Battery Pack Housing Brackets for Front Impact Load Transfer
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Solution Overview
Problem
Existing battery pack housings in electric vehicles face challenges in effectively distributing front impact loads to the longitudinal baseplates without reducing packaging space for battery modules, as straight longitudinal baseplates not aligned with frame rails decrease impact load transfer but increase packaging space requirements.
Innovation Solution
Incorporating triangular-shaped brackets that connect the central longitudinal baseplate to the lateral baseplate at locations aligned with frame rails, forming an angle greater than 40 degrees, to transmit front impact loads efficiently to the central longitudinal baseplate, thereby avoiding the need for additional structure at the front end of the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If straight longitudinal baseplates not aligned with frame rails are used, then packaging space for battery modules is increased, but impact load transfer to longitudinal baseplates is decreased
Solution Approach 1:
Triangular brackets are introduced as intermediary structural elements that connect the lateral baseplate to the longitudinal baseplate. These brackets serve as mediators to transfer front impact loads from the lateral baseplate to the longitudinal baseplate, enabling effective load distribution without requiring the longitudinal baseplates to be directly aligned with the frame rails, thus preserving packaging space while maintaining impact resistance
Solution Approach 2:
The solution transitions from a one-dimensional direct alignment approach to a two-dimensional triangular configuration. By forming triangles with the lateral baseplate, longitudinal baseplate, and triangular brackets, the structure creates rigid geometric relationships that efficiently transmit impact loads across multiple dimensions, achieving both packaging space optimization and impact load transfer
2Strength
If additional structure is added at the front end of the battery pack to transfer impact loads, then impact resistance is improved, but packaging space for battery modules is reduced
Solution Approach 1:
The front end structure is segmented into distinct functional components: the lateral baseplate for load reception, the triangular brackets for load transmission, and the longitudinal baseplate for load distribution. This segmentation allows each component to be optimized for its specific function while working together as an integrated system, achieving impact resistance without requiring a bulky monolithic front end structure
Solution Approach 2:
The triangular brackets act as intermediaries that enable impact load transfer between the lateral and longitudinal baseplates. This intermediary mechanism allows the structure to achieve improved impact resistance through efficient load path creation rather than through addition of massive structural elements, thereby preserving packaging space
Data Source
AI summary
A housing for a battery pack of a vehicle is described herein. The housing includes a lateral baseplate, a central longitudinal baseplate, and at least one bracket. The lateral baseplate is configured to extend in a lateral direction of the vehicle and attach to a front cradle of the vehicle rearward of left and right body mount seats on the front cradle. The central longitudinal baseplate is configured to extend in a longitudinal direction of the vehicle and attach to the lateral baseplate. The at least one bracket is configured to connect the central longitudinal baseplate to the lateral baseplate and to form an angle with the lateral baseplate that is greater than 40 degrees.