Heavy-Duty EV Battery Mounting With Integrated Vibration Isolation
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Solution Overview
Problem
Existing electric power systems for larger and heavy-duty vehicles have not been widely commercialized, particularly for those using alternative fuels and electrical motors, due to challenges in modular design, integration, and vibration isolation.
Innovation Solution
A modular electric vehicle system is developed, comprising a battery assembly with a housing and mounting system that includes vibration isolators and a fastener assembly for secure and efficient integration with the vehicle chassis, allowing for expansion of storage capacity and rapid assembly, while maintaining ingress protection and reducing exposure to moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a battery assembly is integrated into a vehicle chassis, then storage capacity and assembly efficiency are improved, but vibration and shock transmission to the battery housing increases
Solution Approach 1:
The patent introduces vibration isolators as intermediary elements between the mounting system and the battery housing. These isolators act as mediators that allow the battery assembly to be securely mounted to the chassis while simultaneously reducing the transmission of vibrations and shocks to the housing, thus resolving the contradiction between secure integration and vibration protection
2Reliability
If the housing is sealed to protect battery units, then ingress protection is improved, but moisture exposure reduction is compromised
Solution Approach 1:
The patent employs seals and gaskets as flexible barrier elements that maintain the protective enclosure of the housing while allowing for controlled interfaces. These flexible sealing elements prevent moisture ingress at connection points and interfaces, thus maintaining both ingress protection and moisture exposure reduction simultaneously
3Object-affected harmful factors
If vibration isolators are added to the mounting system, then vibration isolation is improved, but device complexity increases
Solution Approach 1:
The patent integrates vibration isolators directly into the mounting system structure, merging the vibration isolation function with the existing mounting brackets and fasteners. This integration approach allows vibration protection to be achieved without adding separate, complex isolation systems, thus improving vibration isolation while minimizing increases in device complexity
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 modular system enables improved vibration and shock isolation, maintains ingress protection, and allows for flexible integration with existing chassis configurations, enhancing the performance and durability of electric power systems in larger vehicles.
Implementation Method 1
The vibration isolator is configured to reduce load transmission from the frame member of the vehicle to the housing
Data Source
AI summary
A battery assembly for an electric vehicle is provided that includes a housing, one or more battery units, and a mounting system. The one or more battery units are disposed within the housing. The mounting system is disposed adjacent to a top surface, e.g., on a planar top surface or within an upwardly oriented concavity. The mounting system has a frame member bracket and a housing bracket system. The housing bracket system includes a housing bracket, a load member and a vibration isolator. The housing bracket is configured to be coupled to the frame member bracket. The load member has a first portion disposed adjacent to an upper surface and a second portion disposed along a lateral portion of the housing. The vibration isolator is disposed between the load member and the housing bracket. The vibration isolator is configured to reduce load transmission from the frame member of the vehicle to the housing.