EV Battery Support Layer Integrating Contacting and Crash Protection
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Solution Overview
Problem
Existing drive battery housings for electric vehicles are complex and difficult to manufacture, requiring multiple components and support structures for rigidity and collision resistance.
Innovation Solution
A simplified drive battery design featuring a support layer between the battery cell layer and the bottom wall, which serves as a deformation layer to absorb collision energy and integrates the battery cell contacting system, reducing the number of components and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple longitudinal members and cross members are used in the drive battery housing, then the rigidity and collision resistance are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the support layer and battery cell contacting system into a single integrated component. The support layer serves multiple functions: it provides structural support, acts as a deformation layer for collision protection, and integrates the battery cell contacting system. This merging eliminates the need for separate longitudinal members and cross members, reducing device complexity while maintaining rigidity and collision resistance.
Solution Approach 2:
The support layer is designed as a multi-functional component that simultaneously provides structural support, collision protection through deformation, and electrical contacting functionality. By making one component perform multiple functions, the patent reduces the total number of components needed while achieving the required strength and rigidity.
2Strength
If additional longitudinal members and cross members are added to the drive battery housing, then the collision resistance is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The support layer is manufactured as a single integrated component that combines structural support, deformation capability, and battery cell contacting functions. This eliminates the need to manufacture and assemble multiple separate support members, significantly simplifying the manufacturing process while maintaining collision resistance.
Solution Approach 2:
The support layer is designed with integrated deformation zones that are segmented into specific regions for different functions (support, deformation, contacting). This segmentation is built into the single component design, allowing complex functionality to be achieved without complex assembly processes.
3Ease of operation
If the battery cell contacting system is separately assembled, then the ease of assembly is improved, but the production time and complexity increase
Solution Approach 1:
The battery cell contacting system is integrated into the support layer as a single component. This means the contacting elements are already positioned and secured during support layer manufacturing, eliminating the need for separate assembly operations. This improves production efficiency while maintaining ease of assembly through the simplified single-component structure.
Solution Approach 2:
The battery cell contacting system is pre-integrated into the support layer during its manufacturing process. This preliminary action of combining components before final assembly reduces the number of assembly steps required and improves overall production efficiency.
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 solution enhances the rigidity and strength of the drive battery while simplifying production, eliminating the need for additional support structures and ensuring a durable connection between the battery cell contacting system and the support layer.
Implementation Method 1
The support layer is arranged between the battery cell layer and the bottom wall to protect the battery cell layer in the event of a collision with the bottom wall. The support layer is designed as a carrier for the battery cell contacting system.
Implementation Method 2
the battery cell contacting system is conductively connected, in particular soldered or welded, to the contacts of each battery cell
Implementation Method 3
the battery cell contacting system is conductively connected, in particular soldered or welded, to the contacts of each battery cell
Implementation Method 4
The battery cell contacting system is preferably adhesively bonded to the support layer. This enables a durable and good connection between the battery cell contacting system and the support layer during operation of the drive battery
Data Source
AI summary
A drive battery for a motor vehicle has a drive battery housing with a bottom wall and a top wall, a battery cell layer arranged between the bottom wall and the top wall, and a plurality of battery cells and a battery cell contacting system. A support layer, which according to its function can also be called a deformation layer or spacer layer, is arranged between the battery cell layer and the bottom wall, in order to protect the battery layer in the event of a collision of the bottom wall. The support layer is designed as a carrier for the battery cell contacting system.