Modular EV Battery Unit Layout Between Frame Rails
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Solution Overview
Problem
Existing electric vehicles face issues with battery degradation from external factors, space constraints, and reduced modularity due to the positioning of batteries in front of hydrogen fuel cells, which also increase manufacturing complexity and reduce energy storage capacity.
Innovation Solution
A modular EV battery unit with a central section housing batteries and lateral sections for a cooler and inverter, positioned between longitudinal frame rails, allowing for efficient attachment to the EV chassis, even weight distribution, and integration with a hydrogen fuel cell assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If batteries are positioned in front of hydrogen fuel cell and below the cab, then space utilization is improved, but battery degradation from external factors increases and energy storage capacity is constrained
Solution Approach 1:
The patent repositions batteries from the conventional front/below-cab location to a lateral position between the frame rails, utilizing previously underutilized lateral space. This dimensional relocation simultaneously protects batteries from road debris while accommodating larger battery packs that increase energy storage capacity.
2Reliability
If power distribution unit is spaced away from batteries and positioned adjacent to hydrogen gas cylinders, then safety is improved, but manufacturing complexity increases and modularity is reduced
Solution Approach 1:
The patent integrates the power distribution unit with the battery assembly into a single modular unit, eliminating the need for separate positioning while maintaining safety through controlled integration. This merging reduces manufacturing complexity and improves modularity without compromising safety requirements.
Solution Approach 2:
The integrated power distribution unit is designed to serve multiple functions: electrical distribution, safety monitoring, and modular connection. This multi-functional design allows the same component to fulfill multiple roles, reducing overall system complexity while maintaining safety standards.
3Object-affected harmful factors
If batteries are positioned laterally between frame rails, then protection from external factors is improved, but space constraints may increase
Solution Approach 1:
The patent utilizes the lateral dimension between frame rails, which is typically underutilized, to position batteries. This approach provides protection from road debris while accessing previously unavailable space, thereby accommodating larger battery packs without compromising vehicle structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances adaptability, manufacturing efficiency, and reduces battery degradation by protecting batteries from external impacts while enabling efficient installation and modular integration with the fuel cell system, maintaining vehicle handling performance.
Implementation Method 1
a battery cooler that is designed to reduce the temperature of the plurality of batteries
Data Source
AI summary
An electric vehicle (EV) battery unit and installation method is provided herein. The EV battery unit includes a modular housing with a central section with batteries positioned therein and a first lateral section with a battery cooler that is designed to reduce a temperature of the batteries and an inverter that is positioned therein and electrically coupled to the batteries. The modular housing further includes a first frame attachment interface profiled to attach to a first longitudinal frame rail in an EV and a second frame attachment interface profiled to attach to a second longitudinal frame rail in the EV, where the batteries are positioned laterally between the first and second frame attachment interfaces.