Battery Floor Assembly With Bonded Cell Modules for Rigid EV Packaging
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Solution Overview
Problem
Existing energy storage systems for motor vehicles face challenges in achieving a space-saving, lightweight, and rigid attachment to the vehicle floor structure, which affects the overall rigidity and efficiency of energy storage.
Innovation Solution
The energy storage floor assembly features a floor structure with interconnected longitudinal and cross members, where prismatic storage cells are arranged in modules and adhesively bonded to an upper housing part, forming a composite construction that integrates the energy storage system beneath the floor structure, eliminating the need for separate floor panels and enhancing rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electrical energy store is arranged on the underside of the floor structure, then space utilization is improved, but the attachment complexity increases
Solution Approach 1:
The patent merges the floor panel and energy store housing into a single integrated upper housing part. The prismatic storage cells are directly arranged on the underside of this integrated housing part, eliminating the need for separate attachment mechanisms and reducing overall structural complexity while maximizing space utilization beneath the vehicle floor.
Solution Approach 2:
The upper housing part serves multiple functions: it acts as both the floor panel closing the intermediate space and the housing for the electrical energy store. This multi-functional design reduces the number of separate components needed and simplifies the attachment to the vehicle floor structure.
2Productivity
If prismatic storage cells are arranged in modules and adhesively bonded, then manufacturing efficiency is improved, but bonding reliability requirements increase
Solution Approach 1:
The storage cells are arranged in modular configurations with systematic bonding patterns. The adhesive bonding is applied in organized sequences across the module interfaces, allowing for controlled manufacturing processes while maintaining consistent bonding quality across all modules.
Solution Approach 2:
The patent specifies particular adhesive bonding parameters including bond strength requirements, bond line thickness control, and curing conditions. These parameter specifications ensure reliable bonding while enabling efficient manufacturing processes through standardized bonding procedures.
3Device complexity
If the upper housing part is used as a floor panel, then the number of parts is reduced, but the structural strength requirements increase
Solution Approach 1:
The upper housing part combines the functions of floor panel and energy store housing into a single structural component. This merged design reduces the total number of parts while concentrating structural strength requirements into one optimized component that must simultaneously support floor loads and protect the energy store.
Solution Approach 2:
The upper housing part is designed as a composite structure combining materials with different properties to simultaneously achieve floor panel strength and energy store protection. The composite construction allows optimization for both structural loading and protective functions within a single integrated part.
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
This configuration allows for a lightweight, space-efficient, and highly rigid energy storage system that maximizes storage capacity while minimizing the number of parts and installation complexity, enabling efficient electrical energy storage for hybrid or electric vehicles.
Implementation Method 1
the storage cells are adhesively bonded to the upper housing part and thereby joined to the floor structure
Data Source
AI summary
Please substitute the new Abstract submitted herewith for the original Abstract: An energy storage floor assembly for a motor vehicle has a floor structure, which includes longitudinal members and crossmembers connected to one another as carrier elements, and has an electrical energy store, which is arranged on the bottom side of the floor structure, is connected to the floor structure, and has a storage housing with a housing top part, by way of which at least one intermediate space between at least two of the carrier elements is overlapped at the bottom in the vehicle vertical direction and as a result is closed. Prismatic storage cells are arranged in the storage housing. First ones of the storage cells are arranged in succession along a first stacking direction so as to form a first cell module. Second ones of the prismatic storage cells are arranged in succession along a second stacking direction so as to form a second cell module. The cell modules are arranged next to one another and joined to one another. The first and second storage cells are joined to the housing top part.