Three-Point EV Battery Mount for Flexible Truck Chassis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial truck chassis become too rigid when battery packs are rigidly mounted, leading to excessive force and stress on the battery packs, compromising durability and flexibility.
Innovation Solution
A three-point battery mount system that isolates the battery pack by mounting it between frame rails, using bushings or brackets on either the chassis or the battery, allowing the chassis to remain flexible in torsion while reducing stress and force on the battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery packs are rigidly mounted to the frame rails, then the battery packs are securely fixed and protected, but the frame becomes too rigid which applies excessive force and stress on the battery packs
Solution Approach 1:
The patent introduces an intermediary mounting system consisting of brackets attached to the frame rails and separate attachment mechanisms that connect the battery pack to these brackets. This intermediary structure allows the battery to be securely held while isolating it from direct rigid connection to the frame, thereby reducing stress transmission during torsional events.
Solution Approach 2:
The mounting system is divided into separate components: frame rail brackets and battery pack attachments. These segmented elements work together to provide secure mounting while allowing independent movement, enabling the battery to be firmly positioned without creating a rigid continuous path for stress transmission.
2Reliability
If battery packs are rigidly mounted to the frame rails, then the battery packs are securely fixed, but the chassis loses torsional flexibility
Solution Approach 1:
The bracket system serves as a mediator between the rigid frame rails and the battery pack, providing secure fixation while allowing the chassis to maintain its natural torsional flexibility. The brackets are attached to the frame rails but connect to the battery in a way that doesn't create a rigid continuous structure.
Solution Approach 2:
The mounting system is designed to be dynamic rather than statically rigid, allowing movement and flexibility in response to chassis torsion while maintaining secure battery fixation during normal operation. This enables the system to adapt to changing mechanical conditions.
3Ease of operation
If battery packs are mounted on top of or next to the frame rails, then they are easily accessible, but they are not well protected and experience excessive stress
Solution Approach 1:
The battery pack is effectively nested within the structure formed by the frame rails and mounting brackets. This nested arrangement provides protection by surrounding the battery with the robust frame structure while maintaining accessibility from the exterior of the vehicle.
Solution Approach 2:
The mounting brackets act as an intermediary layer between the battery and the frame rails, providing both protection and secure attachment. This intermediary structure shields the battery from direct exposure to harmful forces while maintaining ease of installation and access.
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 system effectively maintains torsional flexibility of the chassis while containing rigid battery packs, reducing stress and force on the battery structures, thereby enhancing durability and protection.
Implementation Method 1
The system isolates the battery with a three-point mount whereby the battery pack stresses are then reduced while maintaining torsional flexibility of the chassis
Implementation Method 2
Bushings are mounted either on the chassis or on the battery... the three-point mount allows the electric vehicle chassis to remain flexible in twist along the longitudinal axis
Data Source
AI summary
A battery mount system for a battery pack on an electric vehicle. The system isolates the battery with a three point mount whereby the battery pack stresses are then reduced while maintaining torsional flexibility of the chassis. By mounting the batteries between the frame rails, they are better protected. The present system allows an electric vehicle chassis to remain flexible in twist (torsion) along the longitudinal axis while containing one or more rigid battery packs inside and/or underneath the frame rails, reducing stress and force on the battery packs. Bushings are mounted either on the chassis or on the battery. There are two bushings or brackets on either the front or rear of the battery, and one bushing on either the front or rear of the battery. (i.e. 2 on the front, 1 in the rear, or 1 in the front, 2 in the rear).