Electrified Vehicle Battery Modules with Transverse Sliding Interlocks

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Solution Overview

Problem

Conventional battery arrangements in electrified vehicles lack effective distribution and absorption of side impact forces, often requiring additional reinforcements that increase weight and reduce energy efficiency.

Innovation Solution

The battery arrangement features interlocking battery module housings that slide relative to each other in a transverse direction, connected by flexible lines and shear bolts, allowing for controlled movement during impacts while preventing movement in longitudinal and vertical directions, thus distributing impact forces effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery arrangements are used with rigid mounting, then structural stability is maintained, but side impact forces cannot be effectively distributed and absorbed

Engineering Contradiction:

Improveimpact force distributionVSAvoidchassis reinforcement structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery module housings are designed to move relative to each other in the transverse direction during side impacts. The interlocking connection with elongated holes allows controlled movement, transforming the rigid structure into a dynamic one that can absorb impact forces through controlled displacement rather than requiring complex reinforcement structures.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The battery arrangement is divided into multiple independent battery modules with individual housings that can move relative to each other. This segmentation allows each module to independently respond to impact forces, distributing the impact energy across multiple modules rather than concentrating it on a single rigid structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If additional chassis reinforcements are added to protect the battery, then safety is improved, but vehicle weight increases and energy efficiency decreases

Engineering Contradiction:

Improvebattery protectionVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The battery module housings themselves serve as the protective structure through their interlocking connection design. The elongated holes and interlocking surfaces enable the housings to automatically absorb and distribute impact forces without requiring additional external reinforcement structures, making the battery system self-protecting.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The design converts the harmful impact force into beneficial controlled movement of the battery modules relative to each other. The interlocking connection with elongated holes allows the modules to slide in the transverse direction during impact, transforming the harmful kinetic energy into controlled displacement that dissipates impact energy without requiring additional protective structures.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If battery modules are rigidly fixed together, then structural stability is maintained, but impact forces concentrate on specific points causing potential failure

Engineering Contradiction:

Improvestructural stabilityVSAvoidimpact force concentration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The interlocking connection with elongated holes creates a dynamic structure that allows controlled movement during impact. This prevents force concentration by distributing the impact loads across the entire length of the elongated holes and across multiple interlocking surfaces, rather than concentrating forces at single rigid connection points.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection parameters are changed from fixed rigid joints to movable interlocking connections with elongated holes. This parameter change allows the connection to accommodate impact forces through controlled displacement, transforming the stress distribution from concentrated point loads to distributed line loads across the elongated hole surfaces.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11005135B2Electrified vehicle with battery arrangement permitting relative transverse movement of individual modules

Publication Date: 2021.05.11 FORD GLOBAL TECH LLC

AI summary

This disclosure relates to a battery arrangement for an electrified vehicle. Among other things, the battery arrangement includes first and second battery modules, each of which includes a battery module housing. Adjacent surfaces of these battery module housings are interlocked such that the first and second battery modules are configured to slide relative to one another in a transverse direction of the electrified vehicle. Accordingly, this disclosure increases safety while saving space and without requiring undue reinforcements of the chassis structure, which would increase the weight of the vehicle and reduce the energy efficiency the vehicle. These and other benefits will be appreciated from the following description.