Battery Tray Bracket Structure for EV Crash Load Distribution
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Solution Overview
Problem
The large and heavy battery in electric vehicles is prone to shorting during impacts and coolant leaks from the cooling system can further compromise its integrity, necessitating a solution to distribute forces effectively during crashes and protect the battery from deformation.
Innovation Solution
A bracket system is designed to connect the battery tray, rocker rail, and subframe, distributing force from the subframe to the rocker rail and battery tray during impacts, featuring ribs and sub-brackets to reinforce and protect the battery compartment, while preventing wheel embedding into the wheel well.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the battery is made large and heavy to provide sufficient power, then the power output is improved, but the battery becomes more susceptible to damage during impacts and coolant leaks
Solution Approach 1:
The patent implements a bracket system with force distribution features and impact absorption capabilities that are pre-designed to protect the battery before impacts occur. The bracket includes structural elements positioned to absorb and distribute impact forces away from the battery, and cooling system components are configured to prevent coolant leakage onto the battery, thereby cushioning the battery against potential damage in advance.
Solution Approach 2:
The bracket system acts as an intermediary protective structure between external impact forces and the battery. It includes dedicated force distribution features that intercept and redirect impact loads, and cooling system interface elements that mediate between the cooling system and battery, preventing direct contact between coolant and battery components during leakage events.
2Ease of manufacture
If traditional mounting methods are used to secure the battery, then installation is simple, but forces are not effectively distributed during crashes leading to battery deformation
Solution Approach 1:
The bracket system is segmented into distinct functional features: mounting portions for attachment, force distribution features with specific geometric configurations, and cooling system interface elements. This segmentation allows each feature to perform its specific function optimally while maintaining overall structural integrity during impacts.
Solution Approach 2:
The bracket incorporates local quality variations through its force distribution features, which have specific thicknesses, angles, and material properties tailored to distribute forces effectively at critical locations. The bracket structure includes varying wall thicknesses and reinforcement zones positioned precisely where impact forces are most likely to concentrate, providing localized strength without compromising overall manufacturability.
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.