EV Chassis Brace for Battery Support and Road Clearance
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Solution Overview
Problem
Current electric vehicle chassis frames face challenges in efficiently supporting battery weight while maintaining structural integrity, road clearance, and reducing system costs and complexity.
Innovation Solution
The implementation of a chassis frame with a battery pack support structure that includes a brace extending between the chassis frame and the battery pack, along with a truss beam and compound cross beams, which provide enhanced structural support and packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If batteries are located above the chassis frame to maintain road clearance, then road clearance is maintained, but structural complexity and support requirements increase
Solution Approach 1:
The patent positions the battery pack in the vertical dimension above the chassis frame rather than horizontally within the chassis, allowing road clearance to be maintained while using the vertical space that would otherwise be unused. This dimensional repositioning resolves the contradiction by separating the battery location from the traditional chassis plane.
Solution Approach 2:
The patent introduces a support structure with braces as an intermediary element between the chassis frame and the battery pack. This mediator transfers and distributes the battery weight to the chassis, reducing structural complexity by providing a dedicated support mechanism rather than requiring the entire chassis to bear the load.
2Strength
If traditional chassis frames are used to support battery weight, then structural integrity is maintained, but weight and complexity increase
Solution Approach 1:
The patent segments the support function by creating a separate support structure with braces distinct from the main chassis frame. This segmentation allows the chassis to maintain its original lightweight design while the dedicated support structure handles the battery weight, resolving the contradiction between structural integrity and weight.
Solution Approach 2:
The patent merges the battery support structure with the chassis frame through strategic bracing connections. This merging creates a combined structural system that achieves the required structural integrity for supporting battery weight while minimizing additional weight by sharing load paths with the existing chassis.
3Strength
If multiple cross members are added to support batteries, then structural strength improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent designs the braces to serve multiple functions: supporting battery weight, providing structural rigidity, and potentially serving as mounting points for other components. This multi-functionality reduces manufacturing complexity by eliminating the need for separate dedicated support components.
Solution Approach 2:
The patent applies reinforcement selectively at specific locations where battery support is needed, rather than uniformly strengthening the entire chassis. This localized approach to adding cross members and braces reduces manufacturing complexity and cost by concentrating structural enhancements only where necessary.
Data Source
AI summary
An electric vehicle includes a chassis frame, a battery pack, and a brace. The battery pack includes a support structure vertically spaced at least in-part from the chassis frame. The first brace extends between, and is engaged to, the chassis frame and the support structure.