Stacked Traction Battery Packs for Rigid EV Chassis Integration
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Solution Overview
Problem
Existing electric vehicle designs require large, inefficient installations of traction battery packs on trucks, which consume space and compromise chassis rigidity due to the need for numerous brackets and cables.
Innovation Solution
Stacking traction battery packs between upper and lower frame plates of the chassis, with each pack tightened to neighboring packs and the frame plates, reducing the need for brackets and cables while maintaining structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traction battery packs are suspended onto the chassis with multiple brackets and connected with multitude of cables and connectors, then the battery packs can be securely installed and electrically connected, but the installation becomes space-consuming and compromises chassis rigidity
Solution Approach 1:
The patent merges the mechanical support function and electrical connection function into a single integrated structure. The battery packs are stacked vertically and directly connected to each other through integrated connection points, eliminating the need for separate brackets and multiple cables. This consolidation reduces the number of components while maintaining secure installation and reliable electrical connections.
Solution Approach 2:
The patent transitions from a horizontal distribution of battery packs to a vertical stacking arrangement. By utilizing the vertical dimension for stacking battery packs directly on top of each other, the design eliminates the need for extensive bracket structures that would be required for horizontal mounting, thereby reducing component complexity while maintaining structural integrity.
2Ease of manufacture
If traction battery packs are arranged in a cube shape suspended from the chassis frame, then the battery packs can be mounted externally, but large brackets are required due to bending moments and free space is needed for frame flexing
Solution Approach 1:
The patent utilizes the vertical dimension by stacking battery packs vertically between upper and lower frame plates. This vertical arrangement eliminates the need for large horizontal brackets and the associated free space for frame flexing, as the stacked configuration naturally distributes loads and eliminates bending moments that would require additional clearance.
Solution Approach 2:
The patent combines the mounting function and structural support function into the stacked battery pack arrangement itself. The vertical stacking between frame plates integrates the mounting mechanism with the battery pack configuration, eliminating the need for separate large brackets and reducing the overall space requirement while maintaining ease of manufacture.
3Stability of the object's composition
If multiple brackets and bushings are used to suspend battery packs, then the chassis can flex during normal movement, but lost space is required for relative movement
Solution Approach 1:
The patent resolves the flexibility requirement by moving to a vertical stacking arrangement where battery packs are positioned between upper and lower frame plates. This vertical configuration allows the chassis to flex horizontally during normal movement without requiring additional free space, as the vertical stacking naturally accommodates horizontal flexing motions.
Data Source
AI summary
The invention relates to a battery-powered vehicle comprising a chassis extending between the rear end and the front end of the vehicle. The chassis comprises an upper frame plate and a lower frame plate, wherein the lower frame plate is located vertically below the upper frame plate. The battery-powered vehicle further comprises a battery stack, which comprises a plurality of traction battery packs stacked on top of each other between the upper and lower frame plates, wherein each traction battery pack is vertically tightened to a neighboring traction battery pack and wherein at least one traction battery pack is tightened to one of said upper and lower frame plates.