EV Battery Pack Overlap Sealing for Clean Replacement Gaps
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Solution Overview
Problem
Conventional electric vehicles face inefficiencies in fuel economy due to the difficulty in mounting and removing battery systems, which can lead to foreign matter entering the underbody and accumulating between batteries and the chassis frame during battery replacement.
Innovation Solution
An electric vehicle body design that includes at least one battery pack with a cover bracket and an undercover that overlap to seal off gaps between battery packs, preventing foreign matter from entering and facilitating easy battery replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a battery pack is removably mounted on the chassis frame to facilitate battery replacement, then battery replacement efficiency is improved, but foreign matters may enter the underbody through the exposed area
Solution Approach 1:
The cover bracket is pre-installed on the battery pack before removal, and the undercover is pre-positioned on the chassis frame. When the battery is removed, these pre-positioned components automatically seal the exposed area, preventing foreign matter entry before the problem can occur.
Solution Approach 2:
The cover bracket and undercover act as intermediary components between the battery pack and the chassis frame. They seal the gap formed during battery replacement, serving as a protective barrier that prevents foreign matters from entering the underbody while allowing battery removal and installation.
2Duration of action of moving object
If the battery system is mounted in the vehicle for short-distance trips, then the vehicle can operate, but fuel economy deteriorates due to the heavy battery relative to energy needed
Solution Approach 1:
The battery system transitions from a fixed configuration to a dynamic, replaceable configuration. Users can adjust the battery setup based on trip distance requirements, enabling the vehicle to operate with appropriate battery capacity for each journey, thus optimizing energy efficiency while maintaining operational capability.
Solution Approach 2:
The battery system is divided into modular, replaceable units that can be selectively mounted or removed. This segmentation allows users to carry only the necessary battery capacity for their specific trip needs, reducing unnecessary weight and improving fuel economy for short-distance trips while maintaining full operational capability when needed.
Data Source
AI summary
An electric vehicle body can be configured to minimize the entry of foreign matters in a replaceable battery pack region while facilitating battery pack replacement. An electric vehicle body can include first and second battery packs replaceably mounted on a chassis frame, a cover bracket extending on one side of the first battery pack, and an undercover extending on one side of the second battery pack adjacent to the first battery pack and overlapping the cover bracket to seal off a gap between the first battery pack and the second battery pack.