On-Board Battery Protection Structure for Vibration Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing number of battery stacks in vehicle batteries leads to higher production costs, weight, and vibration-induced damage due to enlarged vibration amplitudes, particularly in the intermediate area of the battery stack, where cells may collide with surrounding components.
Innovation Solution
A protection structure that suspends and supports the battery stack by a frame fixed to the vehicle body, using a combination of frames and fixing members to reduce vibration amplitude and absorb collision impacts, thereby preventing damage from vehicle vibrations and collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of battery stacks is increased to achieve higher capacity, then the battery cell capacity is improved, but the weight and production cost increase
Solution Approach 1:
Multiple battery stacks are combined into a single integrated battery pack structure with a unified protective housing and shared mounting system. The battery stacks are arranged in parallel within the housing and collectively mounted to the vehicle body through a single frame structure, reducing redundant components and overall weight while maintaining high capacity
Solution Approach 2:
The protective housing serves multiple functions: it contains the battery stacks, provides structural protection, acts as a mounting platform for the frame, and serves as a thermal management enclosure. This multi-functionality eliminates the need for separate components, reducing weight and production cost
2Quantity of substance
If the number of battery stacks is increased to achieve higher capacity, then the battery cell capacity is improved, but the production cost increases
Solution Approach 1:
The battery pack is segmented into modular battery stacks that can be independently manufactured and then assembled into the final pack. This modular approach allows for standardized production processes, reducing manufacturing complexity and cost while enabling high capacity through parallel configuration of multiple stacks
Solution Approach 2:
Multiple battery stacks share common structural components including the protective housing, cooling channels, and mounting frame. This consolidation reduces the total number of parts that need to be manufactured and assembled, lowering production costs while achieving high overall capacity
3Stability of the object's composition
If the battery stack is fixed rigidly to the vehicle body, then the stability is improved, but the vibration-induced damage increases due to enlarged vibration amplitudes
Solution Approach 1:
A damping element is inserted between the battery stack and the mounting frame to provide vibration isolation before vibrations can cause damage. This cushioning element absorbs and dissipates vibrational energy, protecting the battery cells from vibration-induced damage while maintaining stable mounting
Solution Approach 2:
The damping element acts as an intermediary between the rigid vehicle body and the battery stack. It transmits necessary mechanical support while filtering out harmful vibrations, mediating between the conflicting requirements of stable mounting and vibration protection
4Object-affected harmful factors
If the battery stack is suspended by a frame, then the vibration-induced damage is reduced, but the device complexity increases
Solution Approach 1:
The mounting frame is integrated with the protective housing to form a unified structural component. The frame serves dual functions as both the protective enclosure and the vibration-isolating mounting structure, eliminating the need for separate mounting brackets or additional vibration isolation components
Solution Approach 2:
The frame structure performs multiple functions: it provides structural support, acts as a vibration isolation mechanism through its flexible mounting points, serves as a thermal management conduit, and provides mechanical attachment to the vehicle body. This multi-functionality reduces overall system complexity despite the sophisticated vibration protection
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 reduces the risk of battery cell damage from vibrations and collisions, allows for increased battery cell capacity without increasing production costs or weight, and minimizes internal resistance by reducing the amount of electric wiring needed.
Implementation Method 1
a damping element is inserted between the battery stack and the mounting frame, the damping element being made of a viscoelastic material
Implementation Method 2
the damping element being made of a viscoelastic material
Implementation Method 3
each frame is coupled to a vehicle body around the housing space... protecting the battery stack from travelling vibration and collision impact of the vehicle
Data Source
AI summary
A protection structure for an on-board battery. The on-board battery includes a battery stack and is configured to be mounted on a vehicle. The protection structure includes a first frame, a second frame, and a fixing member. The first frame is to be coupled to an upper portion of a battery case that contains the battery stack, so as to fix the battery case to a vehicle body of the vehicle. The second frame is to be disposed above the battery case and to be coupled to the first frame. The fixing member is to be fixed to the second frame so as to suspend and support the battery stack. The second frame is to be disposed in a direction crossing a longer direction of the battery stack and at least at an approximate center in the longer direction of the battery stack.