Polymeric Battery Tray With Integrated Terminals and Tool-Free Hold Down
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Solution Overview
Problem
Corrosion of battery tray and hold down components leads to unstable battery positioning in vehicles, accelerating the formation of short circuits and reducing battery life due to jarring and jostling, and frequent replacement of corroded components is necessary.
Innovation Solution
A polymeric battery tray assembly with integrated terminal engaging elements and a simplified hold down mechanism using a tensioner with a grippable handle, allowing for secure and tool-free battery installation and removal, while preventing corrosion and vibration damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal battery tray and hold down components are used, then initial structural strength is adequate, but corrosion occurs over time leading to instability and frequent replacement
Solution Approach 1:
The battery tray is constructed from composite materials including corrosion-resistant metals such as aluminum or aluminum alloys, or alternatively from polymeric materials. This composite approach combines the structural strength needed for initial installation with long-term corrosion resistance, eliminating the need for frequent replacements while maintaining stable battery positioning throughout the vehicle's operational life.
2Reliability
If traditional bolted hold down devices are used, then secure battery attachment is achieved, but tool-based installation and removal is required increasing maintenance time
Solution Approach 1:
The hold down device incorporates a self-retaining mechanism with a release member that can be actuated by hand without tools. The device includes a biasing element that automatically maintains clamping force, and a manually operable release that allows quick battery removal. This self-service design eliminates the need for external tools during installation and maintenance operations.
3Reliability
If metal components are used for battery tray and connectors, then initial electrical conductivity is good, but corrosion accelerates component failure and short circuit formation
Solution Approach 1:
Electrical connectors and terminal engaging elements are constructed from corrosion-resistant materials such as aluminum or polymer-composite structures. These materials maintain stable electrical conductivity over time without suffering from the galvanic corrosion and oxidation that plague traditional steel components, thereby preventing short circuits and extending the electrical system's operational reliability.
4Ease of manufacture
If simple battery tray design is used, then manufacturing cost is reduced, but vibration and shock transmission accelerates battery degradation
Solution Approach 1:
The battery tray design incorporates vibration-damping features and shock-absorbing elements built into the basic tray structure itself. This may include molded-in polymeric elements, rubber isolators, or structurally integrated cushioning zones that attenuate road vibrations and shocks before they reach the battery, protecting it from premature degradation while maintaining a relatively simple overall design.
Data Source
AI summary
An electrified battery tray assembly comprising a pair of battery positive and negative terminal engaging elements wiredly connected to at least one plug receiving connector on the tray for accessing battery power via the at least one connector.