Traction Battery Underbody Impact Sensing With Sealed Air Chamber
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Solution Overview
Problem
The challenge in providing effective impact detection for traction batteries in electric vehicles is the limited installation space and the difficulty in achieving reproducible pressure signal characteristics due to the need for a sealed air-filled chamber, which complicates pressure transfer and increases the risk of damage from shocks.
Innovation Solution
An impact detection device featuring an underbody element with an air-filled chamber sealed by a polyurethane material, incorporating an introduction element for a pressure hose that couples to a pressure sensor, allowing for pressure changes to be detected upon deformation, thereby determining intrusions and minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an underbody element is used to protect the traction battery from shocks, then protection from external influences is improved, but the complexity of sealing and installing pressure sensors increases due to limited space
Solution Approach 1:
The pressure hose is nested within the sealing material (polyurethane), which is applied in multiple layers. The introduction element creates a pathway that allows the pressure hose to be embedded within the sealing material itself, integrating the pressure transfer function into the sealing structure rather than adding separate components
Solution Approach 2:
The introduction element acts as an intermediary component that facilitates the coupling between the pressure hose and the air-filled chamber. It provides a predefined pathway through the sealing material, enabling pressure transfer while maintaining the integrity of the seal
2Measurement precision
If a sealed air-filled chamber is created for pressure sensing, then reproducible pressure signal characteristics are improved, but the difficulty of installation and space requirements worsen
Solution Approach 1:
The introduction element is pre-formed with a passage channel and stop features before being integrated into the underbody element. The sealing material is pre-applied in layers, with the pressure hose positioned and embedded during the sealing process, eliminating the need for complex post-assembly modifications
Solution Approach 2:
The sealing process is segmented into multiple layers of sealing material application. The pressure hose is embedded within these layers, with the introduction element providing a structured pathway. This segmentation allows for systematic installation while maintaining reproducible pressure signal characteristics
3Ease of manufacture
If the pressure hose is directly coupled to the chamber through sealing material, then installation simplicity is improved, but reproducible pressure signal characteristics worsen due to potential slipping
Solution Approach 1:
The introduction element provides a localized structured pathway with a stop feature at a specific position within the sealing material. This localized structure ensures the pressure hose is held at a reproducible depth and position, guaranteeing consistent pressure signal characteristics while maintaining installation simplicity
Solution Approach 2:
The stop feature in the introduction element defines a specific parameter (depth/position) for the pressure hose embedding. By controlling this parameter through the predefined stop, the system achieves reproducible pressure signal characteristics without complicating the installation process
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 solution enables reproducible pressure signal characteristics and effective pressure sensing, even in limited spaces, by embedding the introduction element within the sealing material, preventing slipping and ensuring a secure, gap-free seal, thus accurately detecting impacts and preventing further damage to the traction battery.
Implementation Method 1
at least one air-filled chamber (4), which is formed on the underbody element (3) and which is at least laterally sealed to the outside and defined by a sealing material
Data Source
AI summary
An impact detection device for a traction battery of a motor vehicle includes at least one air-filled chamber formed on an underbody element for the traction battery. An air-filled chamber is at least laterally sealed to outside and defined by a sealing material. A pressure hose and an introduction element for the pressure hose can be provided, wherein the air-filled chamber can be coupled to a pressure sensor through the pressure hose, and the introduction element can be attached to the underbody element and formed to couple the pressure hose to the air-filled chamber through the sealing material in a set position. The introduction element can be embedded by the sealing material which seals the air-filled chamber.