Collapsible Hoop Bracket for Battery Pack Side Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrified vehicles face challenges in effectively absorbing and distributing side impact loads to prevent disruption to the battery pack and other components, as conventional support systems fail to manage loads efficiently above a certain threshold.
Innovation Solution
A support assembly comprising a hoop bracket coupled with a tuned bracket, which controls the collapse of the hoop bracket in response to loads above a threshold level, redirecting the load along a longitudinal axis to reduce the impact on the battery pack, utilizing a combination of hoop brackets and tuned brackets on both sides of the vehicle body structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rigid support system is used to secure the battery pack, then the battery pack is firmly held in place, but side impact loads above a certain threshold are transferred directly to the battery pack causing potential disruption
Solution Approach 1:
The support assembly changes its structural parameters dynamically by incorporating a tuned bracket that remains rigid below a threshold load but collapses controllably above the threshold. This parameter change allows the system to provide firm support during normal operation while redirecting excessive side impact loads away from the battery pack, resolving the contradiction between reliable mounting and load protection.
Solution Approach 2:
The support assembly transitions from a static rigid structure to a dynamic system with controlled collapse capability. The tuned bracket is designed to maintain structural integrity under normal conditions but undergoes controlled deformation when side impact loads exceed the threshold, enabling the system to adapt its load-bearing characteristics in real-time to protect the battery pack.
2Force
If a collapsible support structure is used to absorb side impact loads, then load protection is improved, but the structural stability and firmness of the battery pack mounting is compromised
Solution Approach 1:
The tuned bracket's structural parameters are designed to remain stable below the load threshold, providing firm mounting stability. When the threshold is exceeded, the bracket undergoes controlled parameter changes through collapse, absorbing excess energy while maintaining acceptable mounting stability through the hoop bracket's geometric constraints and the tuned bracket's controlled deformation characteristics.
Solution Approach 2:
The support assembly is segmented into the hoop bracket and tuned bracket components, where the tuned bracket specifically handles excessive loads through controlled collapse while the hoop bracket maintains overall structural stability. This segmentation allows different parts to perform different functions - one for stability and one for load absorption - resolving the contradiction between firm mounting and load protection.
3Reliability
If the tuned bracket is designed to collapse at low load thresholds, then battery pack protection is enhanced, but the support assembly becomes overly sensitive to normal vehicle operations and terrain variations
Solution Approach 1:
The tuned bracket's collapse threshold parameter is carefully calibrated to distinguish between normal operational loads and dangerous side impact loads. By setting the threshold appropriately, the system maintains adaptability to normal vehicle operations while remaining sensitive enough to provide protection when truly needed, resolving the contradiction between protection sensitivity and operational tolerance.
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 support assembly effectively absorbs and redirects side impact loads, reducing the force transferred to the battery pack, enhancing protection and facilitating more efficient packaging of the battery pack within varying vehicle environments.
Implementation Method 1
The tuned bracket is configured to control a collapse of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack
Data Source
AI summary
An exemplary support assembly includes, among other things, a hoop bracket coupling a battery pack to a vehicle body structure, and a tuned bracket within an open area of the hoop bracket. The tuned bracket is configured to control a collapse of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack. An exemplary supporting method includes coupling a battery pack to a vehicle body structure using a hoop bracket disposed alongside the battery pack. The hoop bracket includes an open area that receives a tuned bracket. The tuned bracket is configured to control a deformation of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack.