Battery-to-Subframe Attachment for Structural EV Pack Integration
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Solution Overview
Problem
Existing electric vehicles inefficiently utilize the size, strength, and weight of battery packs by mounting them to a separate vehicle frame, which can be heavy and reduce the vehicle's structural integrity and range.
Innovation Solution
Integrate the battery pack as a structural component by forming a load path from the subframe to the battery pack, using a structural attachment member to couple the battery pack to the subframe, thereby reducing or eliminating the need for a separate vehicle frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate vehicle frame is used to mount the battery pack, then the battery pack is securely supported, but the vehicle weight increases and structural integrity is reduced
Solution Approach 1:
The patent merges the vehicle frame and battery pack into a single integrated structure. The battery pack is designed with structural members that directly form part of the vehicle frame, eliminating the need for a separate mounting frame. This integration maintains structural integrity while reducing overall vehicle weight by removing redundant components.
Solution Approach 2:
The battery pack structure serves multiple functions: it provides structural support for the vehicle frame, houses the battery cells, and acts as a mounting structure for other vehicle components. This multi-functionality eliminates the need for dedicated separate structures for each function, reducing weight while maintaining strength.
2Strength
If a heavy separate vehicle frame is used, then structural support is adequate, but the vehicle range is reduced
Solution Approach 1:
By merging the frame and battery pack structures, the patent eliminates the weight of separate mounting components. This weight reduction directly improves energy efficiency and extends vehicle range, while the integrated structure maintains adequate structural support through the battery pack's own structural members.
3Ease of repair
If the battery pack is mounted to a separate frame, then the battery pack is easily replaceable, but the vehicle structure becomes more complex
Solution Approach 1:
The patent segments the battery pack as a distinct modular unit within the integrated structure. The battery pack can be removed as a complete module while leaving the frame structure intact, maintaining ease of replacement. The structural members are designed with attachment features that allow for straightforward connection and disconnection of the battery pack module.
4Weight of moving object
If the battery pack structure is used as the vehicle frame, then weight is reduced, but attachment and assembly become more difficult
Solution Approach 1:
The patent incorporates preliminary attachment features directly into the battery pack structural members during manufacturing. These pre-integrated attachment points and mounting structures simplify the assembly process, allowing for easier connection of the battery pack to the vehicle frame without requiring complex post-assembly operations.
Data Source
AI summary
Aspects of the subject disclosure relate to a battery-to-subframe attachment for a vehicle. The battery-to-subframe attachment may form a load path from a front subframe of a vehicle to one or more longitudinal members of a battery pack for the vehicle. This attachment may help to utilize the mass and strength of a battery pack as an integral part of the structure of the vehicle, and may also improve torsional and bending stiffness of the vehicle via attachment between the subframe and the battery pack.