Traction Battery Support Assembly with Nested Housings
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Solution Overview
Problem
Existing traction battery structures require separate packaging space for supporting platforms and enclosure covers, leading to increased complexity and footprint, especially when arranging battery arrays in tiers.
Innovation Solution
A support assembly that secures a first housing, a second housing, and a cover using a common attachment, allowing the second housing to nest within the first housing and the cover to enclose the battery structures, reducing the need for separate fastening and packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate platforms and covers are used to support battery arrays in tiers, then the battery structures can be securely supported, but the packaging footprint and structural complexity increase
Solution Approach 1:
The patent combines the platform and cover into a single integrated housing structure that supports multiple battery arrays in tiers. The housing includes nested first and second housings that provide support for lower and upper battery arrays respectively, eliminating the need for separate platforms and covers for each tier.
Solution Approach 2:
The patent employs nesting by placing the second housing within the first housing, creating a compact tiered structure. The second housing nests within the open area of the first housing, allowing upper battery arrays to be supported within the structural envelope of the lower tier support without requiring additional external structures.
2Reliability
If separate platforms and covers are used for each battery tier, then adequate support is provided, but the packaging space and weight increase
Solution Approach 1:
The platform and cover functions are merged into a single housing structure that provides both support and enclosure for multiple battery tiers, reducing the total material required and consequently the weight of the battery assembly.
Solution Approach 2:
By nesting the second housing within the first housing, the patent reduces the overall volume and weight of the support structure compared to using separate external platforms and covers for each tier.
3Reliability
If separate fastening structures are used for each housing component, then secure assembly is achieved, but the number of parts and assembly complexity increase
Solution Approach 1:
The patent merges the fastening operations into a single common attachment process. The cover is attached to both the first housing and the second housing simultaneously, eliminating the need for separate fastening structures and reducing the total number of fasteners required.
Solution Approach 2:
The cover serves multiple functions: it encloses the second battery structure, provides a mounting surface for common attachments, and structurally connects both the first and second housings. This multi-functionality reduces the number of separate fastening components needed.
4Reliability
If separate packaging space is allocated for each support component, then proper support is ensured, but the overall footprint increases
Solution Approach 1:
The nested housing configuration allows the second housing to be positioned within the open area of the first housing, creating a compact tiered arrangement that minimizes the horizontal footprint while maintaining adequate support space for both battery arrays.
Solution Approach 2:
The patent transitions from a horizontal arrangement of separate platforms to a vertical tiered structure with nested housings. This dimensional change allows multiple battery arrays to be supported within a smaller horizontal footprint by utilizing vertical space efficiently.
Data Source
AI summary
An exemplary support assembly includes a first housing that supports a first battery structure, a second housing that supports a second battery structure, a cover, and a common attachment that secures together the first housing, the second housing, and the cover. An exemplary support method includes securing together a first housing, a second housing, and a cover with a common attachment. The first housing supports a first battery structure that is enclosed by the second housing. The second housing supports a second battery structure that is enclosed by the cover.