EV Battery Underbody Sandwich Shield for Impact and Gas Venting
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Solution Overview
Problem
The underbody of electrically drivable motor vehicles, particularly in cell-to-pack storage system architectures, lacks effective protection against intrusion and corrosion, and the entire high-voltage storage system must often be replaced in case of damage, with thermal runaway posing additional risks.
Innovation Solution
A reversibly secured underbody protection device with a sandwich structure, comprising fiber-reinforced plastic elements and a spacer, which can be easily replaced and includes a housing lower part with break points for gas release during thermal runaway, combined with an impact absorption structure for enhanced stability and gas conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the housing lower part is designed without additional reinforcement (cell-to-pack architecture), then the device complexity is reduced, but the underbody protection against intrusion deteriorates
Solution Approach 1:
The underbody protection device is divided into multiple modular elements (first underbody element, second underbody element, and additional elements) that can be independently manufactured and assembled. Each element covers specific regions of the battery housing, allowing the protection system to be built from discrete components rather than a monolithic structure.
Solution Approach 2:
The underbody protection elements are made from composite materials, specifically fiber-reinforced plastics (such as glass fiber or carbon fiber reinforced plastic). These composite materials provide high strength and stiffness-to-weight ratio, enabling effective intrusion protection without adding excessive weight or structural complexity to the housing design.
2Reliability
If the entire high-voltage storage system is replaced in case of damage, then the reliability is maintained, but the loss of time and productivity deteriorate
Solution Approach 1:
The protection system is segmented into modular elements that are reversibly secured to the battery housing. This segmentation allows individual damaged elements to be replaced independently rather than replacing the entire storage system, significantly reducing replacement time while maintaining system reliability.
Solution Approach 2:
The underbody protection device is designed with reversible securing mechanisms (such as snap-fit connections or removable fasteners) that enable dynamic assembly and disassembly. This allows for quick replacement of damaged protection elements without permanent attachment, facilitating rapid maintenance and reducing vehicle downtime.
3Strength
If the underbody protection device is made from fiber-reinforced plastic, then the strength is improved, but the weight increases
Solution Approach 1:
The protection elements utilize fiber-reinforced plastics (glass fiber or carbon fiber reinforced plastic) which provide exceptional strength-to-weight ratio. These composite materials deliver the necessary mechanical strength for intrusion protection while keeping the overall weight significantly lower than traditional metal alternatives.
Solution Approach 2:
The underbody protection elements are designed with varying thicknesses and fiber orientations in different regions. Areas requiring higher strength (such as regions directly over battery cells) have increased thickness or enhanced fiber reinforcement, while less critical areas use thinner sections. This localized optimization provides necessary strength while minimizing overall weight.
4Ease of repair
If the underbody protection device is reversibly secured to the battery housing, then the ease of repair is improved, but the reliability deteriorates due to potential detachment
Solution Approach 1:
The attachment system employs reversible securing mechanisms that balance permanent fixation with removable capability. These mechanisms (such as snap-fit connections with latches or threaded fasteners with locking features) provide secure attachment during normal operation while allowing controlled disassembly for replacement when needed.
Solution Approach 2:
The attachment design incorporates built-in safety features and redundancy to prevent accidental detachment. This may include multiple attachment points, interlocking features, and positioning elements that ensure the protection device remains securely attached under all operational conditions while still allowing intentional removal for repair or replacement.
Data Source
AI summary
Please substitute the new Abstract submitted herewith for the original Abstract; An apparatus for an electrically drivable motor vehicle includes an underbody protection device. The underbody protection device is configured to be reversibly secured to a battery housing of a traction battery of the electrically drivable motor vehicle and that covers at least some regions of the battery housing toward a bottom of a vehicle vertical direction in an installed position. The underbody protection device has a first underbody element and a second underbody element, between which a spacer is arranged, such that the underbody elements form a sandwich structure with the spacer.