Traction Battery Pack Support System Lateral Mounting
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Solution Overview
Problem
Conventional traction battery pack support systems in electrified vehicles often compromise ground clearance, limiting passenger compartment size due to the need for supports extending beneath the battery pack, which restricts the vertical packaging space and affects vehicle design, especially in vehicles with high ground clearance requirements like pickup trucks.
Innovation Solution
A traction battery pack support system that utilizes a vehicle frame rail and a vibration isolator to secure the battery pack, minimizing vertical space usage by positioning the isolator outside the frame rail and using fasteners to couple the battery pack to the frame rail, thereby maintaining ground clearance while providing vibration isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supports extend beneath the battery pack to secure it, then the battery pack is securely supported, but the vertical space is increased and ground clearance is compromised
Solution Approach 1:
The support system transitions from a vertical support configuration (extending beneath the battery) to a lateral support configuration (attaching to side walls). By moving the support direction from vertical to lateral/directional attachment on frame rails, the system achieves secure support without increasing vertical height, thus maintaining ground clearance while ensuring battery pack stability.
2Reliability
If supports extend beneath the battery pack, then the battery pack is securely mounted, but the passenger compartment size is limited due to reduced vertical packaging space
Solution Approach 1:
The mounting system shifts from vertical support (consuming vertical space) to lateral attachment on frame rails (utilizing horizontal/directional space). This dimensional change allows the battery pack to be securely mounted without occupying vertical packaging space, thereby preserving passenger compartment volume while ensuring secure battery mounting.
3Device complexity
If the vibration isolator is positioned inside the frame rail, then the support system is compact, but the isolator cannot effectively isolate vibrations from the battery pack
Solution Approach 1:
The vibration isolator is extracted from the interior of the frame rail and repositioned to engage with the battery pack's side wall in lateral engagement. This extraction allows the isolator to be positioned where it can directly contact and isolate vibrations from the battery pack, improving vibration isolation effectiveness while maintaining support system compactness through lateral rather than vertical space utilization.
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 solution allows for efficient vertical packaging of the traction battery pack, maintaining ground clearance and reducing the overall vertical height of the support system, thus enhancing the design flexibility and space utilization in vehicles with high ground clearance requirements.
Implementation Method 1
a vibration isolator that is disposed outside an interior of the vehicle frame rail and is at least partially vertically aligned with the vehicle frame rail
Implementation Method 2
The fastener is a threaded fastener that extends through an aperture in the flange and an aperture in the bracket... the isolator is compressed vertically between the flange and the bracket
Data Source
AI summary
A traction battery pack support system includes, among other things, a vehicle frame rail of an electrified vehicle, a traction battery pack, a vibration isolator that is disposed outside an interior of the vehicle frame rail and is at least partially vertically aligned with the vehicle frame rail, and at least one fastener that couples the traction battery pack to the vehicle frame rail through the vibration isolator.