Vehicle Battery Case Vertical Module Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle battery case designs fail to effectively protect high-voltage cables and connectors from damage during collisions and consume valuable interior space, particularly in electric vehicles where efficient use of space is crucial.
Innovation Solution
A vehicle battery case apparatus featuring a lower case with a high-voltage battery and electric units, an upper case that covers a module unit housing the electric units, and a connector unit connected via a bus bar unit, which is mounted above the lower case to secure additional rear interior space and enhance collision protection by positioning critical components in a way that reduces cable lengths and minimizes protrusion, thus preventing damage during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric components are installed in the battery case, then the battery module can be protected, but interior space is consumed
Solution Approach 1:
The battery case is divided into an upper case and a lower case, creating vertical separation. The module unit with electric components is mounted on the upper case, utilizing vertical space above the battery cells. This dimensional arrangement protects the battery cells in the lower case while accommodating electric components in the upper portion, thereby preserving interior space that would otherwise be occupied by a single large battery case.
2Reliability
If a battery case is provided under the vehicle body, then battery protection is achieved, but interior space is consumed due to electric components
Solution Approach 1:
The battery case is segmented into two distinct parts: a lower case for housing battery cells and an upper case for mounting electric components. This segmentation allows the electric components to be positioned on the upper case rather than occupying space within the lower case, thereby maintaining the protective enclosure for battery cells while minimizing interior space consumption.
3Device complexity
If high-voltage cables and connectors are not protected, then device complexity is reduced, but damage occurs during collision
Solution Approach 1:
The module unit integrates the high-voltage connector and cable routing within a protected enclosure on the upper case. By merging the connector housing with the upper case structure, the high-voltage electrical components are protected during collisions without requiring separate protective devices, thus maintaining relative simplicity while ensuring collision protection.
4Length of moving object
If the module unit is positioned in the front portion, then cable lengths are reduced, but interior space is reduced
Solution Approach 1:
The module unit is positioned on the upper case, utilizing vertical space above the battery cells rather than occupying horizontal interior space. This vertical positioning allows cable routing to be shortened while the module itself is accommodated in the upper portion of the battery case, preserving interior space that would otherwise be required if the module were positioned in the front interior area.
Data Source
AI summary
A vehicle battery case apparatus includes a lower case provided with a high-voltage battery and an electric unit; an upper case coupled to an upper portion of the lower case; a module unit into which the electric unit is built and which is mounted in a front portion of the lower case; and a connector unit electrically connected to the electric unit by being installed in the module unit through the upper case in a state in which the upper case is mounted on the lower case to cover the module unit. Further, the electric unit may be a power relay assembly (PRA) arranged in a front portion of a vehicle body so as to secure an additional rear interior space, where a connector connected to the PRA has a height protruding upwardly with respect to the lower case so as to ensure stability against collisions.