Battery Junction Box Housing Directing Crash Forces
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Solution Overview
Problem
Conventional electric vehicle battery housing designs lack effective crash force management, which can lead to damage to battery modules and associated electrical components during accidents, potentially causing fires and safety hazards.
Innovation Solution
A battery housing arrangement with a center structural support bar and a battery junction box (BJB) housing positioned between this bar and vehicle chassis bars, directing crash forces to the structural support bar to protect the battery modules and electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery housing designs are used without crash force management structures, then the device complexity is reduced, but the protection of battery modules and electrical components from crash forces is insufficient
Solution Approach 1:
The battery junction box housing is merged with crash force management functionality by positioning it between the center structural support bar and vehicle chassis bars, creating a multi-functional component that both houses electrical components and directs crash forces
Solution Approach 2:
The battery junction box housing serves as an intermediary structure that transfers crash forces from the vehicle chassis bars to the center structural support bar, protecting the battery modules while managing structural loads
2Reliability
If the BJB housing is positioned between the center structural support bar and vehicle chassis bars to direct crash forces, then the protection of electrical components is improved, but the device complexity increases
Solution Approach 1:
The battery junction box housing performs multiple functions simultaneously: it houses electrical components for power distribution and serves as a structural element for crash force management, eliminating the need for separate protective structures
3Strength
If the housing stiffness is enhanced to improve crash force direction, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The housing structure is designed as an integrated assembly combining the battery junction box, electrical components, and crash force management features into a single manufacturable unit, reducing overall manufacturing complexity
Data Source
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AI summary
In an embodiment, a battery housing arrangement integrated into a vehicle floor of an electric vehicle includes a BJB housing including a BJB configured to be electrically coupled to each of a plurality of battery modules in a battery housing upon installation of the plurality of battery modules into the battery housing. The BJB housing is positioned between at least one center structural support bar and one or more vehicle chassis bars, and is configured to protect the plurality of battery modules in the battery housing from crash forces by directing crash forces from the one or more vehicle chassis bars to the at least one center structural support bar.