Battery Support Pad Structure for Shock and Vibration Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery support systems fail to adequately protect batteries from vibrational and gravitational shocks, leading to premature failure and reduced performance due to micro-fractures and short-circuits, and are often costly and bulky, lacking customization options.
Innovation Solution
A support pad made of shock-absorbing elastomer material with a raised grid pattern that disperses gravitational forces along the z-axis, x-axis, and y-axis, reducing impact shock by 65-80% and preventing battery slippage, manufactured using a mixture of elastomer scraps and virgin material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery trays or boxes are used to hold batteries, then batteries are supported in place, but they fail to adequately protect batteries from vibrational and gravitational shocks, leading to micro-fractures and premature failure
Solution Approach 1:
The patent applies beforehand cushioning by incorporating a shock-absorbing gel material between the battery and the tray/box structure. This gel layer is pre-positioned to cushion against vibrational and gravitational shocks before they reach the battery, preventing micro-fractures and internal damage. The gel material specifically addresses the harmful shock forces that cause battery failure during vehicle operation.
Solution Approach 2:
The shock-absorbing gel serves as an intermediary layer between the battery and the rigid tray or box structure. This intermediary material absorbs and dissipates the impact forces generated during vehicle operation, particularly during rough terrain or wave conditions, thereby protecting the battery from direct shock transmission while maintaining structural support.
2Reliability
If battery isolation cases or boxes are used to protect batteries from shock, then vibration protection is improved, but the cases become bulky and expensive
Solution Approach 1:
The patent merges the shock protection function with the existing battery tray or box structure by integrating a shock-absorbing gel layer into the design. Rather than using a separate bulky isolation case, the gel is incorporated directly into the battery mounting system, combining structural support and shock absorption into a single integrated solution that reduces overall volume.
Solution Approach 2:
The shock-absorbing gel material functions as a flexible protective layer that conforms to the battery shape and tray configuration. This thin, flexible gel film provides effective vibration and shock protection without requiring the bulky rigid structures of traditional isolation cases, thereby reducing volume while maintaining protection efficacy.
3Reliability
If battery isolation cases are used to reduce shock impact, then battery life is extended, but the cases are expensive and lack customization options
Solution Approach 1:
The shock-absorbing gel material allows for parameter changes in terms of customization - the gel can be formulated with different viscosities, densities, and shock absorption characteristics to match specific battery requirements. Additionally, the gel layer thickness and coverage area can be adjusted to fit various battery sizes and configurations, providing adaptability without requiring completely different isolation case designs.
Solution Approach 2:
The shock-absorbing gel provides universal protection that can be applied across different battery types, sizes, and configurations. Rather than requiring specialized isolation cases for each battery model, the gel material serves multiple functions - cushioning, vibration damping, and thermal management - making it a versatile solution that extends battery life across various applications without customization limitations.
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 support pad significantly extends battery life by reducing vibrational and gravitational forces, preventing micro-fractures and short-circuits, while being cost-effective and customizable to fit various battery sizes.
Implementation Method 1
absorbing energy from vibrational forces applied to a battery
Implementation Method 2
absorbing energy from gravitational forces applied to a battery
Implementation Method 3
transferring the gravitational force along a z-axis of the shock absorbing material resulting from up and down movement of the battery
Implementation Method 4
dispersing the gravitation force through the shock absorbing material along an x-axis and a y-axis thereby reducing the impact shock on the battery
Data Source
AI summary
This invention relates to a support pad formed of a shock absorbing material capable of absorbing energy resulting from vibration and gravitational forces acting on a battery disposed in engagement with the support pad and, correspondingly, transferring gravitational forces that occur along a z-axis resulting from up and down movement of the battery and dispersing these gravitation forces along an x-axis, a y-axis and the z-axis so as to reduce the impact shock on the battery by between about 65% to about 80% and, in doing so, prolonging the performance and life-cycle of the battery.