EV Battery Mounting Side Rail Layout for Low-Floor Packaging
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Solution Overview
Problem
The existing methods for mounting batteries in electric vehicles occupy a significant amount of space, limiting energy density and requiring a large vertical dimension, which complicates the layout and structural integrity of the vehicle.
Innovation Solution
A body connection assembly that incorporates a floor panel with a conduit, a rocker rail, and a mounting side rail, where the battery is partially located below the floor panel and mounted on the side rail, with the battery's upper box closing the conduit to reduce vertical space usage, enhance structural stability, and implement hermetic seals to prevent moisture and impurities from entering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery is mounted in a conventional position above the floor panel, then the battery is easily accessible and installed, but it occupies significant vertical space and reduces energy density
Solution Approach 1:
The patent relocates the battery from a conventional vertical mounting position to a horizontal mounting position along the longitudinal direction of the vehicle. The battery is mounted on the mounting side rail that extends along the first direction (longitudinal direction), transforming the space utilization from vertical to horizontal dimension. This dimensional change reduces the vertical space occupied by the battery while maintaining secure mounting through the side rail structure.
2Volume of moving object
If the battery is mounted below the floor panel, then vertical space is reduced, but the structural integrity and hermeticity of the floor panel must be maintained
Solution Approach 1:
The floor panel structure is segmented into multiple functional components: the floor panel itself, the mounting side rail, the rocker rail, and the upper box of the battery. The mounting side rail is connected to both the floor panel and the battery, creating a distributed support structure. This segmentation allows the battery to be mounted below the floor panel while maintaining floor panel integrity through the distributed connection points and structural support.
Solution Approach 2:
The upper box of the battery is designed to close the conduit on the floor panel, merging the battery housing with the floor panel structure. The mounting side rail integrates the floor panel, rocker rail, and battery mounting functions into a single structural assembly. This merging eliminates the need for separate mounting brackets and maintains the hermeticity of the floor panel by using the battery's upper box as part of the floor structure.
3Ease of manufacture
If clearances are left between the battery and surrounding structures, then assembly is easier and thermal management is improved, but impurities and moisture can enter and cause corrosion
Solution Approach 1:
The mounting side rail acts as an intermediary structure between the battery and the floor panel/rocker rail assembly. It provides a controlled interface that maintains necessary clearances for assembly and thermal management while preventing direct exposure of the battery to the external environment. The side rail creates a protected mounting region that isolates the battery from moisture and impurities while allowing easy assembly.
4Ease of manufacture
If the rocker rail and mounting side rail extend perpendicular to the vehicle length direction, then manufacturing is simplified, but structural stability along the vehicle length is reduced
Solution Approach 1:
The rocker rail and mounting side rail are designed with asymmetric orientation: the rocker rail extends along the second direction (perpendicular to vehicle length), while the mounting side rail extends along the first direction (longitudinal direction of the vehicle). This asymmetric configuration optimizes both manufacturing and structural performance. The mounting side rail's longitudinal extension provides enhanced structural stability along the vehicle length, supporting the battery's weight and maintaining floor panel rigidity, while the rocker rail's perpendicular extension simplifies manufacturing and connection to the vehicle body.
Data Source
AI summary
A body connection assembly and a vehicle are disclosed. The body connection assembly includes: a floor panel, including a conduit; a rocker rail, located on one side of the floor panel along a first direction, where the rocker rail is configured to be connected to a body; a mounting side rail, connected to a side of the rocker rail, the side being close to the floor panel; and a battery, at least partially located below the floor panel and mounted on a side of the mounting side rail along the first direction, the side being away from the rocker rail. The battery includes a box assembly. The box assembly includes an upper box. The upper box closes the conduit.