Battery Pack Mounting Structure for Frame Torsion Absorption
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Solution Overview
Problem
In frame vehicles, where the side frames and body are separated, the torsional rigidity is low, leading to potential twisting and failure of the battery pack when mounted directly to the side frames, and traditional rubber mounts with hard spring characteristics fail to absorb torsional displacement effectively.
Innovation Solution
The battery pack is supported by a longitudinal member at an intermediate position between the right and left side frames, connected via lateral members and rubber bushes, allowing for flexible support that absorbs torsional displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery pack is simply fastened to the side frame, then the mounting structure is simple, but the battery pack is greatly twisted due to large torsion angle of the side frame
Solution Approach 1:
The patent introduces a longitudinal member as an intermediary component positioned at the intermediate position between the right and left side frames. This longitudinal member serves as a mediator that connects to both side frames via lateral members, absorbing torsional forces before they reach the battery pack, thereby resolving the contradiction between simple mounting structure and battery pack stability.
Solution Approach 2:
The patent adds a longitudinal dimension to the mounting structure by introducing the longitudinal member that extends in the vehicle front-rear direction at an intermediate position between the side frames. This dimensional addition creates a three-dimensional support system that effectively counters torsional forces, transforming the simple two-point mounting into a distributed multi-point support system.
2Reliability
If the battery pack is supported by rubber mount, then torsion absorption is improved, but the hard spring characteristic requires several hundred N/mm making it difficult to absorb torsion
Solution Approach 1:
The patent changes the mounting parameters by relocating the support point from the side frames directly to the longitudinal member positioned at the intermediate position between the side frames. This parameter change in support location fundamentally alters the torsional characteristics, allowing the system to absorb torsion without requiring extremely hard spring characteristics.
Solution Approach 2:
The patent introduces a new spatial dimension to the support system by adding the longitudinal member that extends in the vehicle front-rear direction. This dimensional addition creates a lever arm effect that mechanically amplifies the torsion absorption capability, allowing softer rubber mounts to effectively absorb torsional forces that would otherwise require very hard spring characteristics.
3Adaptability or versatility
If the side frames and body are separated in frame vehicle, then vehicle assembly flexibility is improved, but the torsional rigidity of the side frame becomes relatively low
Solution Approach 1:
The patent segments the battery support function from the side frames by introducing a separate longitudinal member that is independently supported by lateral members connecting to both side frames. This segmentation allows the side frames to remain flexible for assembly while the dedicated longitudinal support structure provides the necessary torsional rigidity for battery pack stability.
Solution Approach 2:
The longitudinal member acts as an intermediary that decouples the battery pack from direct connection to the side frames. This intermediary structure allows the side frames to maintain their flexibility for vehicle assembly while the longitudinal member, positioned at the intermediate position, provides the torsional rigidity needed to protect the battery pack.
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
This configuration suppresses battery pack twisting and failure by minimizing displacement and absorbing torsional forces, ensuring stable support even with increased torsion angles.
Implementation Method 1
the battery pack is connected to the right and left side frames via a rubber bush
Data Source
AI summary
A battery mounting structure of a frame vehicle, which supports a battery pack by a pair of right and left side frames extending in the vehicle front-rear direction and provided in the frame vehicle, includes: a plurality of lateral members extending in the vehicle width direction and bridging the pair of right and left side frames; a longitudinal member supported by the plurality of lateral members so as to extend in the vehicle front-rear direction at an intermediate position of the side frames; and a support member that supports the battery pack such that a plurality of longitudinal members are provided at intervals in the vehicle front-rear direction and a gap in the vertical direction is generated between the plurality of longitudinal members. The battery pack is connected to the side frame via a rubber bush.