EV Chassis Frame with Compound Cross Beams for Battery Support
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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 support structure that includes compound cross beams and truss beams, along with a battery pack support structure engaged to the chassis frame via fasteners and bushing mounts, to distribute the battery weight effectively and enhance structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack is supported by the chassis frame using traditional mounting methods, then the battery weight can be supported, but the structural integrity and vibration reduction are insufficient
Solution Approach 1:
The patent employs compound cross beams comprising a first material (e.g., steel) and a second material (e.g., aluminum alloy) with different mechanical properties. The first material provides high strength and stiffness to support battery weight, while the second material provides damping characteristics to reduce vibration. This composite structure resolves the contradiction between supporting heavy battery packs and reducing harmful vibrations.
Solution Approach 2:
The battery pack support structure is nested within the chassis frame structure, with the support structure integrating cross members that align with and engage to the compound cross beams of the chassis. This nested arrangement allows the battery pack to be securely supported while utilizing the vibration-damping properties of the compound cross beams, thereby reducing transmitted vibrations.
2Length of moving object
If the batteries are located above the chassis frame to maintain road clearance, then road clearance is maintained, but the structural complexity and design difficulty increase
Solution Approach 1:
The patent transitions from locating batteries above the chassis frame (vertical dimension) to locating them below the chassis frame (utilizing the space between the chassis and ground). This dimensional change allows batteries to be positioned in the available under-chassis space, maintaining road clearance while simplifying the support structure by utilizing the existing chassis frame as the upper boundary.
Solution Approach 2:
The chassis frame cross members serve dual functions: providing structural support for the vehicle body and serving as mounting structures for the battery pack. The compound cross beams are designed to both maintain chassis structural integrity and provide engagement points for the battery support structure, reducing overall system complexity.
3Volume of moving object
If various shapes and sizes of batteries are used to utilize storage space, then storage efficiency improves, but the manufacturing cost and design complexity increase
Solution Approach 1:
The battery pack is divided into multiple modular battery modules that can be independently manufactured using standardized processes. These modules are then arranged in configurations that utilize available storage space while maintaining manufacturing efficiency. The support structure similarly uses segmented cross members that can accommodate different battery module arrangements.
Data Source
AI summary
An electric vehicle includes a chassis frame and a battery pack disposed below and engaged to the chassis frame. The chassis frame includes a first cross member, and the battery pack includes a support structure having a first cross component. The first cross component co-extends with, and is engaged to, the first cross member.