EV Battery Tray Bracket Structure for Impact Load Distribution
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Solution Overview
Problem
The large and heavy electric vehicle battery is prone to shorting during impacts and coolant leakage from the cooling system, which poses risks to the battery's integrity and functionality.
Innovation Solution
A bracket system is designed to connect the battery tray, rocker rail, and subframe, distributing force during impacts and preventing wheel embedding into the wheel wells, thereby reducing battery tray deformation and protecting the battery from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the battery is packaged below the passenger compartment to accommodate its large size and weight, then the battery can be installed in the vehicle, but the battery becomes vulnerable to shorting during impacts and coolant leakage
Solution Approach 1:
The battery support structure is divided into multiple components: a battery tray that directly supports the battery, a bracket system with multiple attachment points, and a cooling system with separate coolant flow paths. This segmentation allows each component to be optimized independently for its specific function while maintaining overall structural integrity during impacts.
Solution Approach 2:
The bracket system is designed with impact absorption capabilities before crashes occur. The bracket includes structural features that cushion and distribute impact forces, protecting the battery from direct impact damage. The cooling system is also designed to prevent coolant leakage that could cause shorting, addressing potential failures before they occur.
2Strength
If a bracket system is designed to connect the battery tray, rocker rail, and subframe to distribute impact forces, then the battery tray deformation is reduced, but the device complexity increases
Solution Approach 1:
The bracket system merges multiple structural functions into a single integrated component. The bracket simultaneously connects the battery tray to both the rocker rail and the subframe, providing structural support and impact force distribution through a unified design rather than separate components.
Solution Approach 2:
The bracket is designed as a multi-functional component that performs multiple roles: it supports the battery tray, connects to the rocker rail for lateral support, connects to the subframe for longitudinal support, and distributes impact forces from multiple directions. This multi-functionality reduces the need for additional separate structural components.
Data Source
AI summary
An electric vehicle includes an electric-vehicle battery tray including a frame member elongated along a vehicle-longitudinal axis. The electric vehicle includes a rocker rail elongated along the vehicle-longitudinal axis. The electric vehicle includes a subframe. The electric vehicle includes a bracket connecting the battery tray, the rocker rail, and the subframe.