Traction Battery Crash Frame With Modular Rod Connectors
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Solution Overview
Problem
Heavy-duty vehicles with large traction batteries face challenges in protecting these batteries from external damage while maintaining a simple assembly process and reducing the number of components to minimize cost and weight.
Innovation Solution
A battery crash protection arrangement comprising a crash protection frame with interconnected frame portions and rods, utilizing connector elements to secure a secondary frame, and a crash protection plate to absorb impacts, while minimizing components and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a comprehensive crash protection arrangement is provided for large traction batteries, then protection reliability is improved, but device complexity and weight increase
Solution Approach 1:
The crash protection arrangement is divided into a modular envelope frame structure with four distinct frame portions (first, second, third, and fourth frame portions) that can be separately manufactured and assembled. This segmentation allows for simplified production and assembly while maintaining comprehensive protection coverage around the battery pack.
Solution Approach 2:
The connector elements integrate multiple functions into single components: they connect frame portions to each other, provide mounting points for secondary structures, and serve as structural load-bearing elements. This merging reduces the total number of separate components needed while maintaining structural integrity.
2Reliability
If more components are used to ensure sufficient protection, then protection reliability is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The connector elements are designed as multi-functional components that simultaneously perform frame connection, structural support, and mounting functions for additional protection elements. This universality reduces the number of different component types needed, simplifying manufacturing processes and inventory management.
Solution Approach 2:
The frame portions are designed with standardized aperture positions and connector element configurations that can be adjusted based on specific battery pack sizes and protection requirements. This parameter flexibility allows the same basic design to serve multiple applications without requiring completely different component sets.
3Reliability
If a robust crash protection structure is implemented, then protection reliability is improved, but weight increases
Solution Approach 1:
The envelope frame is segmented into four portions that can be optimized independently for weight efficiency. Each frame portion can be designed with appropriate material thickness and cross-sectional geometry based on the specific protection needs of different battery pack regions, reducing overall weight compared to a fully uniform structure.
Solution Approach 2:
The frame portions and connector elements can be manufactured from composite materials or aluminum alloys that provide high strength-to-weight ratios. This allows the structure to maintain robust protection capabilities while minimizing the added weight of the safety system.
Data Source
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AI summary
The present disclosure relates to a battery crash protection arrangement for a traction battery of a vehicle, the battery crash protection arrangement comprising a first rod connector element comprising a first portion rotationally connected to a first rod, and a second portion, arranged on an opposite side compared to the first portion, the second portion being configured to connect to a first secondary rod, and a second rod connector element comprising a first portion rotationally connected to a second rod, and a second portion, arranged on an opposite side compared to the first portion, the second portion being configured to connect to a second secondary rod, wherein the first rod connector element protrudes out from a first aperture of a crash protection frame, and the second rod connector element protrudes out from a second aperture of the crash protection frame.