Multi-Chamber Battery Undertray With Integrated Intrusion Sensing
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Solution Overview
Problem
Existing underbody components for motor vehicles lack effective lightweight protection and reliable damage detection systems, particularly for traction batteries, which are prone to damage from external forces like collisions and stone chips.
Innovation Solution
A multi-chamber underbody component with a plate-like element and support elements, integrated with an electrically conductive sensor wire that detects penetration by measuring changes in electrical resistance, allowing for the assessment of damage intensity and localization, and is designed to be lightweight and cost-effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor device is integrated into the underbody component to detect damage, then damage detection capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The sensor wire is integrated directly into the plate element during the molding process, combining the structural component with the sensing function into a single integrated element. This eliminates separate sensor installation and reduces overall device complexity while maintaining damage detection capability.
Solution Approach 2:
The plate element serves dual functions: providing mechanical protection as a structural component and detecting damage through the integrated sensor wire. This multi-functionality reduces the need for separate components and simplifies the overall device structure.
2Reliability
If a sensor device is integrated into the underbody component to detect damage, then damage detection capability is improved, but manufacturing cost increases
Solution Approach 1:
The sensor wire is embedded into the plate element during the molding process, combining manufacturing steps and eliminating separate sensor installation. This integration reduces overall manufacturing complexity and cost despite adding sensing functionality.
Solution Approach 2:
The plate element itself serves as the mounting structure for the sensor wire, eliminating the need for separate mounting components and installation steps. The structure provides its own sensing capability through the integrated wire.
3Weight of moving object
If the plate element is made lightweight using plastic or foamed core materials, then weight is reduced, but strength and protection capability may be compromised
Solution Approach 1:
The plate element is constructed from fiber-reinforced plastic or foamed core materials with outer layers, combining lightweight materials with strength-providing reinforcement. This composite structure achieves both weight reduction and adequate protection capability.
Solution Approach 2:
The plate element can have varying material properties in different regions, with reinforced areas providing additional strength where needed and lighter materials used in less critical areas, optimizing the balance between weight and protection.
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 provides enhanced protection and reliable damage detection, enabling the differentiation between critical and non-critical damage, facilitating timely protective measures such as warning systems and preventing further damage to the vehicle components.
Implementation Method 1
a sensor device having at least one electrically conductive sensor wire arranged in or on the plate element, wherein the sensor device is provided to detect or record an intrusion of the plate element into at least one of the chambers caused by an external force from below
Data Source
Figure 1~2b
Figure 3~5
AI summary
The invention relates to an undertray component (500) for a motor vehicle (100), comprising - a plate element (510) which has a bottom side and a top side; - at least one supporting element (520) which is arranged on the top side of the plate element (510) and is provided for supporting and spacing apart the plate element (510) with respect to a vehicle-side structure, wherein this supporting element (520) is designed at the same time as a separating wall which subdivides the region above the plate element (510) into a plurality of chambers (530); - a sensor device which is provided for detecting an ingress of the plate element (510) into at least one of the chambers (530) due to an external action of force (K) onto the bottom side. The invention further relates to a battery arrangement (200) for a motor vehicle, said battery arrangement having such an undertray component (500).