Battery Pack Crossmember and Bracket Assembly for Secure Mounting
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Solution Overview
Problem
Conventional battery packs face challenges in securely mounting and supporting battery arrays and other components, which can lead to movement and instability within the enclosure assembly, potentially affecting the performance and safety of electrified vehicles.
Innovation Solution
The proposed solution involves a crossmember and support bracket assembly that secures both battery arrays to the crossmember, with mechanical fasteners and anchoring arms, and includes a second tier structure supported by the bracket, along with isolator mounts to isolate the battery pack from vehicle loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting methods are used for battery arrays, then the structure is simple, but the battery arrays are not securely retained and may move inside the enclosure assembly
Solution Approach 1:
The mounting structure is segmented into multiple independent crossmembers positioned between adjacent battery arrays. Each crossmember independently secures battery arrays at multiple locations, distributing the retention function across separate structural elements rather than using a single complex mounting system.
Solution Approach 2:
The crossmembers extend in a direction transverse to the longitudinal axis of the battery arrays, creating a three-dimensional mounting framework. This dimensional approach allows securing of battery arrays from the sides rather than only from ends, providing more secure retention without increasing planar complexity.
2Stability of the object's composition
If battery arrays are securely mounted to prevent movement, then reliability improves, but the mounting structure becomes more complex
Solution Approach 1:
The crossmembers serve multiple functions simultaneously: they structurally support the battery arrays, provide mounting locations for electronic components, and act as retention elements preventing array movement. This multi-functionality achieves stable battery array composition without proportionally increasing structural complexity.
Solution Approach 2:
The mounting structure merges the support function and retention function into a single integrated crossmember system. The same structural elements that provide mechanical support also prevent movement, combining multiple stabilization functions into one unified structure rather than separate systems.
3Adaptability or versatility
If additional components are mounted within the battery pack, then functionality increases, but the risk of movement and instability increases
Solution Approach 1:
The internal space is segmented into distinct mounting zones using multiple crossmembers positioned at different locations. Electronic components and other elements can be mounted on different crossmembers or at different heights, allowing versatile component placement while each segment independently maintains stability.
Solution Approach 2:
The crossmembers act as intermediary structures between the battery arrays and the mounted components. They provide stable intermediate platforms that isolate components from direct contact with moving battery arrays, enabling versatile mounting while maintaining component stability through the mediating crossmember structure.
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
This configuration ensures stable and secure mounting of battery arrays and additional components, enhancing the performance and safety of electrified vehicles by preventing movement and isolating the battery pack from external loads, such as noise, vibration, and impact.
Implementation Method 1
an isolator mount attached to the crossmember. The isolator mount includes an elastomeric bushing
Implementation Method 2
isolating the battery pack from external loads, such as noise, vibration, and impact
Data Source
AI summary
This disclosure details assemblies for mounting and supporting components within battery packs. Exemplary battery packs may include a first battery array, a second battery array positioned adjacent to the first battery array, a crossmember positioned between the first battery array and the second battery array, and a support bracket connected to the crossmember. Together, the crossmember and the support bracket established an assembly. Both the first battery array and the second battery array may be secured to the crossmember, and the support bracket may support a second tier structure above at least one of the first battery array or the second battery array.