Passive Structural Stopper Bracket for EV Battery Protection
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Solution Overview
Problem
Electrified vehicles face the challenge of protecting battery packs from contact with frame members and cross-members during impact load events, which can cause damage and compromise the safety of the battery pack.
Innovation Solution
A bracket is mounted between the side frame member and the seat cross-member, creating a gap that prevents direct contact between the cross-member and the battery pack. The bracket, which can have various cross-sectional shapes and be connected to either the side frame or cross-member, plastically deforms to absorb energy and maintain separation during an impact load, thereby protecting the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cross-member is positioned close to the battery pack to reduce vehicle height or improve packaging, then vehicle space utilization is improved, but the battery pack becomes vulnerable to impact damage from the cross-member
Solution Approach 1:
A stopper bracket is introduced as an intermediary component between the cross-member and the battery pack. The bracket extends into the gap and prevents the cross-member from directly contacting the battery pack during impact events, while allowing the cross-member to remain in its original position for space optimization.
Solution Approach 2:
The stopper bracket is pre-positioned in the gap between the cross-member and battery pack to provide protective cushioning before any impact occurs. The bracket is designed to deform plastically during impact, absorbing energy and preventing direct contact between the cross-member and battery pack.
2Reliability
If a protective structure is added between the cross-member and battery pack to prevent impact contact, then battery pack protection is improved, but device complexity increases
Solution Approach 1:
The protective function is segmented from the main structural components. Instead of making the cross-member or battery pack housing more complex, a separate, simple stopper bracket is added that performs solely the protective function of preventing impact contact.
Solution Approach 2:
The stopper bracket is designed as a sacrificial component that may deform or fail during severe impact events, protecting the more expensive and critical battery pack. The bracket can be replaced after impact events, while the battery pack remains intact.
3Loss of energy
If the bracket is designed to plastically deform and absorb energy during impact, then impact energy absorption is improved, but the bracket's structural strength decreases
Solution Approach 1:
The bracket's material properties and geometric parameters are optimized to enable controlled plastic deformation at impact loads. The bracket uses materials or designs that yield at specific stress levels, allowing energy absorption through deformation while maintaining sufficient strength during normal vehicle operation.
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 solution effectively prevents the seat cross-member from contacting the battery pack during impact loads, ensuring the battery pack's safety and integrity by absorbing energy and maintaining structural stability.
Implementation Method 1
the bracket plastically deforms and absorbs energy to prevent the cross-member from direct contact with the cover
Data Source
AI summary
A method and an apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a battery pack supported by at least one vehicle frame member, a side frame member positioned adjacent to an edge of the battery pack, and a cross-member extending away from the side frame member and above the battery pack. The cross-member is spaced from the battery pack by a gap. At least one bracket is mounted to at least one of the side frame member and cross-member within the gap such that in response to an impact load, the bracket prevents the cross-member from direct contact with the battery pack.