Sacrificial Shield for Traction Battery Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traction batteries in electrified vehicles are vulnerable to impact damage from obstacles like curbs, which can lead to costly repairs or replacements, and existing solutions do not effectively protect these batteries without requiring extensive modifications to the vehicle.
Innovation Solution
A longitudinally extending shield is secured beneath the traction battery, made from extruded metal or metal alloy, with apertures for mechanical fasteners to attach it to the battery's side rails, acting as a sacrificial component to absorb impact energy and protect the battery from curb strikes without needing to detach the battery from the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shield is added beneath the traction battery to protect it from impact damage, then the battery's protection level is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The shield is designed as a sacrificial component that can be easily replaced after impact events, rather than protecting the expensive battery permanently. This allows using simpler, cheaper materials for the shield that don't need to withstand repeated impacts, resolving the contradiction between protection level and device complexity
Solution Approach 2:
The shield is divided into multiple segments corresponding to different battery cells, allowing individual replacement without affecting the entire battery assembly. This segmentation reduces the complexity of installation and maintenance while maintaining comprehensive protection
2Reliability
If the shield is securely fastened to the traction battery, then the protection effectiveness is improved, but the ease of repair deteriorates
Solution Approach 1:
The shield incorporates pre-configured attachment features such as clips, tabs, or fastener holes that align with corresponding features on the battery housing. This preliminary configuration enables quick installation and removal without requiring complex alignment procedures or specialized tools, thus maintaining ease of repair while ensuring effective protection
Solution Approach 2:
The attachment mechanism allows for dynamic assembly and disassembly of the shield. The shield can be quickly secured during installation and just as quickly removed for replacement, providing the flexibility needed for easy maintenance while maintaining firm attachment during operation
3Reliability
If the shield extends the full length of the battery, then the protection coverage is improved, but the weight and material usage increase
Solution Approach 1:
The shield provides enhanced protection specifically at the lower portions of the battery where impact from curbs and road debris is most likely to occur. The upper portions have reduced shielding, optimizing the weight-protection ratio by concentrating material where it is most needed rather than uniformly distributing it
Data Source
AI summary
An electrified vehicle assembly includes, among other things, a traction battery, and at least one shield extending longitudinally and having a portion that is vertically beneath the traction battery. The shield is removably fastened directly to the traction battery.