Rigid Battery Pack Linkages for Underbody Impact Articulation
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Solution Overview
Problem
Electrified vehicle traction battery packs mounted underbody locations are susceptible to deformation from vehicle loads, which can lead to direct load transfer and potential damage if not adequately supported.
Innovation Solution
A rigid linkage system connecting the traction battery pack to a vehicle frame, allowing it to articulate away from deforming structures, utilizing a four-bar linkage configuration with a boron steel rigid linkage, dual phase steel cross-member, and mild steel floor panel, to maintain a gap and prevent contact with deforming structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the traction battery pack is mounted directly to the vehicle frame at underbody locations, then packaging efficiency is improved, but the battery pack becomes susceptible to deformation and load transfer from deforming structures
Solution Approach 1:
A rigid linkage acts as an intermediary between the battery pack and the vehicle frame's deforming structures. The linkage includes a first mount section connected to the battery pack, a second mount section connected to the frame, and a curved bridge section that articulates to maintain separation, preventing direct contact while preserving mounting functionality.
Solution Approach 2:
The rigid linkage is designed with articulation capability, allowing it to dynamically adjust its configuration as the vehicle frame deforms during impact events. The curved bridge section enables the linkage to pivot and maintain the gap between the battery pack and deforming structures, transforming the static mounting into a dynamic protective system.
2Reliability
If the rigid linkage maintains a gap between the battery pack and deforming structures, then load transfer is minimized, but the mounting system becomes more complex
Solution Approach 1:
The rigid linkage performs multiple functions within a single integrated component: it mounts the battery pack to the frame, maintains the protective gap, allows for articulation during deformation, and distributes loads. This multi-functionality reduces the need for separate protective components, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The rigid linkage is constructed from high strength low alloy material, providing the necessary strength and rigidity to maintain the gap and resist deformation while keeping the component design relatively simple. The material properties enable the linkage to function effectively as both a structural support and a protective element.
3Strength
If the rigid linkage is made of high strength low alloy material, then strength and rigidity are improved, but manufacturing cost increases
Solution Approach 1:
The high strength low alloy material is applied specifically to the rigid linkage where maximum strength and rigidity are required to maintain the protective gap and resist deformation forces. Other components of the mounting system may use different materials optimized for their specific functions, allowing cost-effective material selection throughout the assembly while maintaining overall performance.
Data Source
AI summary
This disclosure details rigid linkages for mounting traction battery packs to portions of a vehicle frame. The rigid linkages are designed to allow the traction battery pack to articulate away from deforming structures of the vehicle frame as part of an energy distribution system. During the articulation, the rigid linkage is capable of conserving its integrity to push the traction battery pack away from the deforming structures, thereby preventing the deforming structures from contacting the traction battery pack.