Battery Pack Support Isolation for Vehicle Load Decoupling
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Solution Overview
Problem
Electrified vehicle battery packs mounted under the vehicle body are susceptible to various loads such as impact, durability, torsional, bending, and NVH loads, which can compromise their performance and durability.
Innovation Solution
A mounting system comprising a battery support structure and isolators that decouple the battery pack from the vehicle frame, using a metallic platform and fasteners to support the battery pack while isolators, typically with a damping portion, absorb and dissipate loads, preventing direct transmission to the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery pack is directly mounted to the vehicle frame, then the mounting structure is simple, but the battery pack is susceptible to impact, durability, torsional, bending, and NVH loads
Solution Approach 1:
The patent introduces a battery support structure as an intermediary component between the vehicle frame and the battery pack. This support structure includes mounting points that attach to the frame and additional mounting points that secure the battery pack, thereby mediating the connection and isolating the battery pack from direct exposure to vehicle loads.
Solution Approach 2:
The mounting system is segmented into distinct functional components: the vehicle frame, the battery support structure with multiple mounting points, and the battery pack. This segmentation allows each component to perform its specific function independently, with the support structure bearing the brunt of mechanical loads while the battery pack remains protected.
2Device complexity
If the battery pack is directly mounted to the vehicle frame, then the mounting system is simple, but the battery pack is exposed to noise, vibration, and harshness loads
Solution Approach 1:
The battery support structure serves as a mediator that decouples the battery pack from the vehicle frame, preventing direct transmission of noise, vibration, and harshness loads. The support structure absorbs and isolates these harmful factors while maintaining the necessary mechanical connection.
3Reliability
If isolators are added between the battery pack and support structure, then the battery pack is isolated from loads, but the mounting system becomes more complex
Solution Approach 1:
Isolators are introduced as intermediary elements between the battery pack and the battery support structure. These isolators provide mechanical decoupling that prevents direct transmission of impact, torsional, and bending loads while maintaining the structural connection necessary for support.
Solution Approach 2:
The isolators provide beforehand cushioning by being pre-installed between the battery pack and support structure, ready to absorb and dissipate mechanical loads before they can reach the battery pack. This proactive protection mechanism mitigates potential damage from various vehicle operational loads.
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 supports the battery pack while isolating it from vehicle loads, enhancing durability and reducing noise, vibration, and harshness, thereby improving the overall performance and longevity of the battery pack.
Implementation Method 1
isolators, typically with a damping portion, absorb and dissipate loads, preventing direct transmission to the battery pack
Data Source
AI summary
This disclosure details systems and methods for supporting and isolating vehicle body mounted battery packs from various vehicle loads. An exemplary electrified vehicle may include a frame, a battery support structure mounted to the frame, a battery pack, and one or more isolators. The battery pack is supported by the battery support structure but is not mechanically coupled to the frame. The isolator is mounted between the battery pack and the battery pack support structure for isolating the battery pack from loads that may be imparted on the frame and/or the battery support structure.