An external battery mount for electric vehicles

Abstract

This invention relates to the field of new energy vehicle technology and discloses an external battery support for electric vehicles, comprising a load-bearing body, a main frame with a closed cross-section frame structure for providing rigid support space; a protective liner, an energy-absorbing base plate laterally connected to the bottom edge of the main frame to form a physical barrier to the bottom of the internal battery pack; and an adaptive limiting mechanism consisting of multiple elastic clamping components arrayed on the inner wall of the main frame. The invention utilizes a main frame formed by mutually perpendicular intersecting front longitudinal beams, rear longitudinal beams, left cross beams, and right cross beams, with several sets of suspension lugs extending radially outwards along the circumferential side of the main frame. These suspension lugs suspend the support as a whole at the load-bearing points of the vehicle chassis. The reinforcing ribs have a hollow, irregular structure with their interiors forming closed air ducts. A passive air cooling circulation system, independent of the battery pack, is constructed inside the support.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle technology, specifically to an external battery support for electric vehicles. Background Technology

[0002] With the explosive growth of the global new energy vehicle industry, the power battery system, as the heart of electric vehicles, has become a key factor restricting overall vehicle performance in terms of safety, stability, and thermal management efficiency. Traditional electric vehicle battery installation solutions mostly employ built-in or simple external chassis structures. However, in practical applications, existing battery mount technologies have revealed many shortcomings that urgently need to be addressed: First, in terms of structural strength and collision safety, traditional supports mostly use simple welded frames and lack scientific energy-absorbing and crumple design. When a vehicle encounters complex conditions such as bottoming out, side collisions, or stone impacts, the impact energy often bypasses the support and acts directly on the battery pack casing, causing the cells to be squeezed and deformed or even thermal runaway. At the same time, the existing rigid connection installation method makes it difficult for the battery pack and the frame to effectively buffer stress, and long-term vibration can easily cause structural fatigue.

[0003] Secondly, in terms of environmental adaptability and fixed reliability, existing limiting mechanisms are usually fixed blocks or bolts that are hard-locked. Due to the manufacturing tolerances of the parts, it is difficult to achieve a perfect clearance fit between the battery pack and the support, resulting in shaking and abnormal noise during driving (poor NVH performance), and it cannot cope with the small volume changes caused by thermal expansion of the battery during charge and discharge cycles.

[0004] Furthermore, the integration and efficiency of thermal management systems still need improvement. Current mainstream solutions rely excessively on active liquid cooling, which, while providing significant cooling, consumes a lot of energy under high load conditions. Existing support structures often serve only as load-bearing components, failing to fully utilize the reverse airflow during vehicle movement for passive heat dissipation, resulting in low energy efficiency.

[0005] Finally, in terms of electrical integration and corrosion protection, traditional chassis supports provide rudimentary protection for high and low voltage wiring harnesses. The liquid cooling interfaces are exposed and lack standardized interface modules, making them highly susceptible to electrical short circuits or interface corrosion and leakage in harsh environments such as salt spray, acid and alkali, and muddy water. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides an external battery support for electric vehicles, which enhances the chassis's resistance to bottoming out while simultaneously achieving zero-power auxiliary cooling.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an external battery support for an electric vehicle, comprising: The main load-bearing structure is a closed-section frame structure used to provide rigid support space. Protective liner: An energy-absorbing base plate that is laterally connected to the bottom edge of the main frame, forming a physical barrier at the bottom of the internal battery pack; Adaptive limiting mechanism: multiple elastic clamping components arrayed on the inner wall side of the main frame; The main frame is formed by mutually perpendicular intersecting front longitudinal beams, rear longitudinal beams, left cross beams and right cross beams, and several sets of suspension ears are provided on the outer periphery of the main frame in a horizontal radial pattern. The suspension ears are used to suspend the entire support on the load-bearing points of the vehicle chassis.

[0008] Furthermore, at least one reinforcing rib is provided between the front longitudinal beam and the rear longitudinal beam. The reinforcing rib has a hollow irregular structure and its interior forms a closed cavity air duct. The front end of the cavity air duct is provided with an air inlet that communicates with the outside air, and the rear end is provided with an exhaust grid for the exhaust of gas after heat exchange, thereby constructing a passive air cooling circulation system independent of the battery pack inside the support.

[0009] Furthermore, a multi-layered filter screen with a dustproof structure is horizontally embedded at the air inlet to block moisture and particulate dust from entering the air duct; the inner surface of the cavity air duct is not a smooth surface, but is integrally formed with multiple spiral guide grooves with equal pitch along the longitudinal axis, which aims to improve the heat exchange efficiency of the inner wall of the air duct by increasing the air turbulence effect.

[0010] Furthermore, the elastic clamping assembly adopts a piston-type buffer structure, specifically including a telescopic sleeve fixedly connected to the inner wall of the left or right crossbeam, a piston rod that performs linear reciprocating motion within the telescopic sleeve, and a return spring disposed inside the telescopic sleeve; a flexible pressure block is fixed to the free end of the piston rod for generating pre-tightening contact with the battery pack casing.

[0011] Furthermore, the flexible pressure block is made of an elastomer material with damping properties, and its end face facing the battery pack is provided with staggered anti-slip textures by laser etching or mold pressing process, so as to limit the lateral drift of the battery pack in the vibration environment by increasing static friction.

[0012] Furthermore, L-shaped positioning brackets for precise guidance and rigid connection are provided at the four inner corners of the main frame. The positioning brackets are fastened to the frame skeleton by a set of high-strength bolts with anti-loosening properties. A flame-retardant rubber pad with a thickness of not less than 2mm is pasted on the inner working surface of the positioning bracket. The flame-retardant rubber pad has the dual functions of insulation protection and local stress buffering.

[0013] Furthermore, the energy-absorbing base plate adopts a heterogeneous composite sandwich structure, which includes, from the inside out, an upper aluminum plate with high thermal conductivity, a lower carbon fiber plate with lightweight and high modulus characteristics, and a honeycomb energy-absorbing structure layer metallurgically bonded between the two; the honeycomb energy-absorbing structure layer is composed of a large number of hexagonal prism units, which are used to absorb collision energy through plastic deformation when the chassis is subjected to scraping or bottoming impact.

[0014] Furthermore, the lower surface of the lower carbon fiber plate is integrated with rows of heat sinks using an adhesive or brazing process. The extension trajectory of the heat sinks is parallel to the longitudinal driving centerline of the vehicle, thereby utilizing the reverse airflow during vehicle movement to perform forced convection heat transfer on the energy-absorbing base plate.

[0015] Furthermore, the side wing space of the main frame integrates an electrification and liquid cooling interface module, including a wiring harness fixing clip for fixing high and low voltage wiring and a liquid cooling pipe connector for connecting the vehicle's cooling circulation system; the wiring harness fixing clip consists of a base with a self-locking function and an elastic buckle.

[0016] Furthermore, the exposed metal surfaces of the main frame and the energy-absorbing base plate are covered with a dense ceramic anti-corrosion coating by electrostatic spraying. In addition, preheated reinforcing patches are attached to the heat-affected zone of the main frame or stress concentration areas such as geometric abrupt changes, in order to improve the overall fatigue life of the support.

[0017] Compared with the prior art, the present invention has the following beneficial effects: First, this type of external battery support for electric vehicles constructs a three-layer protection system from the outside in through the closed cross-section design of the main frame and the sandwich composite structure (aluminum plate + honeycomb layer + carbon fiber plate) of the energy-absorbing base plate. The honeycomb energy-absorbing layer absorbs the impact energy from the bottom through plastic deformation, effectively protecting the expensive battery module from physical compression and greatly improving the chassis's resistance to bottoming out.

[0018] Secondly, this type of external battery support for electric vehicles utilizes elastic clamping components (piston rod, return spring, and flexible pressure block) to achieve flexible reinforcement of the battery pack. This adaptive mechanism can automatically compensate for manufacturing tolerances and eliminate fit gaps through pre-tightening force. Under bumpy road conditions, it can act as a miniature shock absorber to absorb high-frequency vibrations, not only solving the problem of abnormal noise but also reducing stress concentration through flame-retardant rubber pads, thus extending the fatigue life of the battery pack casing.

[0019] Third, this type of external battery mount for electric vehicles incorporates an independent air cooling circulation system within its reinforcing ribs. Utilizing the wind pressure generated by the vehicle's movement, combined with the turbulence effect produced by the spiral guide channels, it significantly improves air heat exchange efficiency. This passive air cooling system, working in conjunction with an active liquid cooling system connected to a liquid cooling pipe connector, achieves zero-power auxiliary cooling, effectively reducing the power consumption of the vehicle's temperature control system and increasing the driving range.

[0020] Fourth, the ceramic anti-corrosion coating and the reinforcing patches on the weld heat-affected zone of this type of external battery bracket for electric vehicles give the bracket extremely strong resistance to salt spray and fatigue. Meanwhile, the self-locking function of the wiring harness clamp and the modular integration of the liquid cooling interface achieve a scientific "water-electricity separation" arrangement, which not only reduces the risk of electrical faults but also greatly facilitates the rapid disassembly and assembly of the battery pack and subsequent maintenance.

[0021] Fifth, the application of high-strength bolt pairs and microcapsule anti-loosening technology in this type of electric vehicle external battery support, along with L-shaped positioning angle codes, ensures the structural connection stability of the support throughout its entire life cycle and eliminates the safety hazards caused by easy loosening of bolts in traditional structures. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the entire invention; Figure 2 This is a top view of the entire invention; Figure 3 This is an exploded view of the energy-absorbing base plate of the present invention; Figure 4 This is a three-dimensional structural diagram of the main frame of the present invention; Figure 5 This is a cross-sectional three-dimensional structural diagram of the reinforcing rib of the present invention; Figure 6 This is a cross-sectional three-dimensional structural diagram of the elastic clamping component of the present invention; Figure 7 yes Figure 4 Enlarged view of point A above; Figure 8 yes Figure 6 Enlarged view of point B above.

[0023] In the diagram: 1. Main frame; 2. Energy-absorbing base plate; 3. Front longitudinal beam; 4. Rear longitudinal beam; 5. Left crossbeam; 6. Right crossbeam; 7. Suspension lug; 8. Vehicle chassis; 9. Reinforcing rib; 10. Cavity air duct; 11. Air inlet; 12. Exhaust grille; 13. Filter dustproof mesh; 14. Spiral guide channel; 15. Telescopic sleeve; 16. Piston rod; 17. Return spring; 18. Flexible pressure block; 19. Anti-slip texture; 20. Positioning corner bracket; 21. High-strength bolt; 22. Flame-retardant rubber pad; 23. Aluminum plate; 24. Carbon fiber plate; 25. Honeycomb energy-absorbing structure layer; 26. Corrugated heat sink; 27. Wiring harness fixing clip; 28. Liquid cooling pipe connector; 29. ​​Base; 30. Elastic buckle; 31. Ceramic anti-corrosion coating; 32. Reinforcing patch. Detailed Implementation

[0024] The embodiments of this disclosure will be further described in detail below with reference to the accompanying drawings and examples. The detailed description of the embodiments and the accompanying drawings are used to illustrate the principles of this disclosure by way of example, but should not be used to limit the scope of this disclosure. This disclosure can be implemented in many different forms and is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

[0025] These embodiments are provided to make the disclosure thorough and complete, and to fully express the scope of the disclosure to those skilled in the art. It should be noted that, unless otherwise specifically stated, the relative arrangement of components and steps, material composition, numerical expressions, and values ​​set forth in these embodiments should be interpreted as exemplary only and not as limiting.

[0026] It should be noted that, in the description of this disclosure, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicating orientation or positional relationship, are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0027] Furthermore, the terms "first," "second," and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. "Vertical" is not strictly vertical, but within the permissible margin of error. "Parallel" is not strictly parallel, but within the permissible margin of error. Terms such as "including" or "contains" mean that the element preceding the word encompasses the element listed after the word, and do not exclude the possibility of encompassing other elements as well.

[0028] It should also be noted that, in the description of this disclosure, unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this disclosure depending on the specific circumstances. When a particular device is described as being located between a first device and a second device, an intermediary device may or may not be present between the particular device and the first or second device.

[0029] All terms used in this disclosure have the same meaning as understood by one of ordinary skill in the art to which this disclosure pertains, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant art, and not as having idealized or highly formalized meanings, unless expressly defined herein.

[0030] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0031] Please see Figures 1 to 8 This embodiment proposes an external battery support for electric vehicles, the core structure of which is supported by a main frame 1. The main frame 1 is constructed from high-strength, irregularly shaped aluminum alloy profiles with a closed cross-section, through CNC bending and precision welding processes. The front longitudinal beam 3, rear longitudinal beam 4, left cross beam 5, and right cross beam 6 together enclose a rectangular sealed space with high torsional stiffness. To enhance integration with the vehicle, several sets of suspension lugs 7 are radially extended horizontally outward from the circumferential outer side of the main frame 1.

[0032] These suspension lugs 7 are not simple metal sheets, but cast aluminum parts with an interlaced design of reinforcing plates. The battery mount is suspended as a whole from the load-bearing longitudinal beam of the vehicle chassis 8 by high-strength anti-loosening bolts. This suspension installation method effectively utilizes the physical space under the chassis and makes the battery mount an integral part of the chassis reinforcement structure. In the event of a collision, they can participate in energy transfer and dissipation, significantly improving the passive safety performance of the entire vehicle.

[0033] To address the risk of horizontal displacement of the battery pack during driving, this device incorporates a matrix-style elastic clamping assembly on the inner wall of the main frame 1. The base of the telescopic sleeve 15 is fixed to the inner side of the crossbeam via laser welding or high-strength riveting. The sleeve houses a high-stiffness return spring 17, which is always in a pre-compressed state. One end of the piston rod 16 abuts against the spring, while the other end extends through the sleeve and points towards the geometric center of the frame.

[0034] The piston rod 16 is fitted with a flexible pressure block 18, which is made of flame-retardant polyurethane material with a Shore hardness between 60 and 80. When the battery pack is placed into the frame, the pressure block is squeezed, causing the piston rod 16 to retract into the sleeve, thereby generating a strong pressure perpendicular to the side wall of the battery. The anti-slip texture 19 on the surface of the pressure block generates a large static friction force with the metal shell of the battery pack, fundamentally eliminating the shaking phenomenon of the battery pack during violent steering or sudden braking. At the same time, this piston structure constitutes a miniature hydraulic or pneumatic damping system, which can effectively absorb high-frequency vibrations from the road surface and prevent fatigue fracture of the battery cell terminal block due to resonance.

[0035] The main frame 1 is not a simple support structure; it has at least one reinforcing rib 9 running through it. This reinforcing rib 9 is manufactured using a hollow extrusion molding process, and the resulting cavity air duct 10 creates a passive air exchange center independent of the liquid cooling system. The air inlet 11 at the front end of the air duct is cleverly positioned in the windward negative pressure zone of the vehicle chassis, and its embedded filter dustproof mesh 13 has a multi-layer gradient filtration structure from coarse to high efficiency, which can both block rainwater splashes and capture fine particulate dust.

[0036] To maximize heat dissipation efficiency, the inner surface of the cavity air duct 10 is not smooth, but rather integrally molded with spiral guide grooves 14 of equal pitch. When the vehicle is in motion, external cold air is forced into the air duct under dynamic pressure and guided by the guide grooves to form a turbulent state similar to a cyclone. According to the principles of heat transfer, turbulence can significantly disrupt the laminar boundary layer in the airflow process, resulting in a substantial reduction in thermal resistance. This design allows the heat dissipated from the battery pack to the reinforcing ribs 9 through conduction to be quickly carried away by the swirling air and discharged from the exhaust grille 12, effectively sharing the power consumption of the liquid cooling system.

[0037] The energy-absorbing base plate 2 serves as the physical barrier at the bottom of this support, employing a complex heterogeneous composite sandwich structure. The upper aluminum plate 23, made of high thermal conductivity 6-series aluminum alloy, is directly bonded to the bottom of the battery pack; the lower carbon fiber plate 24 utilizes its high specific strength and corrosion resistance to serve as the first line of defense against the road surface. The middle layer is a honeycomb energy-absorbing structure layer 25, consisting of numerous hexagonal prism units sandwiched between the aluminum plate 23 and the carbon fiber plate 24 through metallurgical bonding.

[0038] Under normal conditions, the honeycomb layer acts as an insulating air layer. However, when the vehicle experiences an accidental bottoming out or impact from a flying rock, the honeycomb structure undergoes controlled plastic collapse. This collapse process smoothly absorbs the enormous impact energy, ensuring that the deformation does not propagate upwards to the battery pack. In addition, rows of corrugated heat sinks 26 are integrated at the bottom of the lower carbon fiber plate 24. These heat sinks are arranged according to aerodynamic simulation results, and their extension trajectory is consistent with the streamline of the underside of the vehicle during driving. They utilize the high-speed airflow under the chassis to perform forced convection heat transfer on the entire underside, forming a three-layer thermal management system of internal conduction, middle energy absorption, and external convection.

[0039] Within the clearance space on the side of the main frame 1, a highly integrated electrification and liquid cooling interface module is integrated. The wiring harness clamp 27, through its self-locking base 29 and elastic latch 30, neatly arranges the complex high-voltage power lines and low-voltage signal lines. This structure not only improves assembly speed but also avoids frictional wear between the wiring harness and the metal frame. The liquid cooling pipe connector 28 provides a standardized quick-change interface, ensuring efficient circulation of coolant within the sealed liquid cooling plate.

[0040] To address the corrosion risk caused by long-term exposure to the chassis, the metal surfaces of the main frame 1 and the energy-absorbing base plate 2 are covered with a dense ceramic anti-corrosion coating 31. This coating is formed by electrostatic spraying followed by high-temperature curing, and possesses properties such as resistance to salt spray, acids and alkalis, and stone chip removal. In the stress-concentrated weld heat-affected zone, additional preheated reinforcing patches 32 are attached. These patches, by altering local geometric stiffness, disperse the stress peaks under dynamic loads, ensuring that the fatigue life of the supports covers the entire lifespan of the vehicle.

[0041] The L-shaped positioning bracket 20 provides the final physical position locking, followed by locking the electrical control wiring harness with the elastic buckle 30, and then plugging in the liquid cooling pipe connector 28. The high-strength bolts 21, used in the connection between the L-shaped positioning bracket 20 and the main frame 1, are not merely simple fastening components, but also the core guarantee for the integrity of the entire support structure. These bolts are made of alloy steel (such as 40Cr or 35CrMo) through quenching and tempering heat treatment, achieving a nominal performance grade of 10.9 or 12.9, possessing extremely high tensile and yield strength. This ensures that under extreme conditions such as severe side impacts and rollovers, the positioning bracket 20 will not detach due to excessive shear force, thus preventing catastrophic displacement of the battery pack within the frame. Considering that electric vehicles are exposed to variable frequency vibration environments for extended periods, a special microcapsule pressure-sensitive anti-loosening coating is applied to the bolt surface. During screwing, the microcapsules rupture, releasing a chemical adhesive that forms a high-strength filling layer between the threads. Furthermore, the accompanying washers are double-layered self-locking washers, utilizing the principle of ramp tension. This ensures that the bolts not only do not loosen under vibration, but also tighten further due to increased tension, completely solving the industry pain point of chassis components being prone to loosening. Surface treatment and electrochemical corrosion protection: The bolt surface undergoes zinc-nickel alloy electroplating, followed by the application of sealant, achieving a salt spray resistance of over 1000 hours. This design is to prevent potential difference corrosion between the bolts and the aluminum main frame 1, ensuring that the fastening nodes maintain a stable preload throughout the vehicle's entire lifespan.

[0042] The multi-functional properties of the flame-retardant rubber pad 22, adhered to the inner working surface of the positioning bracket 20, extend far beyond the realm of physical filling. Its thickness is precisely set between 2mm and 5mm, using ethylene propylene diene monomer (EPDM) rubber as the base material and incorporating a high proportion of aluminum hydroxide or phosphorus-based flame retardants. Providing both flame retardancy and insulation, this pad meets the UL94 V-0 flame retardant standard. In extreme cases, if the battery pack casing experiences thermal runaway or arcing, the flame-retardant rubber pad 22 effectively blocks heat conduction and provides extremely high insulation resistance, preventing high-voltage current from being conducted through the metal frame to the vehicle chassis 8, protecting passengers from electric shock. When the battery pack is assembled to the bracket, there is often a slight angular deviation. The flame-retardant rubber pad 22, utilizing its low compression set, can absorb localized compressive stress during installation, acting like a flexible buffer. This minute deformation not only compensates for manufacturing tolerances but also avoids stress concentration at point contact between the hard edges of the corner brackets and the battery pack casing, transforming point stress into surface stress and preventing fatigue cracks in the battery pack casing under long-term alternating stress. For sealing and noise reduction, the rubber gasket tightly adheres to the contact surface, forming a miniature sealing ring to prevent road moisture from seeping into the positioning joint. More importantly, it breaks the rigid sound bridge between metals, significantly suppressing frictional noise between the battery pack and the bracket during driving, thus improving the vehicle's NVH (noise, vibration, and harshness) performance.

[0043] The complete operation and protection logic of the patented device of this invention is as follows: Guided by the assembly process, on the vehicle assembly line, the battery pack is lowered into the main frame 1 via a robotic arm along a vertical trajectory. At this point, the sidewalls of the battery pack contact the various sets of elastic clamping components. Under gravity guidance, the flexible pressure block 18 is pressed outward, the piston rod 16 retracts into the telescopic sleeve 15, and the spring is compressed to store pre-tension energy. After the battery pack descends to the bottom, the L-shaped positioning bracket 20 provides the final physical position locking, and then the electronic control wiring harness is locked by the elastic buckle 30 and connected to the liquid cooling pipe connector 28.

[0044] The thermal management linkage logic ensures that when the vehicle is traveling at low speeds or charging, the system primarily relies on the coolant supplied through the liquid cooling pipe connector 28 for circulating heat dissipation. As the vehicle speed increases, the windward air is forced into the air intake 11. Within the cavity air duct 10, the air is transformed into a high-speed swirling flow due to the action of the spiral guide groove 14, carrying away the heat from the battery core. Simultaneously, the corrugated heat sink 26 at the bottom utilizes the negative pressure airflow under the vehicle for auxiliary heat dissipation, forming a multi-medium composite heat exchange mechanism.

[0045] Multi-condition dynamic protection: First, on bumpy roads, when the vehicle sways from side to side, the elastic component on one side is further compressed to absorb energy, while the other side is kept tight by spring force to ensure zero drift of the battery pack relative to the vehicle chassis 8; Second, in the event of a bottoming-out accident, when a road obstacle hits the bottom, the lower carbon fiber plate 24 blocks the puncture, and the honeycomb energy-absorbing structure layer 25 consumes the impact kinetic energy through instantaneous collapse and deformation, ensuring that the upper aluminum plate 23 and the battery cells above it are not physically damaged.

[0046] For maintenance and decommissioning, when the battery needs repair or recycling, simply loosen the connecting bolts of the suspension lug 7 and disconnect the quick-change interface. After the elastic component loses pressure, the return spring 17 drives the piston rod 16 to return to its initial extended state, facilitating quick and seamless replacement of the next battery pack.

[0047] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An external battery support for an electric vehicle, characterized in that, include: The main load-bearing structure is a main frame (1) with a closed cross-section frame structure, which is used to provide rigid support space; Protective liner: an energy-absorbing base plate (2) that is laterally connected to the bottom edge of the main frame (1) to form a physical barrier to the bottom of the internal battery pack; Adaptive limiting mechanism: multiple elastic clamping components arrayed on the inner wall side of the main frame (1); The main frame (1) is formed by the front longitudinal beam (3), the rear longitudinal beam (4), the left cross beam (5) and the right cross beam (6) that intersect each other perpendicularly. Several sets of suspension ears (7) are provided on the outer side of the main frame (1) in a horizontal radial pattern. The suspension ears (7) are used to suspend the support as a whole on the load-bearing point of the chassis (8).

2. The external battery support for an electric vehicle according to claim 1, characterized in that: At least one reinforcing rib (9) is provided between the front longitudinal beam (3) and the rear longitudinal beam (4). The reinforcing rib (9) has a hollow irregular structure and its interior forms a closed cavity air duct (10). The front end of the cavity air duct (10) is provided with an air inlet (11) that communicates with the outside air, and the rear end is provided with an exhaust grid (12) for the exhaust of gas after heat exchange, thereby constructing a passive air cooling circulation system independent of the battery pack inside the support.

3. The external battery support for an electric vehicle according to claim 2, characterized in that: The air inlet (11) is horizontally embedded with a multi-layer filter dustproof net (13) to block moisture and particulate dust from entering the air duct; the inner surface of the cavity air duct (10) is not a smooth surface, but is integrally formed with multiple spiral guide grooves (14) with equal pitch along the longitudinal axis, which aims to improve the heat exchange efficiency of the inner wall of the air duct by increasing the air turbulence effect.

4. The external battery support for an electric vehicle according to claim 1, characterized in that: The elastic clamping assembly adopts a piston-type buffer structure, specifically including a telescopic sleeve (15) fixedly connected to the inner wall of the left crossbeam (5) or the right crossbeam (6), a piston rod (16) that makes linear reciprocating motion inside the telescopic sleeve (15), and a return spring (17) set inside the telescopic sleeve (15); the free end of the piston rod (16) is fixed with a flexible pressure block (18) for making pre-tightening contact with the battery pack shell.

5. The external battery support for an electric vehicle according to claim 4, characterized in that: The flexible pressure block (18) is made of an elastomer material with damping properties. Its end face facing the battery pack is provided with staggered anti-slip textures (19) by laser etching or mold pressing process, so as to limit the lateral drift of the battery pack in the vibration environment by increasing static friction.

6. The external battery support for an electric vehicle according to claim 1, characterized in that: At the four inner corners of the main frame (1), L-shaped positioning brackets (20) are provided for precise guidance and hard connection. The positioning brackets (20) are fastened to the frame skeleton by a set of high-strength bolts (21) with anti-loosening performance. The inner working surface of the positioning brackets (20) is pasted with a flame-retardant rubber pad (22) with a thickness of not less than 2mm. The flame-retardant rubber pad (22) has the dual functions of insulation protection and local stress buffering.

7. The external battery support for an electric vehicle according to claim 1, characterized in that: The energy-absorbing base plate (2) adopts a heterogeneous composite sandwich structure, which includes, from the inside out, an upper aluminum plate (23) with high thermal conductivity, a lower carbon fiber plate (24) with lightweight and high modulus characteristics, and a honeycomb energy-absorbing structure layer (25) metallurgically bonded between the two. The honeycomb energy-absorbing structure layer (25) is composed of a large number of hexagonal prism units, which are used to absorb collision energy through plastic deformation when the chassis is subjected to scraping or bottoming impact.

8. The external battery support for an electric vehicle according to claim 7, characterized in that: The lower surface of the lower carbon fiber plate (24) is integrated with rows of heat sinks (26) by bonding or brazing. The extension trajectory of the heat sinks (26) is parallel to the longitudinal driving center line of the vehicle, thereby using the reverse airflow during vehicle driving to perform forced convection heat exchange on the energy-absorbing base plate (2).

9. The external battery support for an electric vehicle according to claim 1, characterized in that: The main frame (1) integrates an electrification and liquid cooling interface module in the side wing space, including a wire harness fixing clip (27) for fixing high and low voltage wiring and a liquid cooling pipe connector (28) for connecting the vehicle cooling circulation system; the wire harness fixing clip (27) consists of a base (29) with self-locking function and an elastic buckle (30).

10. An external battery mount for an electric vehicle according to any one of claims 1 to 9, characterized in that: The exposed metal surfaces of the main frame (1) and the energy-absorbing base plate (2) are covered with a dense ceramic anti-corrosion coating (31) by electrostatic spraying. In addition, preheated reinforcing patches (32) are attached to the heat-affected zone of the main frame (1) or stress concentration areas such as geometric abrupt changes, in order to improve the overall fatigue life of the support.

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