Underbody Battery Support Plate for Load and NVH Isolation
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Solution Overview
Problem
Electrified vehicle battery packs mounted under the vehicle body are susceptible to various loads such as impact, durability, torsional, bending, and noise, vibration, and harshness (NVH) loads, which existing support structures fail to adequately address, leading to potential damage and performance issues.
Innovation Solution
A frame assembly with a battery support plate secured to passenger and driver side rails, using mechanical fasteners to engage cross-members within the battery pack enclosure, along with isolators and a rib structure to provide protection and isolation from these loads, while maintaining a less complex mounting system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing support structures are used for battery packs, then the battery pack can be mounted to the vehicle frame, but the battery pack is susceptible to impact, durability, torsional, bending, and NVH loads that are not adequately addressed
Solution Approach 1:
A battery support plate is introduced as an intermediary component between the battery pack and the vehicle frame rails. The support plate includes isolators that mediate the connection, absorbing and isolating impact, torsional, bending, and NVH loads from the battery pack while maintaining secure mounting to the frame.
Solution Approach 2:
The isolators are pre-installed on the battery support plate to provide beforehand cushioning against various vehicle loads. These isolators are designed to absorb and mitigate impact, torsional, and bending loads before they can reach the battery pack, enhancing its protection and reliability.
2Reliability
If a protective support structure is implemented, then the battery pack is protected from various loads, but the mounting system becomes more complex
Solution Approach 1:
The battery support plate merges multiple functions into a single component: it provides structural support, mounts the battery pack to the frame rails, incorporates isolators for load protection, and includes ribs for additional structural reinforcement. This integration reduces the number of separate components needed while maintaining comprehensive protection.
Solution Approach 2:
The battery support plate is designed as a multi-functional component that simultaneously performs mounting, protection, and structural reinforcement functions. The isolators provide universal protection against multiple types of loads (impact, torsional, bending, NVH), making the system versatile without requiring separate specialized components for each function.
Data Source
AI summary
An electrified vehicle assembly includes a frame that has a passenger side rail and a driver side rail. The assembly further includes a battery support plate and a battery pack. The battery support plate is secured to the passenger side rail and the driver side rail. The battery pack has a plurality of cross-members. To secure the battery pack to the battery support plate, mechanical fasteners each extend through an aperture in the battery support plate to engage one of the cross-members.