EV Battery Cage Structural Assembly for Load Distribution
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Solution Overview
Problem
The integration of rechargeable battery packs in electric vehicles is challenging due to their increased weight and larger footprint, which complicates load distribution and efficient integration into vehicle structures, especially in varying operating conditions.
Innovation Solution
A three-dimensional backup structure joint system comprising a subframe rear mount, battery cage longitudinal member, hinge pillar, and rail torque unit, along with additional components like inner straps and compression tubes, is used to secure the battery pack and distribute loads away from it, ensuring efficient load paths and structural support across the front suspension of the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rechargeable battery packs are integrated into the vehicle structure, then electric vehicle propulsion capability is improved, but vehicle weight increases
Solution Approach 1:
The battery pack is divided into multiple battery modules that are distributed across the vehicle floor pan. This segmentation allows the heavy battery mass to be spread out, enabling better load distribution through the vehicle structure while maintaining the total energy capacity needed for propulsion.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning battery modules at different heights and locations within the vehicle floor structure. This three-dimensional arrangement optimizes weight distribution and allows structural members to efficiently transfer loads in multiple directions, reducing the impact of battery weight on overall vehicle performance.
2Quantity of substance
If rechargeable battery packs with larger footprint are integrated into the vehicle, then energy storage capacity is improved, but integration complexity increases
Solution Approach 1:
The vehicle floor structure is designed to serve multiple functions: it provides the platform for mounting battery modules, acts as a load-bearing structure, and creates passenger cabin space. This multi-functionality reduces integration complexity by combining several structural requirements into a single unified design rather than adding separate components for each function.
Solution Approach 2:
The patent merges the battery mounting structure with the vehicle floor structure. Instead of creating a separate battery enclosure and mounting system, the battery modules are integrated directly into the floor pan design, with structural members serving both as floor support and battery mounting points, thereby simplifying the overall integration process.
3Strength
If battery pack is secured within lower body frame extending across front suspension, then structural support is improved, but load distribution efficiency decreases
Solution Approach 1:
The vehicle structure incorporates local reinforcement and varying material properties at specific locations where battery modules are mounted. This allows the structure to provide enhanced support exactly where needed while maintaining efficient load distribution paths, rather than uniformly increasing structural weight throughout the entire vehicle.
Data Source
AI summary
A structural assembly for use in an electric vehicle having a lower body frame and a battery pack secured within the lower body frame. The structural assembly includes a subframe rear mount, a battery cage longitudinal member, a rocker, a hinge pillar, and a rail torque unit. The battery cage longitudinal member is secured to the subframe rear mount. The rocker extends along and is secured to the battery cage longitudinal member. The hinge pillar includes a lower portion that is secured to the rocker. The rail torque includes an s-brace and an inner rail. The s-brace is secured to the hinge pillar at one end and to the inner rail at another end. The inner rail is secured to the hinge pillar at one end and is configured to extend around a wheel of the electric vehicle and form a portion of a wheel well.