Inclined Battery Frame Mount for EV Breakover Clearance
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Solution Overview
Problem
The placement of a battery pack in the underfloor area of electric vehicles can reduce breakover clearance, particularly when positioned at or toward the midpoint between the axles, compromising off-road capability and requiring a balance between battery volume and breakover clearance.
Innovation Solution
A vehicle assembly featuring a battery housing with a principal axis inclined relative to the horizontal, mounted using a frame mount with an elongate body having a first edge region attached to a frame member and a second edge region inclined and attached to the battery housing, allowing for increased breakover clearance while maximizing battery volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery pack is positioned at the midpoint between the axles to maximize battery volume, then the battery volume is maximized, but the breakover clearance is reduced
Solution Approach 1:
The battery housing is positioned asymmetrically within the frame mount, with its longitudinal axis inclined at an angle (e.g., 5 degrees) relative to the longitudinal axis of the vehicle. This asymmetric positioning allows the battery to be located more centrally to maximize volume while the inclined orientation creates clearance space at the rear, improving breakover clearance without sacrificing battery capacity
Solution Approach 2:
Instead of only adjusting the horizontal position of the battery, the invention introduces a vertical/dimensional aspect by inclining the battery housing at an angle relative to the horizontal plane. This angular dimension allows the battery to occupy central space while projecting upward at an angle that clears obstacles during breakover, effectively using a new dimensional degree of freedom to resolve the contradiction
2Object-affected harmful factors
If the battery pack is positioned toward the front or rear to improve breakover clearance, then the breakover clearance is improved, but the battery volume is reduced
Solution Approach 1:
The frame mount and battery housing are designed with asymmetric geometries where the battery housing has different dimensions at its front and rear ends. The larger end is positioned toward the center of the vehicle to maximize volume, while the smaller end extends forward at an incline, allowing central positioning without compromising breakover clearance
3Object-affected harmful factors
If the battery housing is inclined relative to the horizontal, then the breakover clearance is improved, but the manufacturing complexity increases
Solution Approach 1:
The mounting system is divided into separate modular components: a frame mount attached to the vehicle frame, and a battery housing with an inclined orientation. This segmentation allows each component to be manufactured independently using standard processes, with the inclination achieved through the geometric design of mounting surfaces rather than complex machining of the entire assembly
Solution Approach 2:
The inclination angle of the battery housing is designed as a specific geometric parameter (e.g., 5 degrees) that can be incorporated into the CAD models and manufacturing specifications of the frame mount and battery housing. By defining this as a fixed design parameter rather than an adjustable feature, the manufacturing process remains straightforward while achieving the desired breakover clearance improvement
Data Source
AI summary
Aspects of the disclosure relate to a vehicle assembly, to a frame mount for a vehicle assembly, and to a vehicle. The frame mount comprising an elongate body having a first edge region and a second edge region, the second edge region spaced apart from and inclined relative to the first edge region for attachment to a battery housing.