Vehicle Battery Pack Structure for Direct Suspension Load Transfer
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Solution Overview
Problem
Existing vehicle battery packs, particularly in electric vehicles, face challenges in promptly following vehicle behavior due to delayed load transmission paths, which affect vehicle operating stability, especially when the battery weight is concentrated below the floor, occupying a significant portion of the vehicle's weight.
Innovation Solution
The battery pack incorporates stiffened members that are integrally coupled to the frame member and disposed along the load transmission path from the suspension, directly transmitting the load to the battery case, thereby improving stability and allowing for higher-capacity or downsized configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is disposed below the cabin floor with a conventional frame structure, then the battery can be accommodated, but the load transmission path is delayed and vehicle operating stability deteriorates
Solution Approach 1:
The stiffened member is pre-configured with an oblique extension from the coupled portion between the sub-frame and frame member, creating a load transmission path that is ready to immediately transmit suspension loads to the battery case without delay
Solution Approach 2:
The stiffened member extends obliquely in both rear direction and lateral direction, adding a diagonal dimension to the load transmission path that directly connects suspension loads to the battery case, bypassing conventional horizontal transmission routes
2Reliability
If the battery pack is made heavier to ensure stability, then vehicle operating stability improves, but the weight of the moving object increases
Solution Approach 1:
The stiffened member utilizes oblique geometric configuration that efficiently transmits loads through diagonal stress distribution, achieving enhanced stability with minimal additional mass compared to conventional horizontal bracing
Solution Approach 2:
The stiffened member is integrally coupled to the frame member, forming a composite structural unit that maximizes stiffness-to-weight ratio and transmits loads efficiently without requiring separate heavy components
3Productivity
If the battery pack is downsized or made higher-capacity to improve energy density, then productivity improves, but the load transmission efficiency deteriorates
Solution Approach 1:
The battery pack is divided into battery blocks accommodated within the battery case, allowing flexible configuration that maintains structural integrity and load transmission efficiency regardless of battery capacity or physical dimensions
Data Source
AI summary
A vehicle battery pack mounted on a vehicle while accommodating batteries therein includes a battery case and a stiffened member. The battery case includes a frame member that is coupled to a rear portion of a sub-frame of the vehicle. The stiffened member has rigidity and is integrally coupled to a portion of the battery case. The stiffened member is disposed such that the stiffened member extends obliquely in a rear direction and a lateral direction of the frame member from a coupled portion between the sub-frame and the frame member, and that each end is coupled to the frame member.