EV Structural Assembly With Longitudinal Rails for Battery Load Paths
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Solution Overview
Problem
The integration of rechargeable battery packs in electric vehicles is challenging due to their increased weight and larger footprint, which complicates mounting and load distribution, especially under various operating conditions.
Innovation Solution
A structural assembly for electric vehicles featuring a vehicle frame with opposed longitudinal rails and a separate vehicle body, where the rockers overlap or are spaced apart from the rails, providing improved load paths and energy absorption during impacts, and a suspension system secured to the frame and wheels, with a battery frame positioned between the rails and rockers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery packs are integrated into existing vehicle structures, then electric vehicle functionality is achieved, but the increased weight and larger footprint complicate mounting and load distribution
Solution Approach 1:
The vehicle body is divided into separate components: a vehicle frame without cross members at the center, a battery structure with its own frame, and a vehicle body mounted on the frame. This segmentation allows the battery pack to be integrated without requiring modifications to the entire vehicle structure, simplifying mounting while achieving EV functionality
Solution Approach 2:
Opposed longitudinal rails are introduced as intermediary structural elements positioned between the rockers and the battery frame. These rails serve as load transfer mediators, distributing the weight and forces from the battery pack through the vehicle frame, thereby simplifying the overall mounting and load distribution system
2Volume of moving object
If battery packs are positioned to optimize space usage, then passenger and cargo space are preserved, but load paths and energy absorption during impacts must be optimized
Solution Approach 1:
The opposed longitudinal rails serve multiple functions simultaneously: they provide structural support for the vehicle body, establish load paths from the rockers to the battery frame, and act as energy absorption elements during impacts. This multi-functionality allows the battery pack to be positioned optimally without compromising safety or structural integrity
Solution Approach 2:
The longitudinal rails act as intermediary load-bearing elements that connect the vehicle body (through rockers) to the battery frame. This intermediary structure creates optimized load paths that distribute impact forces and weight loads, ensuring reliability while maintaining clear space for passengers and cargo
Data Source
AI summary
A structural assembly for a vehicle includes a battery structure having a battery frame. The structural assembly includes a vehicle frame and a vehicle body. The vehicle frame has opposed longitudinal rails. The vehicle body is separate from and mounted on the vehicle frame. The vehicle body includes opposed rockers extending in a longitudinal direction of the vehicle. Each opposed longitudinal rail is located between a respective rocker and the battery frame of the battery structure.