EV Battery Pack Cover Reinforcement for Cabin Load Transfer
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Solution Overview
Problem
Conventional electric vehicle battery packs are susceptible to damage from loads such as seat submerge pressure and seat pitch, as they often lack sufficient strength to support vehicle cabin loads.
Innovation Solution
The battery pack is reinforced with longitudinal members affixed to the cover and cross members, transferring loads directly to rigid elements within the pack, thereby enhancing its strength and load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional battery pack design is used, then manufacturing simplicity is maintained, but structural strength and load-bearing capacity are insufficient
Solution Approach 1:
The battery pack structure is segmented into distinct functional components: longitudinal reinforcing members for load-bearing, cross members for structural support, and a cover for protection. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity and load-bearing capacity.
Solution Approach 2:
The battery pack employs composite structural elements combining rigid materials (for reinforcing members and cross members) with protective cover materials. This composite approach enables the structure to simultaneously achieve high strength for load-bearing and appropriate flexibility for protection, resolving the contradiction between strength and structural complexity.
2Reliability
If reinforcing members are added to the battery pack, then load distribution and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The longitudinal reinforcing members and cross members are designed and positioned in advance during the manufacturing process, creating pre-established load paths. This preliminary structuring allows for standardized assembly procedures and simplifies the manufacturing process despite the increased structural complexity, as components can be pre-fabricated and then assembled in a systematic manner.
3Object-affected harmful factors
If loads are transferred to rigid cross members, then protection of battery modules is improved, but structural complexity increases
Solution Approach 1:
The longitudinal reinforcing members act as intermediaries that receive compressive loads from the vehicle cabin (such as from seats) and transfer them to the rigid cross members. This intermediary structure protects the battery modules from direct exposure to harmful compressive loads while maintaining a relatively simple overall structure through the use of straightforward load-path geometry.
Data Source
AI summary
An electric vehicle battery pack with a reinforced cover to better support vehicle cabin loads such as seat submerge loads, seat pitch loads, and the like. The cover has a number of reinforcing members affixed thereto and positioned over cross members of the battery pack frame. Loads imposed by the cabin are thus transferred to the reinforcing members and then to the rigid cross members. In this manner, battery packs of embodiments of the disclosure better support cabin loads applied thereto, improving their strength and better protecting more delicate components within the battery pack.