Battery Support Post Design for Multi-Tier Module Stability
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Solution Overview
Problem
Traction batteries in electrified vehicles with multiple tiers face challenges in load absorption due to increased vertical height and higher center of gravity, leading to potential tipping and buckling of upper tier battery modules under applied loads.
Innovation Solution
The use of posts mounted on a cross-member within the traction battery enclosure to support the upper tier tray, which includes a tapered tower portion with flanges and webs for enhanced load distribution and stability, securing the tray through mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If upper tiers of battery modules are arranged in a traction battery, then the energy density and power output are improved, but the vertical height increases and the center of gravity rises, leading to tipping and buckling under load
Solution Approach 1:
The support structure is segmented into multiple posts distributed across the upper tier tray, with each post independently supporting specific regions. This segmentation allows the load to be distributed across multiple support points rather than concentrated at single locations, preventing tipping and buckling while maintaining the multi-tier configuration for high power output.
Solution Approach 2:
The support posts extend vertically from the lower tier tray through the upper tier tray, adding a vertical support dimension to the horizontal battery module arrangement. This vertical dimensionality provides structural stability against tipping and buckling forces while preserving the multi-tier configuration that enables high power output.
2Ease of manufacture
If stamped sheet-metal support brackets are used to support upper tiers, then the manufacturing cost is reduced, but the load absorption capability and structural integrity are insufficient
Solution Approach 1:
The support posts are constructed as composite structures combining aluminum extrusions with integrated attachment flanges and mounting features. This composite design provides superior load absorption capability compared to simple sheet-metal brackets while maintaining manufacturing efficiency through extrusion processes and standardized assembly procedures.
Solution Approach 2:
The support posts utilize tapered cylindrical geometry with curved surfaces that provide structural strength and load distribution. The curved, tapered shape naturally resists buckling forces and distributes loads more effectively than flat sheet-metal brackets, while the extrusion process makes this complex geometry manufacturable.
3Quantity of substance
If the vertical height of the traction battery is increased to accommodate multiple tiers, then the energy capacity is improved, but the center of gravity rises and tipping resistance decreases
Solution Approach 1:
The support structure is segmented into multiple posts distributed across the upper tier tray, with each post independently supporting specific regions. This segmentation allows the load to be distributed across multiple support points rather than concentrated at single locations, preventing tipping and buckling while maintaining the multi-tier configuration for high power output.
Solution Approach 2:
The support posts act as intermediary structural elements between the lower tier tray and the upper tier battery modules. These intermediaries transfer and distribute the weight and load forces from the elevated upper tiers down to the lower tier structure, enabling high energy capacity while mitigating tipping risks through proper load path management.
Data Source
AI summary
A battery assembly includes, among other things, an upper tier tray, an upper battery module supported on the upper tier tray, and a post that supports the upper tier tray. A battery module support method according to another exemplary aspect of the present disclosure includes, among other things, supporting an upper tier tray with a post; and supporting an upper battery module with the upper tier tray.