Battery Pack Insulation Retention Under Vehicle Vibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle battery packs are prone to mounting members, such as heat conductive members, heat sinks, or heat insulating sheets, falling off due to external forces like vibrations or impacts.
Innovation Solution
The vehicle and battery pack design incorporates a projecting portion on the upper surface of the battery pack that is inserted into a hole portion of the mounting member, ensuring the shortest distance between the projecting portion and the vehicle underbody is less than the minimum thickness of the mounting member, thereby preventing it from falling off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mounting member is attached to the battery pack using conventional methods, then the battery pack can be secured to the vehicle, but the mounting member may fall off due to vibration loads, impact loads, or other external forces
Solution Approach 1:
The projecting portion is inserted into a corresponding hole in the mounting member, creating a nested configuration where one component fits within another. This mechanical nesting provides positive engagement that prevents the mounting member from detaching under vibration or impact loads, directly resolving the reliability-strength contradiction.
Solution Approach 2:
The projecting portion acts as an intermediary mechanical feature between the battery pack housing and the mounting member. This intermediate structure provides a dedicated engagement point that transfers and distributes mechanical loads, enhancing attachment strength while maintaining reliable retention of the mounting member.
2Volume of moving object
If the battery pack is positioned close to the underbody for compact design, then space is optimized, but heat from the exhaust pipe may transmit to the battery pack
Solution Approach 1:
The mounting member made of heat insulating material serves as a thermal intermediary between the exhaust pipe and the battery pack. This intermediate layer blocks radiant heat transmission while allowing the battery pack to maintain its compact position near the underbody, thus optimizing space utilization without compromising thermal management.
Solution Approach 2:
The mounting member is constructed from heat insulating materials that provide both mechanical attachment functionality and thermal insulation properties. This composite approach allows a single component to address both the space optimization requirement and the temperature control requirement simultaneously.
3Volume of moving object
If the battery pack is positioned near the engine compartment for compact design, then space is optimized, but the battery pack may be exposed to air warmed by the engine
Solution Approach 1:
The heat insulating material in the mounting member acts as a thermal barrier that intercepts warmed air currents from the engine compartment before they reach the battery pack. This intermediate insulation layer protects the battery pack from thermal exposure while maintaining the optimized compact positioning near the engine compartment.
4Strength
If the projecting portion is placed in direct contact with the underbody for secure mounting, then attachment strength is improved, but vibration from the vehicle body is transmitted to the battery pack
Solution Approach 1:
The projecting portion serves as a mechanical intermediary that provides secure attachment through engagement with the mounting member while maintaining a controlled gap from the underbody. This intermediate configuration achieves strong mechanical retention without direct rigid contact, thereby reducing vibration transmission to the battery pack.
Solution Approach 2:
The mounting member made of heat insulating material can provide flexible mounting that accommodates vibrations. The material properties and structural design allow the mounting member to absorb or isolate vibration forces while maintaining secure attachment, preventing both detachment and excessive vibration transmission.
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 configuration effectively suppresses the mounting member from falling off, thereby preventing damage to the battery pack and maintaining its secure attachment to the vehicle, while also reducing the risk of temperature rise due to radiant heat or air warmed by the engine.
Implementation Method 1
it is possible to suppress the radiation heat from the exhaust pipe being transmitted to the battery pack using the mounting member (heat insulating material)
Implementation Method 2
The mounting member is formed with a hole portion into which the projecting portion is inserted. A shortest distance between the projecting portion and the underbody is less than a minimum value of a thickness of the mounting member
Data Source
AI summary
The vehicle includes a vehicle body including an underbody, and a battery pack attached to the vehicle body below the underbody. The battery pack includes an upper surface portion provided to face the underbody, and a heat insulating material (mounting member) attached to the upper surface portion. The upper surface portion is provided with a projecting portion protruding toward the underbody side. The heat insulating material is formed with a hole portion into which the projecting portion is inserted. The shortest distance between the projecting portion and the underbody is less than the minimum value of the thickness of the insulation.