Integrated Front Box Structure for Air Tank and Battery Packaging
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Solution Overview
Problem
There is a need to efficiently house components such as battery assemblies, electric motors, radiators, and cooling components in the space typically occupied by the internal combustion engine of traditional vehicles, while ensuring easy installation and structural integrity in electric vehicles.
Innovation Solution
A front box structure utilizing a pair of air tank mounting brackets and elongated braces to support air tanks, which also serve as a structural layer for mounting other components, allowing efficient use of space and facilitating easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If components are mounted on frame rails as in traditional vehicles, then installation is simple, but space utilization is inefficient and structural integration is poor
Solution Approach 1:
The patent combines multiple mounting functions into a single integrated front box structure. The front box serves as both a structural component and a mounting platform for air tanks, batteries, and other components, eliminating the need for separate frame rail mounting systems and improving space utilization.
Solution Approach 2:
The patent transitions from one-dimensional frame rail mounting to three-dimensional volumetric utilization within the front box. Components are arranged in vertical and horizontal layers within the front box structure, maximizing space utilization in all spatial dimensions rather than relying solely on linear attachment to frame rails.
2Volume of moving object
If multiple components are housed in the front box, then space is optimized, but structural soundness and component support become challenging
Solution Approach 1:
The front box structure is divided into multiple layers (first layer, second layer, third layer) with each layer providing specific structural support functions. This segmentation allows the structure to bear multiple loads while maintaining overall structural integrity and soundness.
Solution Approach 2:
The front box structure serves multiple functions simultaneously: it provides structural support for the vehicle, acts as a mounting platform for air tanks and batteries, and offers protective enclosure. This multi-functionality enables space optimization without compromising structural soundness.
3Ease of operation
If traditional mounting methods are used, then component installation is straightforward, but assembly time and production efficiency are reduced
Solution Approach 1:
The front box is designed as a modular structure with distinct layers and standardized mounting locations. This segmentation enables pre-assembly of component groups and facilitates quick installation onto the vehicle chassis, improving both ease of operation and assembly speed.
Solution Approach 2:
The front box structure is pre-configured with mounting brackets, supports, and attachment points during manufacturing. This preliminary preparation eliminates the need for complex on-site fabrication and installation, allowing for rapid assembly while maintaining ease of operation.
Data Source
AI summary
Embodiments herein relate to a front box structure for use on an at least partially electrically powered vehicle. The front box utilizes a first pair of air tank mounting brackets and a second pair of air tank mounting brackets as part of a middle structural layer. Each pair of air tank mounting brackets supports an air tank, as well as other structural components of the front box assembly. The middle structural may also include a first brace and a second brace extending between and coupled to the first and second pairs of air tank mounting brackets. The first pair of air tank mounting brackets are adapted to be coupled to a first air tank, and the second pair of air tank mounting brackets are adapted to be coupled to a second air tank that form a part of the middle structural layer.