Vehicle Battery Pack Mounting Structure for Space and Impact Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack mounting structures in body-on-frame electric vehicles compromise passenger compartment space and passenger access while providing inadequate protection for batteries.
Innovation Solution
A battery pack mounting structure that includes a frame side member, a battery case with a vertical and horizontal section portion, and a cooling plate, designed to overlap with the frame side member, ensuring minimal ground clearance and shock absorption, while using fastening bolts and sleeves for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is mounted on the chassis frame side in body-on-frame electric vehicles, then the batteries are protected from external impacts, but the passenger compartment space is reduced and passenger access is compromised
Solution Approach 1:
The battery pack is positioned in the longitudinal direction along the chassis frame rather than occupying transverse space under the passenger compartment. The case side portion extends in the longitudinal direction and couples to the lower side of the frame side member, transforming the spatial arrangement from a space-consuming transverse layout to a space-efficient longitudinal layout that protects batteries without sacrificing passenger space.
Solution Approach 2:
The battery case is divided into functional sections: a case lower plate supporting the battery, a vertical section portion providing structural connection, and a horizontal section portion coupling to the frame. This segmentation allows the battery pack to be mounted along the chassis frame side, distributing the battery protection function across multiple structural elements that work together to secure the battery while minimizing space occupation.
2Volume of moving object
If the battery pack is mounted on the chassis frame side, then passenger compartment space is maximized, but the battery protection from external impacts is insufficient
Solution Approach 1:
The case side portion is designed with an L-shaped cross-section comprising a vertical section portion and a horizontal section portion. This curved/angled configuration provides multi-directional protection: the vertical portion resists downward forces, the horizontal portion resists lateral impacts, and the connection between them creates a rigid structure that protects the battery from external impacts while maintaining a compact profile that preserves passenger space.
3Strength
If the case side portion is coupled to the lower side of the frame side member, then the battery pack is securely attached, but the ground clearance is reduced
Solution Approach 1:
The coupling structure is designed with differentiated sections: the horizontal section portion couples to the frame side member at a specific location, while the lower end portion and under cover are positioned to align with the minimum ground clearance. This local differentiation allows strong attachment at the coupling point while maintaining adequate ground clearance at the lowest points of the battery pack.
Solution Approach 2:
The case side portion acts as an intermediary element between the battery and the chassis frame. It provides the attachment function through coupling to the frame side member while its geometric design (L-shaped cross-section with specific dimensions) ensures that the attachment strength is sufficient without requiring the entire structure to be elevated, thus maintaining ground clearance.
4Length of stationary object
If the under cover is aligned with the minimum ground clearance, then the ground clearance is optimized, but the battery protection from road debris is compromised
Solution Approach 1:
The under cover is designed to align with the minimum ground clearance, creating a protective shield that extends to the lowest point of the battery pack. This beforehand cushioning approach positions the cover to intercept road debris before it can reach the battery, providing protection at the critical ground clearance boundary without requiring additional elevation that would reduce passenger space.
Data Source
AI summary
A battery pack mounting structure for vehicles, includes a frame side member extending in a front and rear direction on each side of a vehicle to form a chassis frame, a battery disposed to be overlapped horizontally on inside of both frame side members, and a battery case enclosing the battery therein, wherein a case side portion provided on a side of the battery case is coupled to a lower side of the frame side member.