Modular Impact Energy Absorbing Carrier for Electric Vehicle Battery Maintenance
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Solution Overview
Problem
Existing impact energy absorption methods for electric vehicle batteries, such as potting, complicate maintenance due to the difficulty in removing and replacing the gelatinous compounds used for shock and vibration resistance.
Innovation Solution
A modular impact energy absorbing carrier and member system featuring a frame, container, and detachable impact energy absorbing units with a periphery part and protrusion parts made of materials like rubber or thermoplastic polyurethanes, allowing for comprehensive cushioning across a wide frequency range and facilitating easy maintenance by being detachable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting is used to protect battery against impact and vibration, then impact resistance is improved, but maintenance difficulty increases
Solution Approach 1:
The impact energy absorbing unit is divided into separate detachable components: a frame, a container, and multiple impact energy absorbing members. This segmentation allows the battery protection system to maintain impact resistance while enabling easy removal and replacement of individual components without affecting the entire battery assembly.
Solution Approach 2:
The impact energy absorbing members are designed as detachable and replaceable components rather than permanent fixtures. This dynamic design allows the system to transition from a fixed potting structure to a modular system where components can be easily removed, replaced, or adjusted for maintenance purposes.
2Object-affected harmful factors
If gelatinous compound is used for shock resistance, then vibration absorption is improved, but component removal becomes troublesome
Solution Approach 1:
The vibration absorption function is segmented into discrete impact energy absorbing members that can be individually removed from the frame. Unlike gelatinous compounds that require complete removal, these segmented components can be easily detached and replaced without affecting other parts of the system.
Solution Approach 2:
The impact energy absorbing members are designed as replaceable components that can be discarded after use or recovery for reuse. This approach eliminates the need to remove entire battery assemblies or deal with difficult-to-remove gelatinous compounds, allowing for straightforward maintenance and component recovery.
3Reliability
If whole battery replacement is performed, then functionality is restored, but cost and time increase
Solution Approach 1:
The battery protection system is segmented into independent components (frame, container, impact energy absorbing members), allowing only the affected impact energy absorbing members to be replaced rather than the entire battery assembly. This significantly reduces maintenance time and costs while restoring functionality.
Solution Approach 2:
The system transitions from a static whole-battery replacement approach to a dynamic modular replacement approach. The detachable impact energy absorbing members can be quickly swapped out and replaced, enabling rapid restoration of battery functionality without the need for complete battery replacement.
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 system effectively absorbs impact and vibration across a broad frequency range while enabling easy maintenance and reuse of batteries, aligning with eco-friendly requirements.
Implementation Method 1
The impact energy absorbing member includes a periphery part and two protrusion parts... made of materials like rubber or thermoplastic polyurethanes, allowing for comprehensive cushioning across a wide frequency range
Implementation Method 2
An end of the first link is fixed to the frame. An end of the second link is fixed to the container. The first side portion of the periphery part is pivotably disposed on the first link, and the second side portion of the periphery part is pivotably disposed on the second link.
Data Source
AI summary
The invention provides an impact energy absorbing carrier including a frame, a carrier, and multiple impact energy absorbing units. Each of the impact energy absorbing units includes a first link, a second link, and an impact energy absorbing member. The first link and the second link are respectively fixed to the frame and the carrier. The impact energy absorbing member includes a periphery part and two protrusion parts. The periphery part includes a first side portion and a second side portion located opposite to each other. The first side portion of the periphery part are respectively and pivotably disposed on the first link and the second link. The periphery part surrounds the protrusion parts, the protrusion parts are respectively connected to the first side portion and the second side portion of the periphery part, and a first buffering space is located between the protrusion parts.