Battery Pack Support Bracket for Truck Side-Impact and Torsion
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Solution Overview
Problem
Electric trucks face challenges in securing torsional rigidity and side collision safety for battery packs that are too large to fit between frames, and there is a need to adapt passenger car battery packs for use in trucks while ensuring safety and cost-effectiveness.
Innovation Solution
A vehicle battery pack support device with a battery bracket and frame bracket configuration that covers the battery pack's sides and faces, forming a box-like structure to prevent direct impact and improve torsional rigidity, allowing for easy mounting of larger battery packs and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a battery pack with long sides extending beyond side rails is used to increase capacity, then the battery pack size is increased, but the battery pack cannot be arranged between frames and side collision safety cannot be secured
Solution Approach 1:
A support device with brackets is introduced as an intermediary between the battery pack and the vehicle frame. The brackets extend beyond the side rails to provide lateral support and protection for the battery pack, enabling the use of larger battery packs while maintaining side collision safety through the mediating protective structure.
Solution Approach 2:
The support brackets extend in the width direction beyond the side rails, utilizing the spatial dimension outside the traditional frame boundaries. This allows the battery pack to be supported and protected laterally even when its dimensions exceed the distance between frames, resolving the contradiction between size and safety.
2Volume of moving object
If a battery pack larger than the distance between frames is used to increase capacity, then the battery pack volume is increased, but torsional rigidity cannot be secured
Solution Approach 1:
The support device acts as a mediating structure that couples the large battery pack to the vehicle frame. The brackets distribute and transfer torsional loads from the battery pack to the frame, enabling the use of larger battery packs while maintaining torsional rigidity through the mediating load-path structure.
3Device complexity
If passenger car battery packs are used to reduce costs, then the device complexity is reduced, but the battery packs are designed for inside mounting and cannot be directly used in electric trucks with outside mounting requirements
Solution Approach 1:
The support device provides universal mounting capability that adapts standard battery packs for both inside and outside mounting configurations. The bracket design with extensions beyond the side rails creates a universal interface that accommodates battery packs designed for conventional inside mounting while enabling their use in outside mounting applications in electric trucks.
Data Source
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AI summary
A vehicle battery pack support device is provided which is capable of securing torsional rigidity and side collision safety of a battery pack when a battery pack having a dimension that does not fit between frames of an electric truck is mounted. A support device 10 for a battery pack 2 includes: a battery bracket 20 for housing the battery pack 2; and a frame bracket 30 for coupling side rails 3L and 3R and the battery bracket 20, in which the battery bracket 20 includes first brackets 21A and 21B covering side faces 2a and 2b of the battery pack 2, a portion of a top face that is continuous with the side faces, and a portion of a bottom face that is continuous with the side faces, and the first brackets 21A and 21B having a dimension in a vehicle width direction which is equal to or larger than the long side of the battery pack 2, and a second bracket covering end portions of the first brackets in the vehicle width direction and coupled to the frame bracket.