EV Battery Pack Underfloor Reinforcement Against Road Impact
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Solution Overview
Problem
The increase in battery capacity in electric motor vehicles, which reduces the number of frame members in the casing, leads to increased distances between points of attachment for the share panel, making the battery pack susceptible to damage from impulsive forces from the road surface.
Innovation Solution
The implementation of external reinforcements attached to the casing's outer face, with a share panel covering the bottom plate, and a shock absorber mechanism to absorb impact energy, reducing direct force transmission to the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of frame members in the casing is reduced to increase battery capacity, then the battery capacity increases, but the distance between attachment points increases making the battery pack more susceptible to damage from impulsive forces
Solution Approach 1:
The patent introduces external reinforcements as separate structural elements attached to the casing's outer face. These reinforcements segment the load path by providing additional attachment points for the share panel, thereby distributing impulsive forces across multiple localized points rather than allowing them to concentrate between widely spaced frame members. This segmentation approach enables increased battery capacity with fewer frame members while maintaining reliability through the added reinforcement elements.
Solution Approach 2:
The external reinforcements act as intermediary elements between the share panel and the casing's internal frame structure. When impulsive forces occur, these reinforcements serve as mediators that distribute and transfer loads through multiple attachment points, preventing direct force transmission to the battery pack. This intermediary structure resolves the contradiction by enabling both reduced frame member count and maintained force resistance.
2Stability of the object's composition
If the share panel is rigidly attached to the casing to prevent movement, then structural stability improves, but impact energy is directly transmitted to the casing causing damage
Solution Approach 1:
The patent incorporates shock absorbers at the attachment points between the share panel and external reinforcements. These shock absorbers provide beforehand cushioning by being pre-positioned to absorb impact energy before it can be transmitted to the casing. The shock absorbers maintain share panel stability during normal operation while activating during impacts to prevent damage, thus resolving the contradiction between stability and impact protection.
Solution Approach 2:
The patent converts the harmful impulsive forces into beneficial energy absorption through the shock absorbers. When impacts occur, the shock absorbers transform the harmful kinetic energy into other forms (such as elastic deformation or heat), preventing this energy from damaging the casing. This conversion approach allows the share panel to remain stably attached while protecting the casing from impact damage.
3Reliability
If multiple frame members are disposed within the casing to reduce attachment distances, then resistance to impulsive force improves, but the battery capacity decreases due to reduced space for cells
Solution Approach 1:
The patent moves the reinforcement structure from the internal dimension (within the casing) to the external dimension (on the outer face of the casing). By attaching external reinforcements to the exterior surface, the patent provides additional load-bearing points without occupying internal space that would be available for battery cells. This dimensional shift resolves the contradiction by enabling improved force resistance through additional structural elements without reducing battery capacity.
Solution Approach 2:
The external reinforcements are nested onto the existing casing structure, utilizing the outer surface of the casing as a mounting substrate. This nesting approach allows the addition of reinforcement elements without requiring internal space, as the reinforcements are attached externally. The share panel then attaches to these nested reinforcements, creating a multi-layered attachment system that maintains battery capacity while improving impulsive force resistance.
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 configuration effectively reduces damage to the battery pack by absorbing and dispersing impulsive forces, while allowing for easy replacement of the share panel and maintaining structural integrity.
Implementation Method 1
the share panel may be detachably attached, with a shock absorber, to the first lower face of the first external reinforcement. This configuration enables the shock absorber to absorb the impact energy input to the first external reinforcement, thereby reducing damage to the casing caused by the impulsive force from the road surface.
Implementation Method 2
the shock absorber may be a resin adhesive tape interposed between the first lower face of the first external reinforcement and an upper face of the share panel. This configuration enables the adhesive tape to absorb the impact energy input to the first external reinforcement, thereby reducing damage to the casing caused by the impulsive force from the road surface.
Data Source
AI summary
An electric motor vehicle includes a battery pack including a casing containing cells and mounted under a floor of the vehicle, a first external reinforcement attached to an outer face of a bottom plate of the casing, and a share panel disposed under the first external reinforcement to cover the bottom plate of the casing. The first external reinforcement is disposed to overlap with the cells in a top view. The share panel is attached to a first lower face of the first external reinforcement.