Elastic Battery Console Bracket for Vehicle Tolerance
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Solution Overview
Problem
Existing battery console assemblies for vehicles are expensive due to the use of high-cost spring steel and fail to effectively manage tolerances and forces during vehicle travel, leading to potential battery acceleration and safety risks.
Innovation Solution
A battery console design featuring a clamping member with elastic protuberances and integrated mechanical stops, constructed from ordinary steel, which allows for tolerance in assembly and reduces pressure on the battery, ensuring secure fixation and safety without excessive weight or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid clamp or plastic lid is used to retain the battery, then the battery can be secured during vehicle travel, but the manufacturing cost increases due to high material costs and dimensional requirements
Solution Approach 1:
The patent changes the material parameter from expensive spring steel to ordinary steel, and changes the structural parameter from rigid clamp to elastic bracket with protuberances. This allows the use of cheaper materials while maintaining fixation reliability through elastic deformation and tolerance accommodation
Solution Approach 2:
The patent replaces expensive, high-performance spring steel components with cheaper ordinary steel components. The elastic bracket design achieves sufficient functionality at lower cost, accepting that the component may have reduced service life but meeting the operational requirements
2Reliability
If a rigid clamp is used to secure the battery, then the battery is fixed during travel, but excessive pressure is applied to the battery due to tolerance variations in assembly
Solution Approach 1:
The patent changes the structural parameter from rigid to elastic by introducing protuberances on the bracket legs. This elastic structure automatically adjusts to tolerance variations in assembly, maintaining reliable fixation while distributing pressure evenly and avoiding excessive localized stress on the battery
Solution Approach 2:
The patent introduces dynamic elasticity to the fixation system through the elastic bracket design. The bracket can deform elastically to accommodate assembly tolerances and battery dimensional variations, maintaining constant contact and fixation without applying excessive force, unlike rigid clamps
3Ease of manufacture
If gaps are allowed in the assembly due to tolerances, then manufacturing is easier, but the battery can accelerate during rough driving, creating safety risks
Solution Approach 1:
The patent changes the structural parameter from rigid to elastic, allowing the bracket to deform and accommodate assembly gaps. This eliminates the harmful effect of battery acceleration during rough driving while maintaining ease of manufacture through ordinary steel and standard tolerances
Solution Approach 2:
The elastic bracket design provides beforehand cushioning by accommodating assembly gaps and dimensional variations before they can lead to battery movement. The elastic protuberances ensure continuous contact and prevent gaps from forming during vehicle operation, eliminating safety risks
4Reliability
If the battery console is designed to withstand considerable forces, then the battery is secured during travel, but the dimensions and weight of the console increase
Solution Approach 1:
The patent changes the material parameter from heavy spring steel to lighter ordinary steel, and changes the structural parameter to an elastic bracket design. This reduces the weight of the battery console while maintaining reliable battery retention through elastic deformation and proper force distribution
Solution Approach 2:
The patent uses an elastic bracket structure that can deform flexibly to accommodate battery movements and forces. This flexible design provides adequate retention reliability without requiring the heavy, rigid structure that would otherwise be needed to withstand all possible forces
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 design enables cost-effective production using ordinary steel, reduces the risk of battery acceleration, and provides enhanced safety through elastic protuberances and mechanical stops, ensuring secure battery retention during vehicle travel.
Implementation Method 1
the second bracket leg has at least one elastic protuberance protruding, when attached to the battery compartment, towards the floor such that contact between a top side of a battery placed in the battery compartment and the protuberance is ensured by the elasticity of the at least one elastic protuberance irrespective of minor differences in height of the battery
Data Source
Figure 1
Figure 2
AI summary
Embodiments herein relate to a battery console (1) for a vehicle comprising: a battery compartment comprising a floor (2), a rear wall (3), and respective left (4) and right (5) sidewalls. A bracket (6) is provided for fixation of a battery to the battery compartment. The bracket (6) has a first (6a) and a second (6b) bracket leg which are attachable to the battery compartment at a respective first (6a1) and second (6b1) end of the bracket (6) such that the first bracket leg (6a) extends from the floor (2) upwardly in front of a battery placed in the battery compartment and such that the second bracket leg (6b) extends from the top of the first bracket leg (6a) towards the rear wall (3) above the battery. The second bracket leg (6b) has at least one elastic protuberance (6b2) protruding towards the floor (2) such that contact between a top side of the battery and the protuberance (6b2) is ensured by the elasticity of the at least one elastic protuberance (6b2) irrespective of minor differences in height of the battery.