Battery Pack Isolator Mounting for EV Frame Load Distribution
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Solution Overview
Problem
The integration of rechargeable battery packs in electric vehicles is challenging due to their increased weight and larger footprint, which complicates mounting and load distribution, especially when susceptible to various vehicle loads.
Innovation Solution
A battery pack support assembly that includes a plurality of isolators with a housing, an elastic body, and a fastener between the battery pack's outer support frame and the vehicle's longitudinal rails, along with brackets and lateral support members, to securely mount the battery pack and distribute loads effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If battery packs are integrated into the vehicle structure, then the electric vehicle can achieve long travel distance capability, but the mounting and load distribution becomes challenging due to increased weight and larger footprint
Solution Approach 1:
The battery pack support assembly is divided into multiple isolators distributed at different locations (front, rear, left, right) of the battery pack. Each isolator independently supports a portion of the battery pack weight, breaking down the complex mounting problem into manageable discrete units that simplify installation and load management.
Solution Approach 2:
Isolators serve as intermediary components between the battery pack and the vehicle frame. These isolators with elastic bodies provide a buffer zone that simplifies the mounting process by absorbing misalignment tolerances and providing a standardized interface, thereby reducing the overall mounting complexity.
2Duration of action of moving object
If battery packs with larger footprint are used, then long-range capability is achieved, but the integration into existing vehicle structure becomes challenging
Solution Approach 1:
The support assembly uses multiple discrete isolators positioned at key locations rather than a single large mounting structure. This segmentation allows the battery pack to be integrated into existing vehicle frames without requiring complete structural redesign, maintaining ease of manufacture while accommodating larger battery footprints.
Solution Approach 2:
The isolators are designed as universal mounting components that can be applied to various vehicle frame configurations. The standardized isolator design with flanges and elastic bodies provides multi-functional support (mounting, isolation, alignment) that simplifies integration across different vehicle platforms.
3Ease of operation
If battery packs are mounted directly to vehicle frame, then mounting is simple, but the frame is subjected to bending and twisting loads
Solution Approach 1:
Isolators with elastic bodies serve as intermediary components between the rigid battery pack and the vehicle frame. These elastic intermediaries absorb and distribute bending and twisting loads, protecting the frame from direct stress while maintaining simple mounting through the isolator's inherent flexibility and alignment capabilities.
Solution Approach 2:
The elastic bodies in the isolators change their mechanical parameters (stiffness, damping) in response to applied loads. Under normal conditions, they provide flexible mounting simplicity, but under bending or twisting loads, they increase their effective stiffness to protect the frame, dynamically adapting to loading conditions.
4Force
If isolators with elastic bodies are used, then load distribution is improved, but the mount complexity increases
Solution Approach 1:
The load distribution function is segmented across multiple isolators positioned at different locations on the battery pack. Each isolator handles a portion of the total load, distributing forces evenly throughout the vehicle frame. This segmentation achieves excellent load distribution while keeping each individual isolator relatively simple in design.
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 solution enhances load distribution, improves mount durability, and reduces bending and twisting loads on the vehicle frame, providing additional strength and efficiency in vehicle design, particularly beneficial for long-range electric vehicles.
Implementation Method 1
The elastic body is disposed within the central opening. The fastener extends laterally through the central opening of the housing and secures the elastic body to the outer support frame of the battery pack.
Data Source
AI summary
A battery pack support assembly includes a plurality of isolators disposed between an outer support frame of a battery pack and longitudinal rails of a vehicle frame. Each isolator includes a housing, an elastic body and a fastener. The housing defines a central opening and opposed flanges. The opposed flanges are secured to a respective longitudinal rail. The elastic body is disposed within the central opening of the housing. The fastener extends laterally through the central opening of the housing and secures the elastic body to the outer support frame of the battery pack.