Battery-Floor Foam Seal Structure for Vehicle Noise Damping
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Solution Overview
Problem
Existing vehicle designs with a foam layer between the floor and electric battery for sound-deadening have inefficiencies due to the need for multiple parts, leading to increased assembly time, errors, and costs.
Innovation Solution
Incorporating a sound-deadening foam layer with integral seals on both surfaces, either as ribs or grooves, to enhance contact and improve sound insulation while maintaining a seal between the floor and battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a foam layer is inserted between the floor and electric battery for sound-deadening, then sound insulation performance is improved, but the structure requires multiple separate parts (foam layer and sealing elements) leading to increased assembly time and complexity
Solution Approach 1:
The patent combines the sealing function and sound-deadening function into a single integrated foam element. The foam layer incorporates sealing ribs that directly provide sealing contact with the battery casing, eliminating the need for separate sealing elements. This merging of functions reduces the number of parts while maintaining both sealing and sound insulation performance.
Solution Approach 2:
The foam layer serves multiple functions simultaneously: it provides sound deadening, creates sealing contact through integrated ribs, and acts as a vibration dampener. This multi-functional design eliminates the need for separate dedicated sealing elements, reducing assembly complexity while achieving multiple technical objectives.
2Reliability
If sealing elements are added to the foam layer structure, then sealing performance is improved, but assembly time and sources of error increase
Solution Approach 1:
The sealing function is merged into the foam layer itself through integrated sealing ribs. These ribs are formed as part of the foam molding process, creating a single-component solution that provides both structural support and sealing contact, thereby reducing assembly steps and potential errors.
Solution Approach 2:
The sealing ribs are pre-formed as integral parts of the foam layer during the molding process. This preliminary formation of sealing features eliminates the need for separate sealing element installation steps, reducing assembly time while ensuring proper sealing contact is already prepared before the assembly operation.
3Reliability
If separate sealing elements are used with the foam layer, then seal quality is improved, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The sealing function is combined with the sound-deadening foam layer into a single molded component. The sealing ribs are integrated directly into the foam structure, eliminating the need for separate sealing element procurement, storage, and assembly operations, thereby reducing manufacturing costs while maintaining seal quality.
Solution Approach 2:
The foam layer is designed to perform multiple functions including sound insulation, vibration damping, and sealing. This multi-functional integration reduces the total bill of materials and eliminates the need for separate sealing component manufacturing, lowering overall production costs.
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 integrated seals significantly enhance sound-deadening performance and ensure a secure seal without adding extra parts, thus reducing assembly time and costs.
Implementation Method 1
This foam layer acts as a sound-deadening element to limit the noise produced by the vibrations of the electric battery
Implementation Method 2
one of the seals tends to be compressed against a surface of said floor and the other seal tends to be compressed against a surface of the battery
Data Source
AI summary
A vehicle includes a floor and an electric battery placed beneath the floor. The vehicle also includes a layer of sound-deadening foam inserted between the floor and the battery such that the layer has an upper surface that is in contact with the floor and a lower surface that is in contact with the battery. At least one the two surfaces forms at least a seal intended to increase the sound-deadening of the foam between the floor and the battery.