Battery Pack Connector Assembly with Impact Absorbing Braces
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Solution Overview
Problem
Existing connector assemblies for securing battery packs to electrified vehicles do not effectively absorb impact loads and adapt to various vehicle packaging environments, leading to potential intrusion into the battery pack and complexity in integration with different vehicle platforms.
Innovation Solution
The proposed connector assembly includes a bottom brace and a side brace with open areas that allow for load absorption during impacts, connected to a vehicle structure through a bracket, enabling secure attachment to the underbody while accommodating different packaging geometries by providing vertical and lateral spacing, and can be adapted for various vehicle sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid connector assembly is used to securely attach the battery pack, then the attachment strength is improved, but the ability to absorb impact loads deteriorates
Solution Approach 1:
The patent changes the structural parameters of the connector assembly by introducing bracing elements with open areas that can deform under impact loads. The bottom brace and side brace are designed with specific geometric configurations (open areas) that allow controlled deformation to absorb impact energy while maintaining secure attachment during normal operation.
2Adaptability or versatility
If a custom connector assembly is designed for each vehicle platform, then the adaptation to specific packaging envelopes is improved, but the device complexity and integration difficulty deteriorate
Solution Approach 1:
The patent designs a universal connector assembly that can be adapted to multiple vehicle platforms through standardized mounting brackets and configurable bracing elements. The assembly maintains core functionality across different applications while allowing modifications to accommodate various packaging envelopes, reducing the need for completely custom designs for each vehicle platform.
Solution Approach 2:
The connector assembly is segmented into modular components including the bottom brace, side brace, mounting brackets, and fastening mechanisms. This segmentation allows individual components to be configured or replaced to suit different vehicle platforms without redesigning the entire assembly, simplifying integration across diverse applications.
3Object-affected harmful factors
If solid bracing structures are used to prevent battery pack intrusion, then the protection level is improved, but the open area for load absorption deteriorates
Solution Approach 1:
The patent applies local quality by designing bracing elements with non-uniform cross-sections featuring open areas in specific locations. The solid portions provide structural support and intrusion protection, while the open areas are strategically positioned to enable impact load absorption through controlled deformation, creating different functional zones within the same component.
Data Source
AI summary
An exemplary connector assembly includes, among other things, a bottom brace at least partially disposed beneath an enclosure of a battery pack to provide an open area vertically between the enclosure and a floor of the bottom brace. A side brace is disposed alongside the enclosure to provide an open area laterally between the enclosure and a floor of the side brace. A bracket connects the bottom and side braces to a vehicle structure. An exemplary battery pack connection method includes, among other things, supporting an enclosure of a battery pack with a bottom brace at least partially disposed beneath the enclosure. The method includes supporting the enclosure with a side brace that is at least partially disposed alongside the enclosure. The method further includes connecting the bottom and side braces to a vehicle structure through a bracket.