EV Battery Floor Housing With Detachable Side-Impact Profiles
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Solution Overview
Problem
Existing energy store floor systems in electric vehicles face challenges with insufficient space for large profile elements to dissipate energy during side impacts, leading to potential intrusion and thermal events due to coupled motion between profile elements and side sills.
Innovation Solution
The system incorporates connecting devices that release between profile elements and side sills upon relative movement during an accident, using a bolt element and keyhole-like opening to disconnect the profile elements from the side sills, preventing excessive intrusion into the store housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large profile elements are installed to dissipate energy during side impacts, then energy absorption capability is improved, but installation space requirements increase and weight increases
Solution Approach 1:
The connecting device transitions from a static rigid connection to a dynamic system that changes state based on impact conditions. During normal operation, the profile element is firmly connected to the side sill. During a side impact, the connecting device releases, allowing the profile element to move independently and absorb impact energy through controlled intrusion, thus providing energy absorption capability without requiring permanently large structural dimensions.
Solution Approach 2:
The system changes the connection state parameter from fixed to movable based on impact conditions. The connecting device uses a release mechanism that changes the degree of freedom of the profile element from constrained (normal operation) to free-moving (impact condition), enabling the same compact structure to provide both space efficiency and impact energy absorption.
2Stability of the object's composition
If the profile element is firmly connected to the side sill, then structural stability is improved, but excessive intrusion into the store housing occurs during side impacts
Solution Approach 1:
The connecting device provides a dynamic connection that adapts to loading conditions. Under normal loads, the profile element remains firmly connected to maintain structural stability. Under impact loads exceeding a threshold, the connecting device releases, allowing the profile element to move independently and prevent excessive intrusion into the store housing by decoupling the impact force from the energy store structure.
Solution Approach 2:
The connecting device extracts the harmful coupled motion between the side sill and profile element during impact. By providing a release mechanism, it separates the profile element from the side sill connection under impact conditions, removing the transmission path for harmful forces that would otherwise cause excessive intrusion into the store housing.
3Object-affected harmful factors
If the profile element is allowed to move independently during impact, then intrusion into the store housing is reduced, but structural stability during normal operation deteriorates
Solution Approach 1:
The system dynamically adjusts the connection state between profile element and side sill based on operational conditions. During normal operation, the connecting device maintains a firm connection ensuring structural stability. During side impact, the connecting device releases allowing independent movement of the profile element to reduce intrusion into the store housing. This dynamic state change resolves the contradiction between stability and intrusion prevention.
4Strength
If connecting devices with high holding force are used, then structural stability is improved, but release during impact becomes more difficult
Solution Approach 1:
The connecting device uses a release mechanism that changes the force threshold parameter. The connection maintains high holding force under normal operational loads, but under impact conditions with higher forces and/or displacement, the release mechanism activates. This parameter change enables the same connection to provide both high holding force for stability and reliable release during impact.
Solution Approach 2:
The connecting device is pre-configured with a release mechanism that is activated under specific impact conditions. The geometric design of the release mechanism (such as a cam or latch system) is predetermined to release at specific force or displacement thresholds, ensuring reliable release during impact while maintaining high holding force during normal operation.
Data Source
AI summary
An energy store floor system for an electrically drivable motor vehicle includes a floor structure having respective side sills, to the underside of which is fastened a store housing of an energy store for an electrical drive of the motor vehicle, and having respective profile elements, which are arranged along longitudinal sides of the store housing and are fastened to the underside of the respectively assigned side sill. In order to create an energy store floor system with an improved accident behavior in the event of a side impact, the profile elements are connected to the respectively laterally assigned side sill via respective connection devices, which are detachable from the outside inwards when there is a relative movement, caused by an accident, of the respective side sill relative to the assigned profile element in the vehicle transverse direction.