Vehicle Battery Pack Mounting Structure for Impact Protection and Cabin Space
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Solution Overview
Problem
Existing battery pack mounting structures for electric vehicles with a BODY ON FRAME structure face challenges in protecting the battery while ensuring passenger ease of entry and exit, maximizing passenger space, and enhancing vehicle safety and commercial appeal.
Innovation Solution
A battery pack mounting structure featuring a frame side member with reinforcement panels and lockers, a battery case with vertical and horizontal cross-section units, and a vehicle body chamber to absorb impacts, ensuring the battery is protected and securely mounted, while allowing for easy passenger access and space optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is mounted on the chassis frame using existing systems, then the battery can be secured to the frame, but the battery protection effectiveness is insufficient and interior space is not maximized
Solution Approach 1:
The battery case is positioned in the vertical dimension by extending downward from the chassis frame, utilizing the vertical space between the frame and ground rather than consuming horizontal interior space. This dimensional repositioning allows robust battery protection while preserving passenger compartment volume.
Solution Approach 2:
The battery case is divided into multiple segments including a first case portion, second case portion, and third case portion that can be independently configured. This segmentation allows the protective structure to be optimized for safety while minimizing space occupation in critical interior zones.
2Strength
If the battery case is extended downward to improve protection, then impact resistance increases, but the vehicle height increases affecting passenger access
Solution Approach 1:
The battery case employs different structural qualities in different regions: the first case portion has a first thickness, the second case portion has a second thickness greater than the first, and the third case portion has a third thickness greater than the second. This graduated thickness distribution provides enhanced impact resistance at critical locations while maintaining overall compactness for easy passenger access.
3Ease of manufacture
If the battery case structure is simplified to reduce complexity, then manufacturing becomes easier, but the securing strength of the battery to the frame decreases
Solution Approach 1:
The battery case incorporates a movable fourth case portion that can move relative to the third case portion along the longitudinal direction of the vehicle. This dynamic component allows the structure to adapt to manufacturing tolerances and assembly variations, maintaining securing strength while simplifying the manufacturing process through modular design.
Data Source
AI summary
The present disclosure includes a frame side member forming a chassis frame and disposed on both sides of a vehicle in a forward-backward direction, a battery disposed to overlap inwardly from the frame side member in a horizontal direction, and a battery case surrounding the battery and coupled to the frame side member, wherein a cross section of the frame side member forms a plurality of closed spaces.