Battery Pack Bracket Structure for Oversized Truck Pack Mounting
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Solution Overview
Problem
Existing battery packs that are too large to fit between frames of an electric truck pose challenges in securing torsional rigidity and side collision safety, and there is a demand to use common passenger car battery packs in electric trucks, which are typically mounted inside the vehicle body but need to be exposed outside.
Innovation Solution
A vehicle battery pack support device comprising a battery bracket with first and second brackets that cover the side and end portions of the battery pack, coupled to side rails via a frame bracket, ensuring the battery pack is securely mounted and protected from impacts, enhancing torsional rigidity and side collision safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery pack with dimensions exceeding the frame distance is used, then the battery pack size is increased, but the battery pack cannot be securely mounted between frames
Solution Approach 1:
A battery bracket is introduced as an intermediary component between the battery pack and the vehicle frame. The bracket includes first brackets that cover the side faces of the battery pack and extend beyond the frame distance, and second brackets that cover the end portions of the first brackets. This intermediary structure enables secure mounting of oversized battery packs by distributing mounting points along the side rails rather than requiring full frame enclosure.
Solution Approach 2:
The mounting structure transitions from a traditional between-frame mounting approach to a side-rail mounting approach. By utilizing the longitudinal extension of side rails and positioning brackets along this dimension, the system accommodates battery packs with widths exceeding the frame distance while maintaining secure attachment through multiple contact points along the rail length.
2Ease of operation
If the battery pack is arranged exposed to the outside, then the battery pack accessibility is improved, but the side collision safety is compromised
Solution Approach 1:
The first brackets are designed to extend beyond the side faces of the battery pack in the vehicle width direction, creating a protective overhang that cushions lateral impacts before they reach the battery pack. This beforehand cushioning structure absorbs and distributes collision forces, protecting the exposed battery pack from side collision damage while maintaining accessibility.
3Device complexity
If a simple mounting structure is used, then the device complexity is reduced, but the torsional rigidity is insufficient
Solution Approach 1:
The mounting structure is segmented into first brackets covering the side faces and second brackets covering the end portions. This segmentation allows each bracket type to perform its specific function optimally while maintaining overall structural integrity. The distributed bracket configuration provides torsional rigidity through multiple attachment points without requiring a monolithic complex structure.
Data Source
AI summary
A vehicle battery pack support device for a battery pack mounted below a pair of side rails extending in a vehicle longitudinal direction and has a pair of side faces each facing in the longitudinal direction, includes a battery bracket for housing the battery pack and a frame bracket for coupling the side rails and the battery bracket. The battery bracket includes a first bracket covering the side faces of the battery pack, at least a portion of a top face that is continuous with the side faces, and at least a portion of a bottom face that is continuous with the side faces, the first bracket having a dimension in the vehicle width direction which is equal to or larger than the long side of the battery pack and a second bracket covering an end portion of the first bracket in the width direction coupled to the frame bracket.