Battery Pack Enclosure Insulating Layer for NVH Isolation
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Solution Overview
Problem
Existing battery mounting systems in electric vehicles do not fully integrate the battery pack enclosure to utilize its rigidity and strength while protecting the battery from accidental damage and minimizing impact on vehicle occupant comfort and safety.
Innovation Solution
A battery pack enclosure system with an insulating layer for noise, thermal, and vibration damping, mounted between the passenger cabin floor panel and the driving surface, mechanically coupled to vehicle structural members, and featuring a ballistic shield for additional protection, utilizing materials like aluminum, steel, and ceramic fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is mounted directly to the vehicle floor panel, then the integration is simple and secure, but the battery pack may cause noise, thermal transfer, and vibration transmission to the passenger cabin
Solution Approach 1:
An insulating layer is introduced as an intermediary component between the battery pack enclosure and the vehicle floor panel. This layer serves multiple functions: it provides thermal insulation to reduce heat transfer to the passenger cabin, acts as a sound barrier to reduce noise transmission, and dampens vibrations from the battery pack. The insulating layer is secured to both the battery pack enclosure and the floor panel, creating a buffered connection that maintains mounting security while blocking harmful transmissions.
2Strength
If the battery pack enclosure is integrated into vehicle structural members, then the rigidity and strength of the battery pack can be utilized to enhance vehicle structure, but the battery pack may be vulnerable to damage from impact loads during collisions
Solution Approach 1:
A deformable portion is incorporated into the mounting structure that connects the battery pack enclosure to the vehicle frame. This deformable portion is designed to yield or deform under high impact loads during collisions, thereby cushioning the battery pack from direct impact forces. The deformable portion allows controlled deformation to absorb impact energy while maintaining the structural integration benefits, preventing battery pack damage during collision events.
3Reliability
If a deformable portion is added to the mounting structure to protect the battery pack during collision, then the battery pack is protected from impact damage, but the device complexity increases
Solution Approach 1:
The deformable portion is merged with the existing mounting structure that connects the battery pack enclosure to the vehicle frame. Rather than adding a separate protective mechanism, the deformable characteristics are integrated into the mounting structure itself. This allows the mounting structure to serve dual functions: providing structural support during normal operation and providing impact protection during collisions through controlled deformation, thereby reducing overall device complexity.
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 system enhances vehicle performance and impact resistance, provides effective noise isolation, thermal management, and passenger comfort by integrating the battery pack's strength, while minimizing damage and ensuring safety during collisions.
Implementation Method 1
at least one insulating layer interposed between the battery pack enclosure and the passenger cabin floor panel, where the insulating layer provides noise isolation
Implementation Method 2
the insulating layer provides thermal isolation
Implementation Method 3
the insulating layer provides vibration damping
Data Source
AI summary
An improved integration system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing at least one insulating layer interposed between the battery pack enclosure and the passenger cabin floor panel, where the insulating layer provides noise isolation, thermal isolation and vibration damping, and where the insulating layer is compressed when the battery pack enclosure is mounted to the vehicle.