Stacked Vehicle Battery Modules for Lower Frame Rail Stress
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Solution Overview
Problem
Conventional battery placement in heavy-duty vehicles along longitudinally extending frame rails subjects the frame and connecting brackets to high stress, requiring multiple brackets for safe suspension and limiting the efficient use of vehicle volume and cable wiring.
Innovation Solution
A battery assembly with vertically stacked modules connected to the frame rails via horizontally extending brackets, improving load distribution and allowing for increased battery capacity and simpler connections, with detachable modules for easier maintenance and flexible module sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batteries are positioned along the longitudinally extending frame rails, then the battery assembly is easily accessible and connected to the frame, but the frame and connecting brackets are subjected to high stress requiring multiple brackets
Solution Approach 1:
The patent transitions from a conventional longitudinal battery arrangement along the frame rails to a vertical stacking arrangement beneath the frame rails. This dimensional change from horizontal to vertical positioning redistributes the mechanical load from the frame structure to the battery assembly itself, reducing stress on the frame and connecting brackets while maintaining accessibility for connection and maintenance.
2Ease of manufacture
If conventional battery placement is used along frame rails, then connection to frame is straightforward, but vehicle volume utilization is limited and cable wiring becomes complex
Solution Approach 1:
The vertical stacking arrangement utilizes the vertical space beneath the frame rails, effectively converting unused vertical volume into functional battery storage space. This dimensional repositioning optimizes vehicle volume utilization without compromising connection simplicity, as the stacked modules remain easily accessible from above for maintenance and cable wiring.
Solution Approach 2:
The battery assembly is divided into multiple vertically stacked modules, each independently connectable to the frame rails. This segmentation allows for flexible configuration that optimizes space utilization while maintaining straightforward connection processes for each individual module.
3Strength
If multiple brackets are used to suspend batteries along frame rails, then structural strength is sufficient, but device complexity increases
Solution Approach 1:
By repositioning the battery assembly vertically beneath the frame rails rather than along them, the patent reduces the number of brackets required from multiple distributed brackets to fewer support structures. The vertical stacking configuration allows the battery assembly to better bear its own weight, reducing the structural complexity of the suspension system.
Data Source
AI summary
The present disclosure relates to a battery assembly for a vehicle comprising a pair of longitudinally extending frame rails, the battery assembly comprising a first and a second vehicle battery module, the first vehicle battery module being stacked vertically on top of the second vehicle battery, wherein the battery assembly is configured to be connected to the vehicle vertically below the frame rails by attaching an upper surface of the first vehicle battery module to a horizontally extending portion of a pair of brackets, the pair of brackets being attachable to a respective one of the longitudinally extending frame rails.