Integrated Battery Subframe for Heavy-Duty Vehicle Weight Balance

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Solution Overview

Problem

Existing heavy-duty vehicle subframes face challenges with external battery storage structures that increase weight, require additional reinforcement, and complicate load balancing, while also posing risks of battery damage from debris and collisions.

Innovation Solution

A removable and lightweight subframe with integrated battery storage structures that protect batteries and facilitate quick swapping, using hangers and cross members to secure and reinforce the battery housing, reducing material costs and manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If self-contained battery storage structures are integrated into subframes, then battery protection is improved, but vehicle weight increases

Engineering Contradiction:

Improvebattery protectionVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The battery storage structure is merged with the subframe structure itself, where the subframe serves dual purposes as both structural support and battery enclosure. This integration eliminates the need for separate battery housings, reducing overall weight while maintaining protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The subframe is designed to perform multiple functions: providing structural support for the vehicle and simultaneously serving as a protective enclosure for batteries. This multi-functionality reduces the need for additional components and minimizes weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Stability of the object's composition

If batteries are mounted in lower positions to lower center of gravity, then vehicle stability is improved, but exposure to road debris and environmental elements increases

Engineering Contradiction:

Improvevehicle stabilityVSAvoidexposure to road debris

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The subframe structure is merged with the battery enclosure, creating a unified structure that protects batteries from road debris and environmental elements while maintaining their lower position for vehicle stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The subframe structure provides pre-established protection against road debris and environmental elements before any damage can occur to the batteries, allowing batteries to be positioned in lower, more stable locations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If rigid main members and cross members are used in subframes, then structural strength is improved, but subframe weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidsubframe weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The subframe utilizes composite construction methods, combining materials and structural configurations that provide high strength-to-weight ratio, reducing subframe weight while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

4Weight of moving object

If K-shaped cross members are used instead of multiple cross members, then subframe weight is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvesubframe weightVSAvoidmanufacturing complexity

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The K-shaped cross member is segmented into multiple components that can be manufactured separately and assembled, reducing manufacturing complexity while maintaining the weight benefits of the K-shaped design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12600217B2Heavy-duty vehicle subframe with battery storage structure

Publication Date: 2026.04.14 HENDRICKSON USA LLC

AI summary

A subframe for heavy-duty vehicles, the subframe comprising a pair of elongated, longitudinal main members; at least one pair of hangers; and a battery storage structure integrated into the subframe. Each hanger of the at least one pair of hangers is attached to a respective one of the main members.