Cell-to-Body Battery Pack Structure With Integrated Floor Panel
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Solution Overview
Problem
The existing vehicle body structures in electric vehicles have large weight due to separate platy structures for the cell pack case top and floor panel, leading to reduced energy density and endurance mileage, with safety gaps increasing vehicle size and decreasing space utilization.
Innovation Solution
A cell-to-body structure where the power cell pack case body is integrated with a cross beam acting as the vehicle's floor panel, connected to sill beams, enhancing stability and safety by dispersing external forces and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate platy structures are used for cell pack case top and floor panel, then structural strength is improved, but vehicle weight increases
Solution Approach 1:
The patent merges the cell pack case top and the floor panel into a single integrated structure. The case body's top surface directly serves as the floor panel of the vehicle passenger compartment, eliminating the need for separate structural components. This integration reduces the number of parts and overall weight while maintaining structural strength through the unified design.
2Reliability
If safety gaps are increased between cell pack case top and floor panel, then safety is improved, but vehicle size increases
Solution Approach 1:
The patent eliminates the safety gap by merging the case body top with the floor panel. The integrated structure allows the case body top to directly form the floor panel surface, removing the need for spacing between these components. Safety is maintained through the structural integrity of the integrated design and the cross beam reinforcement rather than through physical gaps.
Solution Approach 2:
The patent addresses safety concerns by transitioning from a vertical spacing approach to a horizontal reinforcement approach. Instead of creating vertical gaps for safety, the design uses a cross beam extending in the left-right direction to provide structural reinforcement and safety, effectively moving the safety mechanism to a different dimensional plane.
3Ease of manufacture
If separate structures are used for cell pack case and vehicle body, then manufacturing flexibility is improved, but device complexity increases
Solution Approach 1:
The patent combines the cell pack case and vehicle body structures into an integrated assembly. The case body is directly connected to the vehicle body through the cross beam, forming a unified structure that reduces the number of separate components. This integration simplifies the overall device complexity while maintaining manufacturing flexibility through modular assembly processes.
Data Source
AI summary
A cell-to-body structure includes a vehicle body and a power cell pack, where the vehicle body includes two sill beams, the two sill beams being arranged in a spaced manner in a left-right direction of a vehicle, and a cell pack mounting portion is on each of the sill beams; and the power cell pack includes a cell pack case, the cell pack case including a case body and a cross beam, the case body being connected to the cell pack mounting portion, the cross beam extending in the left-right direction, being located between the two sill beams, being integrated at a top of the case body and being connected to the vehicle body, and the top of the case body being used as a floor panel of the vehicle.