Utility Vehicle Battery Pack Layout Within Frame Rails
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Solution Overview
Problem
There is a need for improved battery packs that can provide sufficient power storage for utility vehicles while being compact and integrated into the existing vehicle frame, minimizing space occupied by other equipment such as truck boxes or beverage bodies, and efficiently powering electric drivetrains for heavy and medium-duty utility vehicles.
Innovation Solution
The development of transversely compact battery assemblies with a housing design that includes a concave enclosure and a mounting system with shoulder brackets and vibration isolators, allowing the battery units to be disposed within the frame assembly, thereby maximizing storage capacity without obstructing other vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery packs are enlarged to provide sufficient power storage for utility vehicles, then power storage capacity is improved, but the area occupied by the battery pack increases and may obstruct other vehicle equipment such as truck boxes or beverage bodies
Solution Approach 1:
The battery pack transitions from a conventional horizontal arrangement to a vertical configuration, utilizing the vertical space between frame rails rather than occupying lateral area. The battery assembly rises vertically between the frame rails, with the top portion extending into the space between rails while the lateral portion extends underneath, creating a three-dimensional utilization of available space that maximizes power storage without obstructing equipment areas.
2Area of stationary object
If battery packs are made transverse compact to fit within frame assembly width, then space for other equipment is preserved, but power storage capacity may be reduced
Solution Approach 1:
The battery pack is nested within the vertical space between frame rails, with the housing positioned to fit into the available dimensional envelope. The lateral portion extends underneath the frame rail while the top portion rises between rails, creating a nested configuration that utilizes unused vertical space without interfering with lateral equipment mounting areas.
3Quantity of substance
If battery assembly is positioned high to maximize power storage volume, then power storage is improved, but the assembly may interfere with other vehicle components and equipment
Solution Approach 1:
The battery housing features differentiated regions with distinct functional properties: the lateral portion is configured to extend underneath the frame rail to minimize vertical profile in critical areas, while the top portion is designed to rise between frame rails to maximize storage volume. This local differentiation of housing geometry allows the assembly to adapt to the complex three-dimensional space constraints of the vehicle frame.
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
The solution enables high-aspect-ratio battery packs to be mounted below the vehicle frame, providing ample power storage while keeping the vehicle's equipment area unobstructed, facilitating the use of electric drivetrains in utility vehicles like Class 5 and 6 trucks without compromising space for other essential components.
Implementation Method 1
The vibration isolator reduces load transmission from the frame member of the vehicle to the housing
Data Source
AI summary
A battery assembly is provided for an electric vehicle that include a housing, one or more battery units, and a connector. The housing has a forward side, a rearward side, a bottom side, and a top portion. The top portion is configured to project into a space between adjacent frame rails. The housing also has a lateral portion configured to extend under a bottom surface of one of the adjacent frame rails. The one or more battery units are disposed within the top portion of the housing. The connector disposed over the lateral portion of the housing. The connector being configured to releasably coupled with one of the adjacent frame rails.