Battery Floor Housing Protection for Frontal Collision Intrusion
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Solution Overview
Problem
Components of an energy-storage floor layout in electrically powered motor vehicles can be displaced rearward during accidents, leading to potential damage and thermal events, particularly in the region of the center tunnel.
Innovation Solution
A protective element is arranged externally on the storage housing, comprising a metal part and an energy-absorbing plastic part, to prevent excessive intrusion and deformation during frontal collisions, with a form-closed and force-closed connection to the storage housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective element is arranged externally on the storage housing, then protection against excessive intrusion and deformation is improved, but device complexity increases
Solution Approach 1:
The protective element is divided into a metal part and an energy-absorbing plastic part, each serving distinct functions. The metal part provides structural protection while the plastic part absorbs impact energy, allowing the system to address multiple protection needs through segmented components rather than a single complex structure.
Solution Approach 2:
The protective element combines metal and plastic materials with different properties. The metal part offers high strength and rigidity for structural protection, while the plastic part provides energy absorption through deformation. This composite approach enables effective protection against intrusion and deformation while maintaining a relatively simple overall structure.
2Ease of manufacture
If the protective element is arranged externally on the storage housing, then preassembly potential is improved, but manufacturing complexity increases
Solution Approach 1:
By segmenting the protective element into separate metal and plastic parts that can be preassembled on the storage housing, the invention enables modular assembly. This segmentation allows the protective element to be prepared in advance and then integrated into the overall vehicle structure, improving manufacturing flexibility and preassembly potential.
Solution Approach 2:
The protective element is designed to be preassembled on the storage housing before the storage housing is fastened or welded to the vehicle body. This preliminary action allows for easier positioning and alignment, and enables quality checks to be performed on the protective element assembly independently of the overall vehicle assembly process.
3Reliability
If the protective element covers the terminal board region, then protection against damage is improved, but access for coupling leads and cables becomes more difficult
Solution Approach 1:
The protective element is designed with differentiated regions: it provides comprehensive coverage and protection for the terminal board area while incorporating openings or access points in specific locations where lead and cable coupling is required. This local differentiation allows the protective element to maintain protection functionality while enabling necessary operational access.
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 protective element effectively prevents excessive intrusion and deformation of the storage housing, reducing the risk of thermal events and damage to the energy-storage unit, while optimizing preassembly and load distribution.
Implementation Method 1
an energy-absorbing plastic part arranged on the inside of the metal part
Data Source
AI summary
An energy store floor system for an electrically drivable motor vehicle, with a storage housing which is arranged below a vehicle floor, has a connection panel and, at a front end, borders a front section of the motor vehicle. In order to achieve an energy store floor system with an energy store which is particularly advantageously protected in the event of a head-on collision of the motor vehicle, a protection element for avoiding excessive accident-induced intrusions is arranged at the front end on the outer side of the storage housing of the energy store.