Battery Box Floor with Deformation Cavity for Crash and Thermal Management
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Solution Overview
Problem
Existing battery box floors for electric vehicles face challenges in providing adequate crash protection and independent cooling from environmental conditions, with complex and costly cooling solutions and high risk of damage from underbody impacts.
Innovation Solution
A battery box floor design featuring an aluminium alloy extruded part with a deformation inner cavity and inner ribs, which provides improved crash performance and thermal insulation for cooling channels, reducing the risk of damage and enhancing cooling efficiency by stabilizing the temperature of the cooling fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are arranged outside the battery box, then cooling performance is improved, but thermal protection and crash performance deteriorate
Solution Approach 1:
The cooling channels are nested within the battery box floor structure itself, with the floor forming the upper wall of the channels. This integrates the cooling function into the structural component, allowing external placement while maintaining protection through the battery box enclosure and underbody protection elements.
Solution Approach 2:
The cooling channels are positioned in the vertical dimension below the battery pack supporting panel, utilizing the space between the battery box floor and underbody protection. This three-dimensional arrangement achieves external cooling while maintaining structural protection.
2Reliability
If cooling channels are arranged inside the battery box, then thermal protection is improved, but cooling performance dependent on environment temperature worsens
Solution Approach 1:
The cooling channels are nested within the battery box floor structure, with the floor forming the upper wall. This integration provides thermal protection through the battery box enclosure while maintaining cooling effectiveness by positioning channels where they can be externally cooled.
3Reliability
If underbody protection is added to protect cooling channels, then crash protection is improved, but device complexity worsens
Solution Approach 1:
The underbody protection is merged with the battery box floor structure, forming an integrated assembly. The cooling channels are positioned within this combined structure, eliminating the need for separate protection components and reducing overall system complexity.
Solution Approach 2:
The battery box floor serves multiple functions: it supports the battery pack, forms the upper wall of cooling channels, and provides structural protection when combined with underbody protection. This multi-functionality reduces the need for additional dedicated components.
4Reliability
If aluminium alloy extruded part with deformation inner cavity is used, then crash performance is improved, but manufacturing complexity worsens
Solution Approach 1:
The deformation inner cavity and cooling channel geometry are pre-formed during the extrusion process itself. The extrusion die is designed to create the complex three-dimensional cavity shape and cooling channel pathways in a single manufacturing step, avoiding subsequent complex machining or assembly operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances crash protection and cooling performance, minimizing the risk of battery damage and fluid leakage, while simplifying manufacturing and reducing environmental temperature's impact on cooling efficiency.
Implementation Method 1
a plurality of lower cooling channels (4) for containing a cooling fluid, said plurality of lower cooling channels being arranged adjacent to and below said battery pack supporting panel such that they can cool said battery cells
Implementation Method 2
a deformation inner cavity (8) arranged between said plurality of lower cooling channels (4) and said underbody protection (6)
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
A battery box floor (1) for electric vehicles for being arranged at the lower part of a vehicle body (100). The battery box floor (1) comprises a battery pack supporting panel (2) for supporting a plurality of battery cells (102), a plurality of lower cooling channels (4) for containing a cooling fluid, a plurality of lower cooling channels (4) being arranged adjacent to and below the battery pack supporting panel (2) such that they can cool the battery cells (102) and an underbody protection (6) arranged below the lower cooling channels (4). The battery box floor (1) further comprises a deformation inner cavity (8) between said plurality of lower cooling channels and said underbody protection (6). Additionally, the battery box floor (1) is integrally formed from a metallic material. Also a vehicle body comprising the battery box floor (1) is disclosed.