EV Battery Support Structure Segmentation
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Solution Overview
Problem
Existing electric vehicle chassis frames face challenges in efficiently supporting and protecting battery packs while maintaining structural integrity, road clearance, and reducing system costs and design complexity.
Innovation Solution
The electric vehicle incorporates a body structure with side rails and a forward sub-frame, featuring a support structure beneath the battery pack with longitudinally spaced components and coupling assemblies that allow for efficient force distribution and protection, including a bulkhead and deformable plates for impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batteries are supported upon the chassis frame in various locations, then battery storage capacity is improved, but structural complexity and design difficulty increase
Solution Approach 1:
The battery pack support structure is divided into multiple longitudinal components (first longitudinal component, second longitudinal component, third longitudinal component, fourth longitudinal component) that are spaced laterally apart. These segmented components can be independently attached to different locations on the chassis frame, allowing flexible battery placement while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The support structure serves multiple functions: it supports the battery pack weight, provides structural reinforcement to the chassis frame, and offers mounting points for coupling assemblies. The longitudinal components can accommodate batteries of various shapes and sizes while maintaining a unified structural approach, reducing design complexity despite varying battery requirements.
2Length of stationary object
If batteries are located above the chassis frame to maintain road clearance, then road clearance is maintained, but structural protection and support complexity increase
Solution Approach 1:
The support structure extends in multiple dimensions: longitudinally along the chassis frame with components spaced at different positions, and laterally with components arranged side-by-side. This multi-dimensional arrangement allows the structure to provide comprehensive support and protection while maintaining vertical clearance for road clearance requirements.
Solution Approach 2:
The support structure acts as an intermediary element between the chassis frame and the battery pack. It distributes the battery weight across multiple attachment points on the chassis frame while providing protective enclosure, simplifying the overall structural design by decoupling the support and protection functions from direct battery-chassis contact.
3Strength
If multiple longitudinal components are used in the support structure, then battery protection and force distribution are improved, but manufacturing complexity increases
Solution Approach 1:
The support structure uses multiple longitudinal components that are substantially identical in configuration and arrangement. Each component (first, second, third, fourth longitudinal components) follows the same design pattern, spaced laterally apart and attached to the chassis frame in a repeating sequence. This homogeneity simplifies manufacturing by allowing production of standardized components rather than custom-designed parts.
Solution Approach 2:
The support structure is segmented into multiple identical longitudinal components that can be manufactured separately and then assembled into the complete support structure. This segmentation allows for simplified manufacturing of individual components while achieving superior force distribution when assembled together, as each component carries a portion of the battery load.
4Reliability
If coupling assemblies with multiple fasteners are used to attach the support structure, then structural robustness is improved, but assembly complexity and cost increase
Solution Approach 1:
The coupling assemblies are designed with pre-configured fasteners (first fastener, second fastener, third fastener, fourth fastener) that are positioned and oriented for direct attachment to the chassis frame. This preliminary configuration of multiple fasteners in each coupling assembly allows for robust structural attachment while simplifying the assembly process, as the fasteners are ready for installation without requiring complex alignment or additional components.
Data Source
AI summary
An electric vehicle includes a body structure, a forward sub-frame, and a battery pack. The body structure includes first and second side rails. The forward sub-frame includes first and second side supports each having and extending longitudinally between forward and rearward end portions. The first and second side supports are located forward of, and substantially parallel to, the first and second side rails. The battery pack includes a support structure disposed beneath, and engaged to, the body structure between the first and second side rails. The support structure has a plurality of longitudinal components spaced laterally apart from one-another, and disposed parallel to the opposite first and second side rails. The rearward end portions of the first and second side supports are proximate to respective first and second longitudinal components of the plurality of longitudinal components.