Skid Plate Joint Structure for Battery Pack Impact Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for securing battery packs in vehicles are inadequate in maintaining a reliable joint over time, especially under conditions of thermal cycling and impact from foreign objects.
Innovation Solution
A skid plate with ribs surrounding openings is used, which engages a washer and deforms it to engage a compression limiter, forming a joint that secures the skid plate to the battery pack enclosure and vehicle body, utilizing a polymer material with embedded glass fibers for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening methods are used to secure battery packs, then initial attachment is achieved, but the joint reliability deteriorates over time under thermal cycling and impact conditions
Solution Approach 1:
The washer is pre-formed with a curved surface that anticipates the deformation needed for engagement. The curvature is designed in advance to match the compression limiter geometry, so that when torque is applied, the washer naturally deforms along its pre-designed path to engage the compression limiter, ensuring reliable joint formation from the outset and maintaining reliability over time
Solution Approach 2:
The washer undergoes a controlled parameter change from a flat state to a deformed state through applied torque. This parameter change transforms the washer's geometry to enable engagement with the compression limiter, creating a joint that can withstand thermal cycling and impact forces, thereby improving joint reliability and durability
2Object-affected harmful factors
If a skid plate is added to protect the battery pack, then protection against impact is improved, but the complexity of the securing system increases
Solution Approach 1:
The skid plate is merged with the battery pack enclosure to form an integrated protective structure. The enclosure itself serves as the mounting surface for the fastening system, eliminating the need for separate complex mounting brackets or additional structural components. This integration provides impact protection while minimizing the increase in system complexity
Solution Approach 2:
The battery pack enclosure serves multiple functions: it houses the battery cells, provides structural support, and acts as the mounting surface for the skid plate and fastening system. This multi-functionality reduces the need for additional dedicated components, thereby providing protection without proportionally increasing system complexity
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 joint remains reliable over time, securely attaching the battery pack to the vehicle body, even under thermal cycling and impact conditions, ensuring effective protection and stability.
Implementation Method 1
The torque applied to the fastener to secure the skid plate also causes the washer to deform and engage a compression limiter positioned in the opening of the skid plate
Implementation Method 2
The ribs provide a counterforce to the washer, causing the washer to undergo a two-dimensional bend
Data Source
AI summary
An apparatus may take the form of a skid plate designed to protect a vehicle, including a battery pack of the vehicle, from damage caused by obstructions or foreign objects. In order to secure the skid plate, several fasteners pass through respective openings of the skid plate. The skid plate includes one or more ribs surrounding each fastener opening. The ribs may engage a washer through which fasteners passes. When a torque is applied to a fastener to secure the skid plate, the fastener moves. The combination of the movement of the fastener the engagement of the washer by the ribs cause the washer to deform, or bend, and engage a compression limiter positioned in the opening. As a result, the fastener, the compression limiter, and the washer form a joint.