Flat Modular Battery Pack Mounting for Utility EV Space Limits

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Solution Overview

Problem

Current battery assemblies for medium and heavy-duty vehicles are custom-designed, complex, and expensive to manufacture due to low volume production, making them inefficient in terms of space utilization and requiring custom housings and power electronics for each application.

Innovation Solution

Modular, thin, and flat battery assemblies with a structural perimeter frame and removable power electronics module, allowing for flexible configuration and mounting options, including stacking, to increase power storage capacity and simplify manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom-designed battery assemblies are used for each vehicle application, then the battery assembly can be optimized for specific vehicle requirements, but the manufacturing cost increases and manufacturing efficiency decreases

Engineering Contradiction:

Improveoptimization for specific vehicle requirementsVSAvoidmanufacturing cost and efficiency

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The battery assembly is designed with a universal flat configuration that can be mounted in multiple locations (underneath vehicle, in cargo areas, on roofs) and adapted to different vehicle types (delivery vehicles, utility vehicles, trucks) using standardized mounting brackets, eliminating the need for custom designs for each application

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If traditional battery assembly shapes are used, then the structural integrity can be maintained, but the space utilization efficiency decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidspace utilization efficiency

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The battery assembly transitions from traditional bulky three-dimensional shapes to a flat, planar configuration with emphasized surface area, allowing it to conform to available spaces in vehicles and improve space utilization while maintaining structural integrity through the flat plate design and perimeter frame

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If thick battery assembly housings are used, then the impact resistance can be improved, but the space utilization and mounting flexibility decrease

Engineering Contradiction:

Improveimpact resistanceVSAvoidmounting flexibility and space utilization

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The battery assembly uses a thin flat plate housing design that provides sufficient impact resistance for its application while minimizing thickness to maximize mounting flexibility and space utilization, allowing installation in confined vehicle spaces

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If integrated power electronics are built into the battery assembly, then the system complexity is reduced, but the manufacturing cost and difficulty increase

Engineering Contradiction:

Improvesystem complexityVSAvoidmanufacturing cost and difficulty

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The power electronics are separated from the battery assembly into a distinct module, allowing the battery assembly itself to be manufactured as a simpler, more cost-effective unit while the power electronics can be integrated separately where needed, reducing overall manufacturing difficulty

Inventive Principle:

Principle #1Segmentation

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 design enables efficient space utilization, reduces manufacturing costs, and allows for adaptable power storage solutions across various vehicle classes without the need for custom designs, enhancing installation and serviceability while maintaining impact resistance and vibration dampening.

Implementation Method 1

at least the first lateral side frame member and the second lateral side frame member comprise a cross-sectional profile configured to at least partially absorb impact loads resulting from a crash

Methodology Applied

Scientific EffectImpact absorption: Impact Force

Implementation Method 2

one or more vibration dampening assemblies coupling the housing bracket to the vehicle bracket

Methodology Applied

Scientific EffectVibration dampening: Damping

Data Source

PatentUS20240166060A1Battery packs for utility vehicle electric drivetrains

Publication Date: 2024.05.23 HEXAGON PURUS NORTH AMERICA HOLDINGS INC

AI summary

A battery system for an electric vehicle includes a battery assembly including a housing that houses one or more battery cells for storing power for an electric vehicle drive system, the housing having an elongate flat outer shape, wherein the housing has a height, a width, and a length, wherein at least one of the length or the width is at least 5 times the height; and one or more mounting systems for attaching the battery assembly to a frame member of an electric vehicle.