Battery Pack Mounting Brackets for Impact Load Absorption
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Solution Overview
Problem
Existing battery pack mounting systems in electrified vehicles fail to effectively absorb and distribute impact loads, particularly side impacts, which can lead to disconnection and potential damage to the battery pack.
Innovation Solution
A mounting system comprising outboard and inboard brackets that secure the battery pack to the vehicle underbody and tunnel, allowing for flexible movement and absorption of impact loads while maintaining attachment, featuring legs that deform to comply with impact forces and prevent crack propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid mounting system is used to securely attach the battery pack, then connection strength is improved, but impact force transmission increases causing potential damage
Solution Approach 1:
The mounting bracket incorporates a flexible element that can deform under impact loads, allowing the system to absorb shock while maintaining connection. This flexible component acts as a shock-absorbing mechanism that prevents rigid force transmission to the battery pack.
Solution Approach 2:
The mounting system includes energy-absorbing features designed to deform during impact events, providing cushioning before the full impact force reaches the battery pack. This pre-planned deformation capability protects the battery from sudden shock loads.
2Stability of the object's composition
If the battery pack is rigidly fixed to prevent movement, then stability is improved, but impact load absorption is reduced
Solution Approach 1:
The mounting bracket transitions from a static rigid connection to a dynamic system that can adapt its stiffness characteristics. The flexible element allows controlled movement and deformation during impact, enabling the system to absorb energy while maintaining overall stability.
Solution Approach 2:
The mounting system changes its mechanical parameters (stiffness, flexibility) in response to impact conditions. Under normal operation, the bracket provides stable rigid support, but during impact, the flexible element deforms to change the effective stiffness, allowing impact load absorption.
3Reliability
If multiple mounting points are used to distribute load, then connection reliability is improved, but system complexity increases
Solution Approach 1:
The mounting system divides the connection into multiple discrete mounting points distributed across the battery pack and vehicle structure. This segmentation allows load distribution while maintaining manageable complexity through modular bracket design with standardized attachment points.
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 system effectively reduces peak forces on the battery pack during impacts, keeping it secured to the underbody and preventing disconnection, while allowing it to move away from the impact zone, thus enhancing safety and durability.
Implementation Method 1
Existing battery pack mounting systems in electrified vehicles fail to effectively absorb and distribute impact loads, particularly side impacts
Implementation Method 2
featuring legs that deform to comply with impact forces
Implementation Method 3
A mounting system comprising outboard and inboard brackets that secure the battery pack to the vehicle underbody and tunnel, allowing for flexible movement and absorption of impact loads
Data Source
AI summary
A battery pack mounting system includes, among other things, an outboard bracket connecting a battery pack to a vehicle underbody, a first inboard bracket connecting the battery pack to the vehicle underbody, and a second inboard bracket connecting the battery pack to a tunnel of the vehicle underbody.