Floor Carpet Wall for Battery Pack Water Protection
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Solution Overview
Problem
Conventional methods for protecting battery packs in vehicles from water exposure, such as using waterproof trays, are not feasible due to space, cost, or mass constraints, necessitating an alternative solution to prevent water ingress.
Innovation Solution
A waterproof structure comprising an underbody with a floor carpet that has a wall portion rising around the battery pack, a bent-back portion for enhanced rigidity, and a covering member to conceal the edge, effectively preventing water entry by directing it away from the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a waterproof tray is used to protect the battery pack from water, then the battery pack is protected from water exposure, but the vehicle space, cost, and mass are adversely affected
Solution Approach 1:
The waterproof function is merged with the existing floor carpet by forming an integrated wall portion from the carpet's peripheral edge. This combines the flooring element with water protection functionality, eliminating the need for a separate waterproof tray and reducing overall mass.
Solution Approach 2:
The floor carpet is given multiple functions: it serves as both the vehicle interior flooring and as a waterproof barrier. The wall portion formed from the carpet's edge provides both structural support and water containment, making the single component multi-functional.
2Object-affected harmful factors
If a waterproof tray is used to protect the battery pack from water, then the battery pack is protected from water exposure, but the vehicle space and cost are adversely affected
Solution Approach 1:
The waterproof function is merged with the existing floor carpet by forming an integrated wall portion from the carpet's peripheral edge. This combines the flooring element with water protection functionality, eliminating the need for a separate waterproof tray and reducing overall mass.
3Object-affected harmful factors
If the wall portion height is increased to prevent water entry, then water protection is improved, but the rigidity of the floor carpet edge deteriorates
Solution Approach 1:
The bent-back portion is formed in advance to counteract the potential weakness of the wall portion. By creating this reinforcing structure beforehand, the design prevents the wall portion from collapsing or deforming under water pressure while maintaining the necessary height for water containment.
Solution Approach 2:
The solution moves from a single-dimensional vertical wall to a two-dimensional structure by adding the bent-back portion that extends horizontally. This creates a fold-back reinforcement that adds structural strength without increasing the wall height, effectively using spatial dimensionality to solve the rigidity problem.
4Object-affected harmful factors
If the wall portion is made visible from the vehicle interior, then the waterproof structure is functional, but the vehicle design quality deteriorates
Solution Approach 1:
The aesthetic concern is extracted and separated from the waterproof function by using the covering member to hide the wall portion. The waterproof function remains intact while the visual appearance is improved by concealing the functional element that might be aesthetically displeasing.
Solution Approach 2:
The covering member acts as an intermediary element between the functional wall portion and the vehicle interior space. It mediates by providing visual coverage while allowing the waterproof structure to function behind it, thus resolving the conflict between functionality and aesthetics.
Data Source
AI summary
Exposure of a battery pack to water is suppressed. The battery pack is mounted on an underbody. A floor carpet laid on the underbody in the vicinity of the battery pack has a wall portion formed of a peripheral edge portion along the battery pack rising upward.