Structural Battery Pack Integration for EV Chassis Load Transfer
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Solution Overview
Problem
Electric vehicles require innovative solutions for integrating battery packs and electric motors with the chassis and suspension system, considering strength, rigidity, and space efficiency, while minimizing component weight and size.
Innovation Solution
The battery pack is designed as a structural element that integrates the battery enclosure to receive and transfer loads from the suspension system, steering system, and seat, providing structural support and rigidity, and optionally houses the battery modules in a water-tight enclosure made of materials like carbon fiber composite or glass fiber reinforced plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery pack is designed as a structural element to receive loads from suspension system, steering system, and seat, then the overall structural efficiency is improved and the number of structural components is reduced, but the battery enclosure must be designed with higher strength and rigidity requirements
Solution Approach 1:
The patent combines the battery enclosure with structural support functions by integrating it into the vehicle frame. The battery enclosure is directly coupled to receive loads from the suspension system, steering system, and seat, eliminating the need for separate structural components and reducing overall device complexity while maintaining necessary strength and rigidity.
Solution Approach 2:
The battery enclosure serves multiple functions: it houses the battery modules, provides structural support, and acts as a load-bearing component for the suspension system, steering system, and seat. This multi-functionality reduces the total number of components needed in the vehicle structure.
2Weight of moving object
If the battery pack is integrated as a load-bearing element, then the vehicle achieves a more compact and lightweight design, but the battery enclosure must withstand higher stress and pressure from multiple load sources
Solution Approach 1:
By merging the battery enclosure with the vehicle's structural frame, the design eliminates redundant components and reduces overall vehicle weight. The integrated structure allows the battery pack to serve dual purposes: energy storage and structural support, achieving a more compact and lightweight vehicle design.
Solution Approach 2:
The patent employs composite materials for the battery enclosure to achieve high strength-to-weight ratio. This allows the enclosure to withstand higher stress and pressure from multiple load sources while maintaining a lightweight design that contributes to overall vehicle weight reduction.
3Device complexity
If the battery enclosure serves dual functions of protection and structural support, then the structural efficiency is enhanced, but the design and manufacturing complexity of the battery enclosure increases
Solution Approach 1:
The patent merges the protective housing function with structural support function into a single battery enclosure component. This integration reduces the total number of structural components needed in the vehicle, enhancing structural efficiency while the modular design of the battery pack facilitates standardized manufacturing processes.
Solution Approach 2:
The battery enclosure is designed as a modular structure that can be segmented into manageable sections for manufacturing and assembly. This segmentation approach allows complex structural requirements to be met through standardized, pre-fabricated modules that can be assembled systematically, reducing overall manufacturing complexity.
Data Source
AI summary
An electric vehicle and a powertrain for an electric vehicle are disclosed. According to an embodiment, an electric vehicle includes a suspension system, a seat, a steering system, an electric motor and a battery pack. The battery pack includes one or more battery modules to provide power to the electric motor and a battery enclosure housing the one or more battery modules. The battery enclosure is a structural element of the electric vehicle to receive loads from at least two of the suspension system, the seat and the steering system.