Vehicle Battery Pack Mounting Structure for Step Height and Impact Protection
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Solution Overview
Problem
In vehicles with a body-on-frame structure, existing battery pack mounting solutions compromise passenger compartment space and safety, as they do not effectively protect the battery while ensuring easy boarding and alighting, and fail to maximize space utilization.
Innovation Solution
A battery pack mounting structure that positions the battery case with its lower end aligned with the lowest ground height, incorporating a frame side member spaced downward from the step height and a case side portion with vertical and horizontal cross-sectional components, coupled to the frame side member, to absorb impacts and maintain battery safety while minimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is mounted on the chassis frame with existing solutions, then the battery is protected to some extent, but the passenger compartment space is reduced and boarding/alighting becomes difficult
Solution Approach 1:
The battery case is positioned such that its lower end aligns with the lowest ground height of the vehicle, utilizing the vertical dimension optimally. This dimensional arrangement allows the battery to be protected by the chassis frame structure while maintaining adequate step height for easy passenger boarding and alighting, thus resolving the contradiction between battery protection and ease of operation.
Solution Approach 2:
The battery case includes a case side portion with a horizontal cross-sectional portion that is coupled to the lower side of the frame side member, with its lower end portion aligned with the lowest ground height. This localized structural configuration provides impact absorption and protection at the critical lower region of the battery, while the upper portion maintains proper spacing for passenger access, thereby achieving both protection and operational ease.
2Reliability
If the battery case is positioned lower to protect from impacts, then battery safety improves, but passenger compartment space is compromised
Solution Approach 1:
The battery case is positioned such that its lower end aligns with the lowest ground height of the vehicle, utilizing the vertical dimension optimally. This dimensional arrangement allows the battery to be protected by the chassis frame structure while maintaining adequate step height for easy passenger boarding and alighting, thus resolving the contradiction between battery protection and ease of operation.
3Ease of operation
If the frame side member is spaced downward from step height, then easy boarding is achieved, but battery protection distance is reduced
Solution Approach 1:
The battery case includes a case side portion with a horizontal cross-sectional portion that is coupled to the lower side of the frame side member, with its lower end portion aligned with the lowest ground height. This localized structural configuration provides impact absorption and protection at the critical lower region of the battery, while the upper portion maintains proper spacing for passenger access, thereby achieving both protection and operational ease.
Data Source
AI summary
A battery pack mounting structure of a vehicle includes: a frame side member of a chassis frame provided so that an upper end portion thereof is located at a position spaced downward by a predetermined reference downward distance from a step height set in consideration of ease of boarding of passengers; a battery case provided so that a battery accommodated in the battery case overlaps the frame side member in a horizontal direction thereof; a case side portion forming a side surface of the battery case, coupled to a lower side of the frame side member, and including a lower end portion aligned with a lowest ground height of the vehicle; and a case lower plate forming the battery case while supporting a lower side of the battery and disposed at a position spaced upwards from the lowest ground height.