Traction Battery Enclosure Rib Load Diversion
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Solution Overview
Problem
In electrified vehicles, the traction battery enclosure lacks effective mechanisms to direct loads away from sensitive components like sense lead connector assemblies during vehicle impacts, potentially causing damage and compromising the integrity of these components.
Innovation Solution
The enclosure features a rib structure that extends from the cover into the interior, contacting battery components such as side plates to divert the load path and prevent it from reaching the sense lead connector assemblies, thereby maintaining their integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the enclosure uses a simple cover and tray structure, then the manufacturing cost and device complexity are reduced, but the ability to direct load away from sensitive components is insufficient
Solution Approach 1:
The cover is segmented by adding ribs that create distinct load-bearing regions. These ribs divide the cover into functional zones: areas that contact the sense lead connector assembly and areas that contact more robust battery components, enabling differentiated load management without complicating the overall enclosure architecture.
Solution Approach 2:
The ribs are strategically positioned to create local variations in stiffness and load-bearing capacity. The regions with ribs have enhanced structural properties to direct loads away from sensitive components, while other regions maintain their original design. This localized structural enhancement protects critical areas without requiring complex modifications throughout the entire enclosure.
2Reliability
If the rib structure is added to direct load paths, then the protection of sense lead connector assembly is improved, but the device complexity increases
Solution Approach 1:
The ribs are integrated directly into the cover manufacturing process, merging the load-directing function with the existing cover structure. This integration eliminates the need for separate load-bearing components or complex assembly steps, as the ribs become an inherent part of the cover itself, adding functionality without proportionally increasing overall device complexity.
Solution Approach 2:
The ribs serve multiple functions simultaneously: they provide structural reinforcement to the cover, create defined load paths, and act as spacing elements between the cover and battery components. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while achieving comprehensive protection.
3Reliability
If the rib contacts the first battery component to inhibit relative movement, then the sense lead connector assembly is protected from load, but the structural design becomes more complex
Solution Approach 1:
The ribs are pre-configured in the cover at designed positions and orientations before assembly. This preliminary positioning ensures that during vehicle operation, the ribs automatically engage with battery components to establish load paths and inhibit relative movement without requiring active control or complex adjustment mechanisms, thereby protecting sensitive components through pre-established structural geometry.
Data Source
AI summary
A battery pack assembly includes, among other things, a first battery component, a different, second battery component and an enclosure that has a cover secured to a tray to provide an interior. The first and second battery components are disposed within the interior. The cover has a first area that is disposed directly above the first battery component. The cover has a second area that is disposed directly above the second battery component. The battery pack assembly further includes a rib of the cover. The rib extends into the interior from the first area. The rib is configured to contact the first battery component to inhibit relative movement of the second area toward the second battery component.