关键词: 电池包支架；轻量化；连续纤维增强热塑性复合材料；CAE 分析

Abstract: To address the design challenges of commercial vehicle battery pack brackets under the triple constraints of "high load-bearing, lightweight, and connection reliability", this paper proposes a composite material bracket solution based on multi-material synergy, with the core concept of "functional deconstruction and material adaptation". The solution employs continuous glass fiberreinforced PA66 organic sheets to form the load-bearing skeleton, uses short glass fiber-reinforced PA6 injection molding to create a zoned rib reinforcement network, and embeds surface-knurled metal bushings at the connection holes to reconstruct the load transfer path, fundamentally avoiding the creep relaxation issue of polymers. Finite element method was used to conduct constrained modal and random vibration simulation analyses on the battery pack assembly. The results show that the first-order natural frequency of the bracket is 39.4 Hz, which can effectively avoid the main frequency band of road excitation; the maximum root mean square (RMS) equivalent stress under random vibration conditions is 9.1 MPa, far below the material fatigue allowable value (35 MPa), with a safety factor of 3.85; compared with traditional steel brackets, the weight is reduced by approximately 60%. This solution demonstrates significant advantages in both lightweighting and vibration resistance reliability, providing a technical solution that balances innovation and feasibility for the engineering application of commercial vehicle battery pack load-bearing structures.

Key words: battery pack bracket; lightweight; continuous fiber-reinforced thermoplastic composites; CAE analysis