Battery Support Structure With Hinge Mechanism For Impact Protection
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Solution Overview
Problem
Electrified vehicle battery systems face challenges in maximizing driving range and protecting battery cells from impact damage, as high voltage traction batteries are often located in impact zones and require structural energy management to maintain integrity.
Innovation Solution
A battery support structure with a hinge mechanism, guide rail, slide rail, and linkages that allow rotational movement of the traction battery relative to a support surface, enabling it to be secured and lifted away from impact zones during collisions, thereby reducing the risk of intrusion into the battery housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery is located in the trunk area adjacent to impact zones, then the vehicle's effective driving range is maximized, but the battery cells are exposed to impact damage and intrusion risks
Solution Approach 1:
The battery support structure transitions from a static fixed position to a dynamic movable position through the linkage mechanism. The battery can rotate between a normal operating position (secured to support surface) and a protected position (raised away from impact zone), allowing the system to adapt its configuration based on operational conditions - secured during normal driving for stability, and protected during impact events
Solution Approach 2:
The hinge mechanism and linkage are pre-configured to automatically activate upon impact detection. The structure is designed in advance with the capability to rotate the battery away from the impact zone before actual intrusion occurs, creating a preliminary protective action that prevents harm rather than responding after damage occurs
2Reliability
If a fixed battery mounting structure is used, then the battery is securely positioned, but the battery cannot be displaced from impact zones during collisions
Solution Approach 1:
The mounting structure transforms from a purely fixed rigid connection to a dynamic system that can change its configuration. The hinge mechanism allows the battery to rotate between a secured fixed position during normal operation and a displaced protected position during impact, providing both stability and adaptability through controlled movement
Solution Approach 2:
The hinge mechanism acts as an intermediary element between the battery and the support surface. This intermediate component enables controlled rotation and movement, serving as a mediator that allows the battery to transition between secured and protected positions while maintaining connection to the vehicle structure
3Ease of manufacture
If the battery is secured directly to the support surface, then installation is simple, but the battery housing is vulnerable to deformation and intrusion
Solution Approach 1:
The hinge mechanism serves as an intermediary component between the battery and support surface, adding protective functionality without significantly complicating installation. This intermediate element enables the battery to rotate into a protected position while maintaining a relatively simple connection system that can be installed using standard mounting procedures
4Object-affected harmful factors
If a movable battery support system is implemented, then the battery can be protected from impact, but the device complexity increases
Solution Approach 1:
The support structure implements a single-degree-of-freedom rotational mechanism rather than a complex multi-axis system. The hinge allows controlled movement in one primary direction (rotation away from impact zone), providing effective protection while maintaining relatively simple mechanical design with fewer moving parts and control requirements compared to more complex dynamic systems
Data Source
AI summary
An electrified vehicle includes a body structure defining a support surface and a crush space adjacent the support surface. The electrified vehicle further includes a traction battery for providing power to a powertrain. The electrified vehicle further includes a battery support structure having at least one hinge mechanism secured to the traction battery and to the support surface to permit rotational movement of the traction battery relative to the support surface. The battery support structure further includes a guide rail secured to the support surface. The battery support structure further includes a slide rail disposed in engagement with the guide rail and slidable relative to the guide rail. The battery support structure further includes at least one linkage rotatably secured at a first end to the slide rail and rotatably secured at a second end to the traction battery.