Central Rubber Mount Connector for EV Battery Tolerance Compensation
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Solution Overview
Problem
Existing vehicle designs face challenges in securely and cost-effectively attaching high-voltage accumulators to the vehicle body, particularly in absorbing relative movements and compensating for tolerances, while minimizing stress on both components.
Innovation Solution
A vehicle design utilizing a central rubber mount with a threaded sleeve and compensation bushing for damping relative movements and compensating for tolerances, featuring a screw element and circlip connection for secure assembly, and additional rubber elements for vibration absorption, allowing for adjustable dimensions and reliable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a central connector is used to support the body on the high-voltage accumulator, then the body is reinforced and relative movements are damped, but the complexity of the connection system increases due to the need for threaded sleeves, compensation bushings, and rubber elements
Solution Approach 1:
The patent applies nesting by placing the compensation bushing inside the threaded sleeve, and the rubber elements inside the housing formed by these components. The screw element passes through the compensation bushing to engage the threaded sleeve. This nested arrangement consolidates multiple functions (damping, tolerance compensation, fastening) into a compact integrated structure, reducing overall system complexity while maintaining stability.
Solution Approach 2:
The patent merges multiple functions into the central connector assembly: the threaded sleeve provides both structural support and thread engagement, the compensation bushing handles tolerance variations, and the rubber elements provide damping. By combining these components into a single integrated connector assembly rather than separate elements, the design reduces the number of separate connection systems needed while achieving reinforced body support with effective movement damping.
2Adaptability or versatility
If tolerance compensation is implemented through adjustable rubber mount dimensions, then the connection becomes more adaptable to manufacturing variations, but the assembly process becomes more complex requiring screwing actions to adjust dimensions
Solution Approach 1:
The patent applies dynamics by making the rubber mount dimensions adjustable rather than fixed. The compensation bushing can be screwed in or out to vary the rubber mount dimension, allowing the connection to adapt to different tolerance conditions. This dynamic adjustability enables the system to accommodate manufacturing variations while the threaded connection mechanism provides a straightforward screwing action for adjustment, balancing adaptability with operational simplicity.
3Reliability
If multiple rubber elements are used for vibration absorption and movement damping, then the reliability of the connection is improved, but the volume and weight of the central connector increase
Solution Approach 1:
The patent uses rubber elements as flexible damping components within the central connector housing. These rubber elements absorb vibrations and dampen relative movements between the body and high-voltage accumulator. By using flexible rubber elements rather than rigid damping structures, the design achieves reliable vibration absorption and movement damping while minimizing the volume and weight of the connector assembly.
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
The solution provides a secure, cost-effective, and reliable attachment of the high-voltage accumulator to the vehicle body, effectively damping movements and compensating for tolerances, thereby reducing stress and ensuring stable support with minimal installation space.
Implementation Method 1
The damping of movements takes place in particular along that axis along which the rubber mount extends between the high-voltage accumulator and the body. The damping takes place in particular by at least one rubber element which converts the energy of the relative movement to deformation work of the rubber element.
Implementation Method 2
The rubber element acts in a vibration-absorbing manner between the body, the latter being connected to the threaded sleeve by way of the screw element, and the high-voltage accumulator which is fixedly connected to the base plate.
Data Source
AI summary
A vehicle has a body and a high-voltage accumulator, which is attached to the body via fastening elements, and at least one central connector, which is different from the fastening elements and which is designed to support the body on the high-voltage accumulator. The central connector has a rubber mount with a threaded sleeve, which has a cylindrical wall with an internal thread and an external thread. The external thread is engaged with a compensation bushing. A screw element for connecting the body and rubber mount is screwed into the internal thread, and the rubber mount extends between the body and the high-voltage accumulator.