Vehicle Battery System Spatial Efficiency and Noise Isolation
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Solution Overview
Problem
Existing battery systems for electric and hybrid vehicles are bulky, require significant space, and lack efficient cooling and noise isolation, leading to suboptimal spatial use, material costs, and potential occupant safety issues during crashes.
Innovation Solution
A compact battery system configuration with a battery module assembly, cooling fan, low voltage battery, power relay assembly, and battery management system aligned in specific directions, using a PRA mounting bracket for independent support and a ducted air cooling system to isolate noise, and a battery frame for occupant protection, with a base plate and upper cover for structural integrity and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a battery system with high voltage battery is mounted under the rear seat, then spatial efficiency in the vehicle body is improved, but the battery system requires a relatively large volume and complex cooling structure
Solution Approach 1:
The battery system is segmented into distinct functional modules: high voltage battery module, low voltage battery module, power relay assembly, and cooling device. Each module is independently arranged and can be optimally positioned within the limited space under the rear seat, allowing efficient space utilization while maintaining functional independence.
Solution Approach 2:
The system utilizes three-dimensional spatial arrangement by positioning components in multiple directions (front-rear, left-right, upper-lower) rather than simple linear arrangement. The battery modules are stacked vertically while cooling ducts extend horizontally, effectively using the available volume under the seat without increasing footprint area.
2Temperature
If a cooling device is added to cool the battery module assembly, then cooling performance is improved, but device complexity and material costs increase
Solution Approach 1:
The cooling device utilizes the vehicle's existing air conditioning system and natural air flow paths to cool the battery modules. Cooling ducts are integrated into the battery housing to guide ambient air through the battery modules, eliminating the need for separate active cooling mechanisms and reducing system complexity.
Solution Approach 2:
The cooling device serves multiple functions: it cools the high voltage battery modules, provides thermal management for the power relay assembly, and integrates with the vehicle's existing HVAC system. This multi-functionality reduces the need for separate cooling systems for different components.
3Area of stationary object
If the power relay assembly is installed adjacent to the battery modules, then spatial efficiency is improved, but noise may be introduced into the vehicle through the cooling path
Solution Approach 1:
The power relay assembly is physically separated from the battery module cooling path by positioning it in an adjacent but isolated location. The cooling ducts for the battery modules are routed to exclude the power relay assembly, effectively extracting the noise source from the cooling air flow path while maintaining compact overall arrangement.
Solution Approach 2:
Different regions of the battery system are assigned different functional qualities: the battery module region is optimized for thermal management with dedicated cooling ducts, while the power relay assembly region is positioned in a noise-isolated zone. This local differentiation allows compact arrangement while preventing noise propagation through the cooling path.
4Area of stationary object
If the battery system is mounted under the rear seat, then spatial efficiency is improved, but the sub-marine phenomenon of rear seat occupants may occur during crashes
Solution Approach 1:
The battery system housing and mounting structure are designed with energy-absorbing features and protective barriers that deform or absorb impact energy during crashes. This beforehand cushioning prevents the battery modules from directly impacting rear seat occupants, mitigating the sub-marine phenomenon while allowing the battery system to be positioned under the rear seat for optimal space utilization.
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 spatial efficiency, reduces material costs and weight, ensures effective and uniform cooling, prevents noise introduction, and mitigates the 'sub-marine phenomenon' for rear seat occupants by providing structural support and crash protection.
Implementation Method 1
a cooling fan installed to be aligned along the first direction on one side of the BMA and configured to discharge air cooling the BMA while passing therethrough
Implementation Method 2
an upper duct may be provided below the inlet duct and inclined downwardly toward the cooling fan from a duct hole, to which the inlet duct is connected, to uniformly supply the introduced air above each battery cell of the BMA
Data Source
AI summary
A battery system of a vehicle is provided and includes a battery module assembly (BMA) formed by overlapping a plurality of battery modules along a first direction, a cooling fan installed to be aligned along the first direction on one side of the BMA and configured to discharge air cooling the BMA while passing therethrough, a low voltage battery installed to be aligned along the first direction on the other side of the BMA, a power relay assembly (PRA) aligned along a second direction perpendicular to the first direction and installed adjacent to the low voltage battery, and a battery management system (BMS) aligned along a third direction perpendicular to the first direction and the second direction and installed adjacent to the low voltage battery and the PRA.