Vehicle Battery Straps for Shock Load Absorption
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Solution Overview
Problem
Conventional battery mounting systems for electric vehicles are unable to effectively absorb shock loads without causing damage to the battery system, leading to safety risks and increased weight, complexity, and cost due to the use of rigid mounts and expensive shock-absorbing carriages.
Innovation Solution
A battery mounting system utilizing a plurality of straps that deform prior to the battery housing when subjected to shock loads, with guides and channels configured to distribute forces and attach to the vehicle, allowing the straps to absorb energy without deforming the battery housing, and adjustable tension to manage stress and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid mounts or non-compliant straps are used to mount the battery system, then the battery system is securely fixed to the vehicle, but the battery system cannot absorb shock loads and undergoes plastic deformation resulting in damage
Solution Approach 1:
The patent changes the mechanical parameters of the mounting system by using compliant straps with specific elastic properties instead of rigid mounts. The straps are designed with controlled stiffness and yield characteristics to deform elastically under shock loads, absorbing energy while protecting the battery system from damage.
Solution Approach 2:
The patent employs flexible strap elements that wrap around the battery housing to provide compliant mounting. These thin, flexible straps can deform under load to absorb shock energy, contrasting with rigid mounts that would transmit shock directly to the battery system.
2Reliability
If carriage or bay mounted on springs is used to damp shock loads, then the battery system is protected from shock damage, but the system adds undesired weight, complexity, and reduces access to the battery system
Solution Approach 1:
The patent extracts the shock-absorbing function from complex carriage-and-spring assemblies and implements it directly through the straps themselves. The compliant straps provide both mounting and shock absorption in a single integrated element, eliminating the need for separate spring mechanisms and reducing overall system complexity.
Solution Approach 2:
The straps serve multiple functions simultaneously: they mount the battery system to the vehicle, provide shock absorption, and maintain battery positioning. This multi-functionality eliminates the need for separate components like carriages and springs, reducing complexity while maintaining protection.
3Reliability
If carriage or bay mounted on springs is used to damp shock loads, then the battery system is protected from shock damage, but the system adds undesired weight to the vehicle
Solution Approach 1:
The patent uses simple, lightweight strap elements that can be replaced if needed, rather than heavy, permanent carriage structures. The straps provide adequate shock protection through their compliant properties without the excessive weight of traditional spring-mounted carriages.
4Stability of the object's composition
If rigid mounts are used to secure the battery system, then the battery system is firmly attached to the vehicle, but the mounts cannot deform to absorb shock loads
Solution Approach 1:
The patent transitions from static rigid mounts to dynamic compliant straps that can adapt their deformation characteristics based on applied loads. The straps remain stable during normal operation but can deform elastically under shock loads, providing both stability and shock absorption.
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 absorbs shock loads up to 50 g's along multiple axes before deforming the battery housing, reducing the risk of damage and maintaining vehicle safety without adding unnecessary weight or expense.
Implementation Method 1
Each of the straps is configured to deform in response to contact with the wall portion of the respective one of the guides, such that upon application of a shock load to the battery housing along a first axis, the plurality of straps deforms prior to deformation of the battery housing
Data Source
AI summary
A vehicle battery system includes a battery housing and a plurality of straps. The battery housing is configured to house a battery for powering the vehicle. Each of the plurality of straps is configured to extend about the battery housing, and includes a first end portion and a second end portion that are configured to be attached to the vehicle. The plurality of straps is configured such that upon application of a shock load to the battery housing along a first axis, the plurality of straps deforms prior to deformation of the battery housing.