Bracket Attachment Structure With Internal Plate For Impact Energy Absorption
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Solution Overview
Problem
Existing battery tray structures in electric vehicles lack effective energy absorption and maintenance of attachment during impacts, which can lead to damage and intrusion of the battery enclosure into other vehicle components.
Innovation Solution
A bracket system with parallel flanges interconnected by a side, featuring a plate disposed at an angle that ruptures at a trigger point to allow the enclosure to shift away from impacts, while the flanges deform to absorb energy and maintain attachment to the floor, ensuring the battery's integrity and preventing intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bracket uses a rigid structure to maintain attachment strength, then the attachment reliability is improved, but the energy absorption capability deteriorates
Solution Approach 1:
The bracket is segmented into multiple functional components: a rigid body portion for maintaining attachment reliability, a sacrificial plate with a trigger portion for energy absorption, and a connection portion for structural integrity. This segmentation allows different parts to perform different functions - the rigid body maintains attachment while the sacrificial plate absorbs impact energy through controlled rupture.
Solution Approach 2:
The sacrificial plate acts as an intermediary element between the rigid bracket structure and the impact force. It mediates the energy transfer by absorbing impact energy through controlled deformation and rupture at the trigger portion, protecting the main bracket structure while maintaining attachment reliability.
2Loss of energy
If the bracket structure is made more complex to absorb energy, then the energy absorption capability is improved, but the device complexity increases
Solution Approach 1:
The sacrificial plate integrates multiple functions into a single component: it serves as both a structural connector and an energy absorption mechanism. The plate's geometry, including the trigger portion and angled surface, combines structural support with impact energy absorption, eliminating the need for separate energy absorption devices.
Solution Approach 2:
The bracket structure utilizes parameter changes in the sacrificial plate during impact - the plate transitions from a rigid structural element to a deforming energy-absorbing component. The trigger portion is designed to rupture at specific stress thresholds, changing the structural parameters dynamically during impact events to absorb energy while maintaining overall structural integrity.
3Loss of energy
If the plate ruptures during impact to allow enclosure movement, then the energy absorption is improved, but the structural integrity deteriorates
Solution Approach 1:
The sacrificial plate is designed as a disposable component that is intended to rupture during impact events. It is a lower-cost element compared to the main bracket structure and battery enclosure, sacrificing itself to absorb impact energy and protect the more valuable components. The plate's controlled rupture at the trigger portion allows energy absorption while the rigid body portion maintains overall attachment integrity.
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 bracket system effectively absorbs impact energy, maintains attachment to the vehicle underbody, and prevents battery enclosure intrusion, enhancing the durability and safety of the battery pack by allowing controlled deformation and rupture of the plate during impacts.
Implementation Method 1
the plate is configured to rupture at a trigger during an impact such that, coupled with deformation of the first flange, the enclosure shifts in a direction away from the impact
Implementation Method 2
the plate includes a wall configured to break at a pre-defined point on the wall during an impact
Implementation Method 3
coupled with deformation of the first flange, the enclosure shifts in a direction away from the impact
Data Source
AI summary
A vehicle underbody includes a battery pack surrounded by an enclosure, and a bracket. The bracket has first and second flanges disposed in a parallel arrangement, and includes a plate having a wall configured to, in response to an impact, rupture at a trigger to allow the enclosure to move away from an impact direction and deform the first flange. The wall is disposed at angle relative to the flanges, and defined such that impact energy is absorbed by the wall and first flange. The first flange, during an impact, moves toward the second flange, which maintains attachment to the vehicle underbody to absorb energy.