Battery Pack Clamped Joint Layout for Distributed Compression Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack clamping systems in electric vehicles often suffer from fatigue, stress, and creep due to concentrated point loads, which can lead to structural failure over time.
Innovation Solution
A clamped joint system using a plurality of fasteners that extend through cross members and flanges of a battery pack, distributing compression loads evenly across the joint, thereby reducing fatigue and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clamped joint system uses conventional fastening methods with concentrated point loads, then the joint can be简单地 assembled, but it suffers from fatigue, stress, and creep leading to structural failure over time
Solution Approach 1:
The clamping force is segmented and distributed across multiple fasteners arranged in a pattern across the joint interface. Instead of relying on a single fastener or concentrated load point, the system divides the total clamping force into multiple discrete application points, which prevents stress concentration and reduces fatigue at any single location.
Solution Approach 2:
The fastener pattern is designed to create localized clamping zones that match the stress distribution requirements of different areas of the joint. By strategically positioning fasteners based on local stress conditions, the system optimizes clamping effectiveness where needed while reducing unnecessary clamping in lower-stress areas, thereby preventing creep and fatigue.
2Ease of manufacture
If compression loads are concentrated at one specific location of the clamped joint, then the joint can be simpler to manufacture, but it experiences increased fatigue, stress, and strain
Solution Approach 1:
The compression load is segmented into multiple discrete load paths corresponding to each fastener location. This segmentation transforms a single concentrated load into multiple distributed loads, which maintains manufacturing simplicity while significantly improving joint strength by eliminating stress concentration at any single point.
3Reliability
If the clamped joint uses distributed line load over the width of the joint, then fatigue and stress are reduced, but the manufacturing complexity increases
Solution Approach 1:
The continuous line load distribution is segmented into discrete fastener locations that approximate the desired load distribution. This segmentation achieves the reliability benefits of distributed loading while maintaining manufacturing simplicity by using standard fastener patterns rather than requiring continuous contact surfaces or complex load-distribution mechanisms.
Data Source
AI summary
A system can include a battery subassembly having a flange. The flange can engage a first cross member and a second cross member of a battery pack using a fastener to clamp the battery subassembly with the first cross member and the second cross member.