EV Battery Mounting Structure With Stacked Closed Sections
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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 makes them susceptible to various vehicle loads and requires efficient load paths in diverse operating conditions.
Innovation Solution
A mounting structure with a single monolithic body having multiple stacked closed sections and a connecting flange, manufactured via roll forming, is used to secure the battery housing to the vehicle frame, enhancing structural integrity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery packs are made larger to increase energy storage capacity, then the energy storage capability is improved, but the weight and footprint increase making the battery pack more susceptible to vehicle loads
Solution Approach 1:
The mounting structure is divided into multiple closed sections stacked relative to each other, creating a segmented design that distributes loads across multiple discrete structural units while maintaining overall structural integrity
Solution Approach 2:
The mounting structure combines multiple materials with different properties - aluminum alloy for the monolithic body providing lightweight strength, and steel for the connecting flange providing high load-bearing capacity, creating a composite structure that optimizes both weight and strength
2Quantity of substance
If the battery pack footprint is increased to accommodate more batteries, then the energy storage capacity is improved, but the structural complexity and difficulty of providing efficient load paths increases
Solution Approach 1:
Multiple functional elements are merged into a single monolithic body - the mounting structure integrates support surfaces, load-bearing walls, and connecting flanges into one continuous formed piece, eliminating the need for multiple separate components and simplifying the overall structure
Solution Approach 2:
The mounting structure serves multiple functions simultaneously - it provides mechanical support for the battery housing, creates closed sections for structural rigidity, provides load paths for vehicle loads, and enables mounting to vehicle rails, making a single component perform multiple critical functions
3Strength
If a single monolithic body with multiple closed sections is used, then the strength and stiffness are improved, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process utilizes parameter changes in the material during forming - the aluminum alloy sheet is plastically deformed through roll forming to create complex three-dimensional closed sections, transforming a simple flat material into a structurally complex form through controlled parameter changes in the forming process
Data Source
AI summary
A single monolithic body extends in a longitudinal direction and includes multiple closed sections stacked vertically. A first end portion of the single monolithic body extends from one of the closed sections into an adjacent closed section, and a second end portion of the single monolithic body extends from one of the closed sections, along an exterior of an adjacent closed section, and laterally away from the single monolithic body to form a connecting flange.