EV Battery Frame Structure With Integrated Mounting Couplers
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Solution Overview
Problem
Existing electric vehicle frames struggle to effectively mount large and heavy batteries, limiting design freedom, reducing mileage, increasing weight and cost, and decreasing production efficiency.
Innovation Solution
A frame structure comprising a front, central, and rear part frames with integrated protrusion coupling members and stays, allowing for efficient mounting and securing of battery modules, enhancing design freedom, increasing battery capacity, reducing weight and cost, and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a traditional vehicle frame structure is used to mount large batteries, then the battery can be installed, but the vehicle weight increases and design freedom is limited
Solution Approach 1:
The patent merges the frame structure with the battery mounting structure by integrating protrusion coupling members directly into the frame. The frame members serve dual purposes: providing structural support and enabling battery installation through integrated coupling features, thereby eliminating the need for separate mounting brackets or additional structural elements that would increase weight.
Solution Approach 2:
The frame members are designed with multi-functionality, serving both as structural load-bearing elements and as battery mounting structures. The protrusion coupling members are simultaneously part of the frame structure and the battery securing mechanism, allowing the same components to fulfill multiple functions without adding extra weight.
2Quantity of substance
If a traditional vehicle frame structure is used to mount large batteries, then the battery can be installed, but design freedom is limited
Solution Approach 1:
The battery mounting system is segmented into modular components: frame members with protrusion coupling members, and corresponding recesses in the battery housing. This segmentation allows independent optimization of each component and enables flexible arrangement of batteries within the vehicle space, greatly enhancing design freedom.
Solution Approach 2:
The coupling mechanism incorporates dynamic features through the protrusion-recess interface that allows for easy assembly and disassembly. The stays that engage with the protrusion coupling members provide a simple, flexible connection that can be easily installed and removed, enabling rapid reconfiguration of battery arrangements.
3Reliability
If complex mounting structures are used to secure batteries, then secure mounting is achieved, but production efficiency decreases
Solution Approach 1:
The protrusion coupling members are designed to self-align with the corresponding recesses in the battery housing during assembly. The geometry of the protrusions and recesses guides the components into proper alignment automatically, eliminating the need for complex alignment procedures or additional adjustment mechanisms, thereby simplifying the assembly process while ensuring secure mounting.
Solution Approach 2:
The stays act as intermediary elements that simplify the connection between the frame and battery. Rather than requiring direct complex fastening between large battery housings and the frame, the stays engage with the protrusion coupling members to provide a simple, efficient connection mechanism that is both secure and easy to assemble.
Data Source
AI summary
A frame for an electric vehicle includes a front part frame located at a front of the vehicle; a rear part frame located at a rear of the vehicle; and a central part frame configured in a flat shape to be coupled between the front part frame and the rear part frame and to accommodate a battery therein.