Modular Battery Enclosure Rails for Scalable Vehicle Pack Fit
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Solution Overview
Problem
Existing vehicle battery systems require unique configurations for different vehicle segments, leading to expensive and time-consuming product development, high waste, and increased business risk due to diverse frame structures and battery dimensions.
Innovation Solution
A modular battery pack with a scalable enclosure structure comprising extruded rails and cover panels that can be trimmed to fit various vehicle frame dimensions, allowing common components to be assembled into customized configurations for different vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If unique battery configurations are designed for different vehicle segments, then adaptability to specific vehicle frames is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single modular battery enclosure that can be configured for multiple vehicle segments. The enclosure uses standardized components (side rails, end rails, cross members) that can be assembled in different configurations to fit various frame sizes and shapes, eliminating the need for segment-specific battery designs while maintaining adaptability
Solution Approach 2:
The battery enclosure is divided into modular segments including side rails, end rails, and cross members that can be independently selected and assembled. This segmentation allows the same basic components to be reconfigured for different vehicle types, reducing overall system complexity while maintaining versatility across vehicle segments
2Adaptability or versatility
If segment-specific battery designs are implemented, then fit to vehicle frame is improved, but productivity and development time decrease
Solution Approach 1:
A universal modular enclosure design allows the same battery platform to serve multiple vehicle segments, significantly improving manufacturing efficiency by enabling standardized production processes, shared tooling, and streamlined supply chain management while maintaining compatibility with diverse vehicle frames through configurable component assembly
3Adaptability or versatility
If diverse battery configurations are used across vehicle segments, then specific vehicle requirements are met, but loss of substance and waste increase
Solution Approach 1:
The modular enclosure design enables a single set of standardized components to be reused across multiple vehicle segments, reducing material waste by eliminating the need to manufacture separate battery enclosures for different vehicle types. Components can be reconfigured and reused rather than discarded, significantly improving resource efficiency
Data Source
AI summary
A modular battery pack for a vehicle includes a scalable enclosure structure that includes a front enclosure rail, a rear enclosure rail, and a pair of rocker attachment rails extending between the front and rear enclosure rails along opposing sides of the enclosure structure. Each of the rocker attachment rails includes a length that is scalable to adjust a length of the battery pack. A bottom cover panel is coupled to respective first sides of the front enclosure rail, the rear enclosure rail, and each of the rocker attachment rails. A top cover panel is coupled to respective second sides of the front enclosure rail, the rear enclosure rail, and each of the rocker attachment rails. A battery module is supported on the scalable enclosure structure between the bottom cover panel and the top cover panel.