Battery Pack Frame Assembly for Cooling Plate Vibration Resistance
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Solution Overview
Problem
Conventional battery pack assemblies in electrified vehicles experience deformation and material damage due to vibrations and impact loads during driving, leading to cracking of cooling plates and surrounding frame members, as gaps between components amplify vibration amplitudes.
Innovation Solution
A structural frame support assembly with strategically positioned protrusions and vibration-resistant holding pads, such as expanded polypropylene, is integrated to inhibit relative movement between the cooling plate and support frame, ensuring uniform transmission of vibrations and impacts, thereby reducing component damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery pack assemblies are used with gaps between components, then ease of manufacture is improved, but vibration resistance deteriorates causing cracking in cooling plates and frame members
Solution Approach 1:
The patent introduces holding pads as intermediary elements positioned between the cooling plate and the battery pack assembly frame members. These holding pads fill the gaps that would otherwise exist between components, providing a mediating structure that absorbs and distributes vibration forces. The holding pads are specifically placed at locations where gaps would amplify vibration amplitudes, thereby preventing cracking while maintaining the modular assembly structure.
Solution Approach 2:
The holding pads serve as pre-installed cushioning elements that are positioned in advance within the battery pack assembly structure. By placing these vibration-absorbing pads beforehand between the cooling plate and frame members, the design prepares the structure to withstand vibration and impact loads before they occur during vehicle operation, preventing damage rather than reacting to it.
2Adaptability or versatility
If gaps exist between cooling plate and frame members, then assembly flexibility is improved, but vibration amplitudes increase causing material damage
Solution Approach 1:
The holding pads act as intermediary elements that are strategically positioned between the cooling plate and the battery pack assembly frame members. These pads fill the gaps that would otherwise exist between rigid components, providing a compliant interface that absorbs vibration energy. The intermediaries maintain the adaptability of the assembly while eliminating the harmful vibration amplification effect of gaps.
Solution Approach 2:
The introduction of holding pads changes the physical parameters of the interface between the cooling plate and frame members. Instead of having direct rigid contact or open gaps, the holding pads modify the contact characteristics by providing controlled compliance and damping. This parameter change transforms the vibration transmission characteristics from harmful amplification to beneficial absorption.
3Strength
If rigid structural support is used without vibration damping, then structural strength is improved, but vibration-induced cracking increases
Solution Approach 1:
The battery pack assembly employs a composite structural approach by combining rigid frame members with compliant holding pad materials. The rigid frame members provide the necessary structural strength and support, while the holding pads made of vibration-resistant materials provide damping and crack prevention. This composite construction allows the system to benefit from both rigidity and flexibility simultaneously.
Solution Approach 2:
Rather than making the entire structure uniformly rigid or compliant, the patent applies local quality by placing holding pads only at specific locations where vibration amplification and cracking risks are highest. The rigid frame members maintain their strength overall, while localized areas with holding pads provide the necessary vibration damping and crack resistance where most needed.
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 solution effectively enhances the anti-impact and vibration absorption capabilities of the battery pack, minimizing the risk of component failure and extending the lifespan of the battery pack assembly by reducing deformation and damage from repeated vibrations.
Implementation Method 1
a holding pad is disposed between the floor module support frame and the cooling plate at the central body. The holding pad can be formed of a vibration resistant material.
Implementation Method 2
The holding pad can be formed of expanded polypropylene
Data Source
AI summary
A battery pack assembly for an electrified vehicle includes a main body assembly comprising a structural frame support assembly including a floor module support frame and a cooling plate. The floor module support frame includes a central body, a first protrusion support and a second protrusion support. The central body has an upper surface that extends along a central body plane. The first protrusion support can be configured along a first edge and have an upper surface that extends along a first support plane that is offset from the central body plane. The second protrusion support can be configured along a second end and have an upper surface that extends along a second support plane that is offset from the central body plane. The first and second protrusion supports can inhibit relative movement between the cooling plate and floor module support frame.