Cell-to-Body Battery Pack Structure for Lighter EV Floors
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Solution Overview
Problem
Existing electric vehicle designs face challenges in weight reduction and energy density due to separate floor panels and cell pack cases, leading to reduced endurance mileage and increased structural weight.
Innovation Solution
A cell-to-body structure where the top of the power cell pack case serves as both part of the cell pack and the vehicle's floor panel, integrated with a cross beam connecting to the vehicle body, reducing structural redundancy and enhancing stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate floor panel and cell pack case are used, then structural strength is improved, but vehicle weight increases
Solution Approach 1:
The patent merges the floor panel and cell pack case into a single integrated structure where the cell pack case top surface serves dual functions as both the cell pack cover and the vehicle floor panel. This eliminates the need for a separate floor panel, reducing structural redundancy and vehicle weight while maintaining structural strength through the integrated design.
2Stability of the object's composition
If separate floor panel and cell pack case are used, then structural stability is improved, but energy density decreases
Solution Approach 1:
By integrating the floor panel function into the cell pack case structure, the patent eliminates redundant structural components, thereby increasing the space available for battery cells. This integration maintains structural stability through the cross beam and mounting portions while increasing energy density by maximizing the battery volume within the vehicle floor area.
3Weight of moving object
If integrated cell pack case and floor panel are used, then vehicle weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The integrated structure is designed with modular segmentation, where the cell pack case includes distinct functional elements (mounting portions, cross beam, sealing structures) that can be manufactured separately and then assembled. This segmentation approach reduces manufacturing complexity compared to creating a fully integrated monolithic structure, while still achieving the weight reduction benefits of integration.
4Device complexity
If integrated cell pack case and floor panel are used, then structural redundancy is reduced, but connection complexity increases
Solution Approach 1:
The cell pack case is designed with universal mounting portions that serve multiple functions: structural connection to the vehicle body, sealing interface, and battery assembly mounting. The cross beam structure provides both structural support and mounting functionality. This multi-functionality reduces the need for separate connection components, thereby reducing connection complexity despite the integrated design.
Data Source
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AI summary
The disclosure relates to a cell-to-body structure and a vehicle, belongs to the field of vehicles. The cell-to-body structure includes a vehicle body (1) and a power cell pack (2), the vehicle body (1) includes two sill beams (11) which being arranged in a spaced manner in a left-right direction of a vehicle, a cell pack mounting portion is on each of the sill beams (11); the power cell pack (2) includes a cell pack case (21) which including a case body (211) and a cross beam (24), the case body (211) being connected to the cell pack mounting portion, the cross beam (24) extending in the left-right direction, being located between the two sill beams (11) and integrated at a top of the case body (211) and connected to the vehicle body (1), the top of the case body (211) being used as a floor panel of the vehicle.