Heavy Vehicle Battery Pack Layout Above the Chassis

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Solution Overview

Problem

The positioning of battery packs in heavy vehicles underneath the chassis reduces available space for reservoirs, exposes batteries to dirt and increases the risk of damage and fire during accidents.

Innovation Solution

A battery pack design that is carried above the chassis, preferably on a catwalk, with a modular structure allowing easy access and secure fixation, minimizing space usage and protecting batteries from external elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery packs are positioned underneath the chassis, then they are protected from external environment, but available space for reservoirs is reduced

Engineering Contradiction:

Improvebattery protectionVSAvoidspace for reservoirs

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The battery pack is relocated from the horizontal space underneath the chassis to the vertical space on the catwalk above the chassis. This dimensional change allows the battery pack to occupy a different spatial zone, thereby increasing the available horizontal space underneath the chassis for reservoirs while maintaining battery protection through the enclosed battery pack housing.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If battery packs are positioned underneath the chassis, then space utilization is optimized, but batteries are exposed to dirt and contaminants

Engineering Contradiction:

Improvespace utilizationVSAvoiddirt exposure

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The battery pack is extracted from the contaminated environment underneath the chassis and relocated to the cleaner environment on the catwalk above the chassis. This separation removes the batteries from direct exposure to road dirt, wheel spray, and other contaminants while still utilizing available vehicle space efficiently.

Inventive Principle:

Principle #2Taking out (Extraction)

3Area of stationary object

If battery packs are positioned underneath the chassis, then installation space is available, but risk of damage and fire during accidents increases

Engineering Contradiction:

Improveinstallation spaceVSAvoidsafety during accidents

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The battery pack is positioned on the catwalk above the chassis, which is structurally stronger and more resistant to impact forces during accidents. This preliminary positioning strategy prevents the batteries from being in the high-risk zone underneath the chassis where they would be vulnerable to impact damage and potential fire hazards during collisions.

Inventive Principle:

Principle #9Preliminary anti-action

Data Source

PatentEP4632908A1Improved battery pack arrangement for a vehicle

Publication Date: 2025.10.15 ON-HIGHWAY BRASIL LTDA

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AI summary

Battery pack (5) for a heavy vehicle (1), the battery pack (5) extending along a longitudinal axis (A'), a transversal axis (B') and a vertical axis (C') and comprising a base (6) configured to be fixed to a portion (2) of the vehicle (1) and a cover (7) selectively carried by said base (6), the cover (7) being connected to one wall of said the (6) via a releasable connection (11) in order to assume an attached configuration wherein said cover (7) is connected to one among said walls (6a, 6b, 6c) of said base (6) or a detached configuration wherein the cover (7) is separated from the base (6).