Structural Battery Pack Chassis Integration for Lower EV Mass
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Solution Overview
Problem
Conventional electric vehicle battery packs are inefficient in terms of space utilization and structural integration, adding significant mass that negatively affects performance and range, while providing improved structural integrity.
Innovation Solution
A structural battery pack (SBP) with a compact, rigid design that integrates battery modules into the vehicle's chassis, using body and battery cross members and longitudinal members to form a unified structure, providing torsional and bending rigidity, and allowing for easy demounting for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery packs are pre-assembled on a separate battery support structure and mounted to the vehicle frame, then the battery pack is easy to manufacture and assemble, but the battery pack adds significant mass to the vehicle, negatively affecting performance and range
Solution Approach 1:
The patent merges the battery support structure with the vehicle chassis by integrating battery modules directly into the chassis structure. The chassis members (longitudinal members, cross members, and floor panels) directly support the battery modules, eliminating the need for a separate battery support structure. This integration reduces overall vehicle mass while maintaining structural integrity and ease of manufacture.
2Ease of operation
If conventional battery packs use a separate battery support structure, then the battery pack can be easily assembled, but the separate battery assembly adds to sheer stresses in the frame and requires thick, heavy frames and robust mounts
Solution Approach 1:
The battery support function is merged with the chassis structure itself. The chassis members (longitudinal members, cross members, and floor panels) are designed to directly support battery modules, eliminating the need for separate support structures and heavy mounts. This integration reduces shear stresses in the frame while maintaining ease of assembly.
3Strength
If conventional battery packs are designed with a rigid metal battery tray, then the battery pack provides structural support, but the battery pack occupies inefficient space and adds significant mass
Solution Approach 1:
The chassis members serve multiple functions: they provide structural support for the vehicle, support the battery modules, and define the vehicle's structural framework. This multi-functionality eliminates the need for dedicated battery trays, optimizing space utilization while maintaining structural support capabilities.
4Ease of manufacture
If conventional battery packs use separate battery assembly mounted to vehicle frame, then the battery pack can be independently manufactured, but the connections between battery assembly and vehicle frame provide pathways for noise, vibration, and harshness
Solution Approach 1:
The battery support structure is merged with the chassis, eliminating separate connection points between the battery assembly and vehicle frame. The chassis members directly support the battery modules, removing the connection pathways that would otherwise transmit noise, vibration, and harshness between the battery pack and vehicle frame.
Data Source
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AI summary
The present disclosure relates to a structural battery pack (200) for integration into an electric vehicle (100), the structural battery pack (200) comprising: a common bottommost interface surface (210), a common uppermost interface surface (220), wherein said bottommost and uppermost interface surfaces (210, 220) when connected, form a structure of the SBP (200). Further, comprising front and rear extrusions (202a, 205a, 202b, 205b) extruding from front and rear portions thereof respectively, each front extrusion (202a, 205a) being arranged to be integrated into a front exterior assembly (250) of a front vehicle portion (104), and each rear extrusion (202b, 205b) is arranged to be integrated into a rear exterior assembly (260) of a rear vehicle portion (106) thereby said SBP establishes a structural chassis of the electric vehicle (100). The disclosure further relates to an electric vehicle (100) comprising said SBP (200).