Vehicle Battery Pack Holder Crash Safety
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Solution Overview
Problem
In electric vehicle battery packs with vertically stacked batteries, there is a risk of contact between upper and lower stage battery stacks during a frontal vehicle crash due to the inertial force causing the holder to move forward and contact the lower stacks, leading to potential deformation and damage.
Innovation Solution
A battery pack design featuring a lower casing with leg portions and a frame connected by reinforcement, where the upper casing and frame are connected to reduce forward tilting deformation, and a protrusion on the frame to prevent holder movement, thereby inhibiting contact between the holder and lower stage battery stacks during a crash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery stacks are arranged vertically in multiple stages to extend cruising range, then energy capacity is improved, but risk of contact between upper and lower stage battery stacks during frontal crash increases
Solution Approach 1:
The holder is segmented into leg portions and a frame, with the reinforcement specifically positioned to connect the lower casing and frame. This segmentation allows the reinforcement to selectively resist forward tilting forces without interfering with the vertical stacking arrangement, thereby maintaining energy capacity while reducing crash damage risk.
Solution Approach 2:
The reinforcement is pre-installed to provide resistance against forward tilting deformation before a crash occurs. This beforehand cushioning structure prevents the holder from tilting forward during a frontal crash, thereby preventing contact between upper and lower stage battery stacks before damage can occur.
2Stability of the object's composition
If reinforcement is added to connect lower casing and frame, then forward tilting deformation is reduced, but device complexity increases
Solution Approach 1:
The reinforcement is merged with the existing holder structure, connecting the lower casing and frame as an integrated component. This merging approach provides the necessary stability without requiring completely separate additional structures, thereby limiting the increase in device complexity while improving holder stability.
3Object-affected harmful factors
If protrusion is added to regulate holder movement, then contact between holder and lower battery stacks is inhibited, but device complexity increases
Solution Approach 1:
The protrusion is designed to serve multiple functions: it regulates forward movement of the holder during a crash, prevents contact between the holder and lower battery stacks, and provides a mounting surface for the upper casing. This multi-functionality reduces the need for additional separate components, thereby achieving contact prevention without significantly increasing device complexity.
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
This design effectively reduces the forward movement of the holder and leg portions, preventing contact with the lower stage battery stacks without the need for additional components, thus enhancing crash safety by minimizing deformation and potential damage.
Implementation Method 1
inertial force of the battery stacks in the upper stage can move the holder forward to urge the leg portions of the holder into contact with the battery stacks in the lower stage
Implementation Method 2
the protrusion abuts against the upper casing to regulate the forward movement of the holder
Data Source
AI summary
A battery pack houses battery stacks vertically in a plurality of stages. The battery pack includes a lower casing, a holder formed of leg portions attached to the lower casing in front and back of the battery stacks in the lower stage and a frame attached on upper portions of the leg portions, and a plate member that connects the lower casing and the frame of the holder. The battery stacks in an upper stage are arranged on top of the frame along the length of the vehicle.