EV Battery Mounting Structure for Flush Rail Load Paths
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Solution Overview
Problem
The integration of rechargeable battery packs in electric vehicles is challenging due to their increased weight and larger footprint, which can make them susceptible to various vehicle loads and require efficient load paths in diverse operating conditions.
Innovation Solution
A structural assembly for electric vehicles that includes a vehicle frame with opposed longitudinal rails and a battery structure secured by mounting structures and fasteners, where the mounting structures have internal stiffening members and a flush outer periphery with the rails, enhancing stability and energy absorption during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the battery pack size and weight are increased to provide longer travel distance, then the energy storage capacity is improved, but the susceptibility to vehicle loads and the challenge of integration into existing vehicle structures increases
Solution Approach 1:
The mounting structure is divided into multiple components including a mounting bracket, mounting plate, and fasteners. The bracket has a first portion that interfaces with the vehicle frame and a second portion that interfaces with the battery pack, allowing the structure to be segmented to manage loads on larger battery packs while maintaining integration feasibility
Solution Approach 2:
The mounting structure extends in multiple dimensions with the bracket providing vertical support and the plate providing horizontal attachment. This multi-dimensional configuration distributes loads across different spatial dimensions, reducing susceptibility to vehicle loads on the enlarged battery pack
2Use of energy by moving object
If the battery pack footprint is increased to accommodate more energy storage, then the energy capacity is improved, but the difficulty of providing efficient load paths in existing vehicle structures increases
Solution Approach 1:
The mounting structure serves multiple functions: it attaches the battery pack to the vehicle frame, provides structural support, distributes loads, and interfaces with both the vehicle frame and battery pack. This multi-functional design simplifies integration into existing vehicle structures despite the larger battery footprint
Solution Approach 2:
The mounting bracket and plate act as intermediary components between the vehicle frame and the battery pack. These intermediaries provide efficient load paths and facilitate integration of the larger battery pack into the existing vehicle structure without requiring major structural modifications
3Strength
If mounting structures with larger cross-sectional area are used to support longitudinal rails, then the strength and stiffness of the vehicle structure is improved, but the overall width of the vehicle structure increases
Solution Approach 1:
The mounting structure has different cross-sectional areas at different locations. The bracket portion that contacts the battery pack has a larger cross-sectional area for strength, while the mounting plate that attaches to the vehicle frame has a reduced cross-sectional area. This local variation in quality provides the necessary structural strength while minimizing the overall width of the mounting structure
Data Source
AI summary
A structural assembly for an electric vehicle includes a vehicle frame, a battery structure, a pair of mounting structures, and a plurality of fasteners. The vehicle frame includes opposed longitudinal rails. The battery structure is disposed between the opposed longitudinal rails and includes a battery housing configured to house power storage units. Each mounting structure is secured to a respective side of the battery housing and supports a corresponding longitudinal rail. The plurality of fasteners extend through a corresponding mounting structure of the pair of mounting structures and a corresponding longitudinal rail of the opposed longitudinal rails to secure the vehicle frame and the battery structure to each other. An outer periphery of the corresponding mounting structure is substantially flush with an outer periphery of the corresponding longitudinal rail.