Integrated Battery Pack Mounting Frame for Lighter Vehicle Chassis

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Solution Overview

Problem

The existing power battery installation structure involves independent components such as the battery pack, battery bracket, and vehicle frame sections, leading to high weight, installation complexity, and cost.

Innovation Solution

A vehicle frame assembly is designed with a battery pack mounting frame that integrates with the vehicle frame front and rear sections, reducing the number of components and weight by dividing the traditional frame into three sections, and incorporating a connection component to secure the battery pack.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the battery pack, battery bracket, longitudinal beams, and middle cross-beam are all independent components, then the installation flexibility is improved, but the device complexity and weight increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the battery bracket with the middle cross-beam into an integrated battery pack mounting frame. This combination reduces the number of independent components while maintaining installation flexibility, as the integrated structure is designed to accommodate battery packs with adjustable positioning features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated battery pack mounting frame serves multiple functions: it acts as both a structural frame component and a battery mounting bracket. The universal design allows it to support battery packs while contributing to the overall vehicle frame structure, reducing the need for separate dedicated mounting components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the battery pack, battery bracket, longitudinal beams, and middle cross-beam are all independent components, then the installation flexibility is improved, but the weight increases

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidvehicle frame weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

By combining the battery bracket and middle cross-beam into a single integrated structure, the patent eliminates the weight of separate connection components and fasteners. The integrated design reduces overall weight while preserving installation flexibility through built-in adjustment features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The battery pack mounting frame is constructed using composite materials that provide high strength-to-weight ratio, allowing the integrated structure to maintain structural integrity and installation flexibility while significantly reducing the weight compared to traditional separate metal components.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If the battery pack, battery bracket, longitudinal beams, and middle cross-beam are all independent components, then the installation flexibility is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The integration of the battery bracket and middle cross-beam reduces the total number of parts that need to be manufactured, stored, and assembled. This consolidation lowers manufacturing costs despite maintaining installation flexibility through the integrated design's adjustable features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated battery pack mounting frame is designed with modular segments that can be manufactured separately and then assembled into the final integrated structure. This segmentation approach simplifies manufacturing processes and reduces costs while preserving the flexibility benefits of the integrated design.

Inventive Principle:

Principle #1Segmentation

4Weight of moving object

If the vehicle frame is divided into three sections with integrated battery pack mounting frame, then the weight is reduced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvevehicle frame weightVSAvoidinstallation accuracy requirements

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

The integrated battery pack mounting frame includes pre-positioned mounting features and alignment guides that are built into the structure during manufacturing. These preliminary features ensure accurate battery pack installation without requiring high precision during the actual installation process, thus reducing the burden on manufacturing precision while maintaining weight benefits.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250276658A1Vehicle frame assembly, energy storage structure, and vehicle

Publication Date: 2025.09.04 BYD CO LTD

AI summary

A vehicle includes a vehicle frame assembly and an energy storage structure. The vehicle frame assembly includes a vehicle frame front section, a battery pack mounting frame and a vehicle frame rear section which are sequentially connected in the length direction of a vehicle body. The battery pack mounting frame is used for mounting a battery pack.