Vehicle Battery Case Interfaces for Single-Opening Floor Assembly
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Solution Overview
Problem
Current solutions for rechargeable batteries in electric and hybrid vehicles require complex and time-consuming installation processes, affecting manufacturing time and cost, as well as driver ergonomics and vehicle habitability due to the need for multiple openings and interventions by technicians or robots for electrical and fluid connections.
Innovation Solution
A rechargeable battery design featuring pre-equipped external connection interfaces for electrical and cooling fluid conduits, which can be coupled directly through a single opening in the vehicle floor, reducing the need for additional installations and preserving driver ergonomics and vehicle accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is coupled to power cables and cooling circuit via separate openings requiring connection plates, then reliable electrical and fluid connections are achieved, but manufacturing time increases and cost increases due to technician or robot intervention
Solution Approach 1:
The patent combines the electrical connection interface and fluid connection interface into a single integrated battery housing structure. Both the power cable connection and cooling circuit connection are achieved through one opening in the vehicle floor, eliminating the need for separate connection plates and reducing assembly steps. This merging of interfaces directly resolves the contradiction by maintaining connection reliability while significantly improving manufacturing productivity.
Solution Approach 2:
The battery housing lower wall is designed with multi-functional interfaces that simultaneously handle both electrical power transmission and fluid cooling functions. The universal interface design allows a single opening to serve dual purposes for both electrical and fluid connections, reducing the number of required openings and assembly operations while maintaining reliable connections for both systems.
2Reliability
If multiple openings are created in the floor for electrical and fluid connections, then necessary connections are established, but driver ergonomics deteriorate and habitability is reduced
Solution Approach 1:
By merging the electrical and fluid connection interfaces into a single integrated unit that passes through one opening in the vehicle floor, the patent minimizes the number of openings required. This reduces disruptions to the floor structure and preserves the interior space and ergonomics while still establishing all necessary connections for battery operation.
3Reliability
If connection plates are fixed under the floor for electrical and fluid connections, then secure connections are achieved, but manufacturing cost increases due to additional interventions
Solution Approach 1:
The patent eliminates the need for separate electrical connection plates and fluid connection plates by integrating both connection functions directly into the battery housing. This single integrated design reduces the number of parts and assembly operations required, thereby lowering manufacturing costs while maintaining secure connections for both electrical and fluid systems.
Solution Approach 2:
The battery housing is designed to self-integrate with the vehicle floor structure, with the lower wall of the housing serving as both the structural element and the connection interface carrier. This self-service design eliminates the need for additional connection plates and reduces the complexity of assembly operations, thereby reducing manufacturing costs while ensuring secure connections.
Data Source
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AI summary
A rechargeable battery (BR) is fitted in the floor (PV) of a vehicle (V) comprising a power unit and utilises the electrical energy supplied by electrical cables (CE) and supply pipes (CA) in which a cooling fluid circulates. Said battery (BR) comprises: - a case (BB) comprising a lower wall (PI) which is connected to the upper surface (FS) of the floor (PV) above an opening (OP) and houses at least one device for storing electrical energy and a cooling circuit, - an external connection interface (IC) which is connected to the cooling circuit, which is rigidly connected to the lower wall (PI), passes through the opening (OP) and is connected to a portion of the supply pipes (CA) passing underneath the floor (PV), and - an external electrical interface (IE) which is rigidly connected to the lower wall (PI), passes through the opening (OP) and is connected to a portion of the electrical cables (CE) passing underneath the floor (PV).