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

摘要： 针对商用车电池包支架在“高承载-轻量化-连接可靠”三重约束下的设计难题，文章提 出一种基于多材料协同的复合材料支架方案，核心思路为“功能解构-材料适配”。方案以连 续玻纤增强 PA66 有机板构成承力骨架，以短玻纤增强 PA6 注塑形成分区加强筋网络，并在 连接孔处预埋表面滚花金属衬套以重构传力路径，从根本上规避聚合物蠕变松弛问题。采用 有限元方法对电池包总成进行约束模态与随机振动仿真分析，结果表明，支架一阶固有频率 为 39.4 Hz，可有效规避路面激励主频段；随机振动工况下最大均方根（RMS）等效应力为 9.1 MPa，远低于材料疲劳许用值（35 MPa），安全系数达 3.85；相较传统钢制支架减重约 60%。 该方案在轻量化与抗振可靠性方面均展现出显著优势，为商用车电池包承载结构的工程化应 用提供了兼顾创新性与可行性的技术方案。

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