Underbody Battery Pack Layout for Sliding-Door Rail Space
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Solution Overview
Problem
Conventional high-voltage battery packs installed under vehicles with sliding doors face limitations in increasing battery capacity due to the need for rail mounting spaces and longitudinal cross members, which reduce the number of battery cells that can be mounted.
Innovation Solution
The proposed high-voltage battery pack design secures a rail mounting space on the lateral side of the battery module and uses this space to mount bus bars and sensing wires, eliminating the need for a longitudinal cross member. This configuration allows for additional battery mounting space, increasing the number of battery cells and thus the battery capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a longitudinal cross member is installed to secure collision safety and mount electrical components, then structural strength and electrical connectivity are improved, but battery mounting space is reduced and weight increases
Solution Approach 1:
The patent removes the longitudinal cross member from the battery pack structure, extracting this component that was previously used for both structural support and electrical connectivity. This elimination directly increases battery mounting space while maintaining safety through alternative structural designs and electrical connections through the rail mounting space.
Solution Approach 2:
The rail mounting space is designed to serve multiple functions: it provides structural support for the battery modules, enables electrical connectivity through bus bars and sensing wires, and maintains structural integrity for collision safety. This multi-functional design replaces the dual role previously fulfilled by the longitudinal cross member.
2Reliability
If a longitudinal cross member is installed to mount bus bars and sensing wires, then electrical connectivity is improved, but device complexity and cost increase
Solution Approach 1:
The patent eliminates the longitudinal cross member and its associated mounting structures for electrical components. Instead, bus bars and sensing wires are directly mounted on the rail mounting space, simplifying the overall structure while maintaining reliable electrical connectivity between battery modules.
Solution Approach 2:
The patent combines the structural support function and electrical connectivity function into a single integrated rail mounting space design. This merging eliminates the need for separate longitudinal cross members and reduces the number of components required for electrical connections, thereby reducing device complexity and cost.
3Strength
If a longitudinal cross member is installed, then structural support is improved, but weight increases
Solution Approach 1:
The patent removes the longitudinal cross member from the battery pack structure, directly reducing the overall weight of the battery assembly. The structural support function is maintained through the optimized rail mounting space and lower casing design, achieving weight reduction without compromising structural integrity.
4Quantity of substance
If rail mounting space is secured on lateral side, then battery capacity is increased, but electrical connection routing becomes more complex
Solution Approach 1:
The rail mounting space is designed to simultaneously accommodate battery modules and electrical connection components. This multi-functional design allows bus bars and sensing wires to be mounted within the same space used for battery support, enabling increased battery capacity while maintaining simple electrical connection routing through integrated pathways.
Data Source
AI summary
An embodiment high-voltage battery pack for mounting under a vehicle body in a vehicle equipped with a sliding door includes a lower casing in which a battery module is mounted, the lower casing defining a rail mounting space to mount a door rail on a lateral side of the battery module, the rail mounting space extending in a front-rear direction, and a bus bar and a sensing wire both mounted in the rail mounting space to electrically connect the battery module and electric components mounted on the lower casing.