Battery Pack Mounting Structure with Ring-Like Sub-Frame
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Solution Overview
Problem
Conventional battery pack mounting structures for electric cars are inadequate in protecting the battery pack from deformation and movement during a rear impact, as they are prone to bending and deformation, which can cause the battery pack to collide with other in-vehicle parts.
Innovation Solution
A battery pack mounting structure featuring a sub-frame with a ring-like support frame that surrounds the battery pack, coupled to rear side members and a cross member, which prevents deformation and movement by distributing impact forces and reinforcing the rear side members, thereby maintaining the battery pack's position during a rear impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mount frame is bent in the vehicle vertical direction at a vehicle-longitudinal intermediate portion to achieve step-like mounting surfaces, then the battery packs can be mounted at different heights, but the mount frame becomes deformed in the vehicle vertical direction during rear impact
Solution Approach 1:
The mounting structure is divided into separate components: the rear side members with bent portions for height adjustment, and the sub-frame with ring-like support frame for stable battery pack mounting. This segmentation allows the rear side members to provide height variation while the sub-frame maintains structural integrity during impact.
Solution Approach 2:
The invention transitions from a single vertical bent frame structure to a three-dimensional sub-frame with ring-like support. The ring-like support frame adds dimensional stability by distributing forces in multiple directions, preventing vertical deformation during rear impact while maintaining the height difference function.
2Shape
If the rear side members include a rising portion that extends upward at a vehicle-longitudinal intermediate portion, then the mount frame can achieve step-like shape, but the rear portion deforms to project to the vehicle upper side during rear impact
Solution Approach 1:
The rising portion function is separated from the main load-bearing path. The rear side members provide the step-like shape through controlled bending, while the ring-like support frame of the sub-frame carries the primary impact loads, isolating the rising portion from deformation.
Solution Approach 2:
Different parts of the structure are optimized for different functions: the rear side members are designed with specific bent portions to create the step-like shape where needed, while the sub-frame's ring-like support frame is designed for overall structural stability and impact resistance. Each component has localized properties suited to its specific role.
3Length of moving object
If the longitudinal length of the rear side members is reduced due to deformation during rear impact, then the battery pack moves toward the vehicle front side, but this causes contact with other in-vehicle parts
Solution Approach 1:
The sub-frame introduces a ring-like three-dimensional support structure that constrains the battery pack in multiple dimensions. This prevents the battery pack from moving forward when the rear side members deform, as the ring structure provides lateral and vertical constraints in addition to longitudinal support.
Solution Approach 2:
The ring-like support frame acts as a pre-configured protective structure that anticipates potential battery pack movement during impact. By surrounding the battery pack with this rigid ring structure before impact occurs, the system prevents harmful forward movement and contact with other vehicle parts.
Data Source
AI summary
A battery pack mounting structure for electric cars in which a pair of rear side members having a front portion, a rear portion, and a rising portion are arranged at both vehicle-widthwise side portions, intermediate portions of the respective rear side members are coupled to each other by a cross member, and a battery pack is mounted on a vehicle body by a sub-frame that is coupled to the respective rear side members and the cross member, wherein the cross member is arranged at a position below a bent portion that connects the rising portion and the rear portion of each of the rear side members, the sub-frame includes a ring-like support frame that extends in a horizontal direction and surrounds an outer periphery of the battery pack, and a front side portion and both vehicle-widthwise side portions of the support frame are respectively coupled to the cross member and the rear portions of the respective rear side members by coupling portions.