Heavy-Duty EV Battery Mounting for Vibration Isolation and Sealing
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Solution Overview
Problem
Existing electric power systems for larger and heavy-duty vehicles have not been widely commercialized due to challenges in integrating battery assemblies effectively, particularly in terms of vibration and shock isolation, and maintaining ingress protection against moisture.
Innovation Solution
The development of modular electric vehicle systems that include multiple battery assemblies and a front end accessory component assembly, with advanced mounting systems that provide improved vibration and shock isolation, and maintain ingress protection through reduced exposure to moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery assemblies are integrated into heavy duty vehicles, then storage capacity and energy availability are improved, but vibration and shock isolation becomes more difficult to maintain
Solution Approach 1:
The mounting system introduces vibration isolation components as intermediaries between the battery assembly and vehicle chassis. These components include: (1) a mounting bracket system with vibration isolators positioned between the battery housing and chassis, (2) a crumple zone structure that deforms under impact to absorb shock energy, and (3) a decoupling mechanism that separates the battery assembly from direct chassis vibrations. This mediator approach allows the battery assembly to be integrated into the vehicle while protecting it from vibration and shock through intermediate protective structures.
2Productivity
If battery assemblies are integrated into existing chassis configurations, then rapid assembly and modularity are improved, but ingress protection against moisture becomes more challenging
Solution Approach 1:
The mounting system incorporates pre-configured sealing structures and ingress protection features before the battery assembly is installed into the vehicle. The housing includes integrated sealing flanges and gasket positions that are prepared in advance, and the mounting bracket system includes pre-attached protective covers and seals. This preliminary preparation ensures that when the battery assembly is rapidly installed, ingress protection is automatically maintained without requiring additional sealing steps during assembly.
3Reliability
If vibration isolators are added to the mounting system, then vibration and shock isolation are improved, but device complexity increases
Solution Approach 1:
The mounting system merges multiple functions into integrated components to reduce overall complexity. The mounting brackets serve both as structural support elements and as vibration isolation mounting points. The housing structure combines structural integrity functions with integrated sealing and mounting attachment features. The crumple zone is integrated into the mounting bracket assembly rather than being a separate component. This merging approach allows vibration isolation to be achieved without proportionally increasing system complexity, as the same structural elements perform multiple functions.
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 efficient expansion of storage capacity, rapid assembly to existing chassis configurations, and improved integration of battery assemblies, enhancing vibration isolation and maintaining ingress protection, thus facilitating wider adoption in larger and heavy-duty 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.