EV Battery Structural Assembly With Offset Rocker Mounting
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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 efficient load paths and mounting within the vehicle structure.
Innovation Solution
A structural assembly for electric vehicles that includes a vehicle body, a battery structure, a pair of mounting structures, lower fasteners, and upper fasteners. The battery structure is positioned between opposed rockers in the vehicle body, with mounting structures secured to the sides of the battery structure and fasteners securing the battery pack to the vehicle body at both upper and lower attachment points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery pack size and weight are increased to provide greater energy storage capacity, then the energy storage capability is improved, but the vehicle structure complexity and mounting difficulty increase
Solution Approach 1:
The battery pack mounting system is segmented into multiple independent components: mounting structures with flange portions, multiple fasteners distributed at different locations, and integration with existing vehicle rockers. This segmentation allows the large battery pack to be secured through distributed attachment points rather than a single complex mounting mechanism, reducing overall structural complexity while accommodating increased battery size and weight
Solution Approach 2:
The mounting system utilizes three-dimensional spatial distribution of fasteners at different heights (upper and lower fasteners) and positions (inboard and outboard locations). This multi-dimensional attachment approach distributes mechanical loads throughout the vehicle structure, enabling accommodation of larger, heavier battery packs without proportionally increasing structural complexity
2Quantity of substance
If the battery pack weight is increased to extend vehicle travel distance, then the energy storage capability is improved, but the load path efficiency and vehicle body stress increase
Solution Approach 1:
The mounting structures are pre-integrated with flange portions that extend toward the vehicle body rockers before final fastener installation. This preliminary structural preparation creates predetermined load paths that efficiently channel forces from the heavy battery pack to the vehicle body, reducing unexpected stress concentrations and improving load path efficiency
Solution Approach 2:
The system distributes vertical loads from the heavy battery pack across multiple horizontal planes through upper and lower fasteners. This multi-level attachment strategy transforms concentrated vertical stress into distributed loads across different heights, reducing peak stresses on the vehicle body while supporting increased battery weight
3Strength
If multiple fasteners are used to secure the battery pack at upper and lower attachment points, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The fastening system is divided into modular components: mounting structures with integrated flange portions, upper fasteners, and lower fasteners. Each component can be manufactured independently using standard fabrication processes, then assembled together. This modular segmentation maintains structural integrity through multiple attachment points while simplifying manufacturing compared to monolithic mounting solutions
Solution Approach 2:
The mounting structures with flange portions serve multiple functions: providing attachment surfaces for fasteners, distributing loads across the battery pack housing, and integrating with the vehicle body rockers. This multi-functionality reduces the need for separate components, simplifying manufacturing while maintaining high structural integrity through upper and lower fastener attachment points
Data Source
AI summary
A structural assembly for an electric vehicle includes a battery structure, a pair of mounting structures, lower fasteners and upper fasteners. The battery structure is configured to house power storage units. Each mounting structure is secured to a respective side of the battery structure. Each lower fastener extends through a lower portion of a respective mounting structure and a bottom portion of a respective rocker of the vehicle body. Each upper fastener extends through an upper portion of the respective rocker and a top portion of the respective mounting structure. The upper fasteners secure the battery pack and the vehicle body at an upper attachment point and the lower fasteners secure the battery pack and the vehicle body at a lower attachment point. The lower attachment point is vertically offset from the upper attachment point.