second part of the elastomeric member is structured and arranged to be elastically deformed mainly by compression of the elastomeric material
Implementation Method 2
The spacer system effectively limits vertical movements, absorbs vibrations
Implementation Method 3
provides thermal insulation
Data Source
Figure 1A
Figure 1B~1C
Figure 1D~1E
AI summary
A spacer is disclosed for limiting movements of a battery pack top cover towards a car body. The spacer comprises a rigid support bracket arranged to be attached to the top cover. An elastomeric member supported by the support bracket has first and second integrally formed parts. The first part is elastically deformed mainly by bending, and the second part is deformed mainly by compression, together generating a non-linear repulsive force. A method for mounting a battery pack using such spacers is also disclosed.