Vehicle Center Floor Structure with Integrated Battery Upper Case
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Solution Overview
Problem
Conventional electric vehicles with high-voltage battery assemblies mounted under the center floor panel increase the weight and manufacturing cost of the center floor structure.
Innovation Solution
A center floor structure with an integrated battery upper case, where the battery assembly is mounted under the center floor panel to cover an opening, using a weather strip for sealing and reinforcing beads for enhanced torsional stiffness, reducing weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-voltage battery assembly is mounted under the center floor panel, then the battery can be protected and the passenger compartment can be sealed, but the weight and manufacturing cost of the center floor structure increase
Solution Approach 1:
The battery upper case is merged with the center floor panel to form an integrated structure. The battery upper case serves dual functions as both the battery enclosure and the center floor panel, eliminating the need for a separate center floor panel and reducing overall weight while maintaining protection and sealing functions
Solution Approach 2:
The battery upper case is designed to perform multiple functions: it serves as the battery enclosure, the center floor panel, and provides sealing for the passenger compartment. This multi-functional design reduces the number of components and overall weight while maintaining all necessary functions
2Reliability
If a high-voltage battery assembly is mounted under the center floor panel, then the battery can be protected and sealed, but the manufacturing cost of the center floor structure increases
Solution Approach 1:
The battery upper case and center floor panel are merged into a single integrated component, reducing the number of parts that need to be manufactured, assembled, and sealed separately. This integration reduces manufacturing complexity and cost while maintaining protection and sealing functions
Solution Approach 2:
The battery upper case is designed as a multi-functional component that replaces both the battery enclosure and center floor panel. This reduces the total number of manufacturing processes and assembly steps required, thereby reducing manufacturing cost while maintaining all necessary functions
3Strength
If the center floor panel is made solid without openings, then structural strength is improved, but weight increases
Solution Approach 1:
The battery upper case is divided into multiple sections with recessed portions and protruding portions that create a segmented structure. This segmentation provides structural reinforcement similar to a solid panel while reducing material usage and weight
Solution Approach 2:
The battery upper case incorporates curved surfaces and rounded corners in its design. These curved features provide structural strength and rigidity while using less material than flat, solid panels, thereby reducing weight while maintaining strength
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 effectively reduces the overall weight and manufacturing cost of the center floor structure while ensuring adequate sealing and improved torsional stiffness, facilitating easier battery assembly replacement and enhanced passenger compartment sealability.
Implementation Method 1
The sealing profile and the lip portion may be deformed by an external force
Implementation Method 2
The battery upper case may include a plurality of beads formed on a top surface thereof. Each of the reinforcing beads may extend in an inclined direction with respect to a longitudinal axis of the battery upper case
Data Source
AI summary
A center floor structure for a vehicle, includes: a center floor panel having an opening, and a peripheral portion of the center floor panel defining the opening; and a battery assembly mounted under the center floor panel, and covering the opening of the center floor panel. The opening is defined in a central portion of the center floor panel, and the peripheral portion includes a plate structure.