Convex Battery Housing Bottom for Impact Protection
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Solution Overview
Problem
Existing battery housings for electric-motor-driven vehicles face challenges in providing effective protection for battery modules while maintaining a low profile and cost-effectiveness, which often results in increased vehicle weight and reduced ground clearance due to additional protective components.
Innovation Solution
A battery housing design featuring a convexly curved bottom part that connects to support elements, allowing forces to be diverted into stable support structures, thereby enhancing protection without significant height increase, achieved through non-positive connections and optimized material usage, such as steel plate components with reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional protective components (underbody linings, hoop guards) are added to protect battery modules, then protection level is improved, but vehicle weight increases and ground clearance is reduced
Solution Approach 1:
The patent combines the protective function with the existing bottom part structure by integrating support elements directly into the bottom part. This merging eliminates the need for separate protective components while maintaining protection functionality, thereby reducing vehicle weight.
Solution Approach 2:
The bottom part is designed to serve multiple functions simultaneously: it provides structural support for battery modules, acts as a protective element against impacts, and maintains ground clearance. This multi-functionality eliminates the need for dedicated protective components.
2Reliability
If additional protective components (underbody linings, hoop guards) are added to protect battery modules, then protection level is improved, but ground clearance is reduced
Solution Approach 1:
The protective function is merged into the bottom part structure itself through integrated support elements. This eliminates the need for additional protective components that would increase the overall height and reduce ground clearance.
Solution Approach 2:
The bottom part serves as both a support structure and a protective element, providing multi-functionality without requiring additional components that would compromise ground clearance.
3Ease of manufacture
If conventional flat bottom part design is used, then manufacturing is simple, but protection capability during impacts is insufficient
Solution Approach 1:
The support elements are designed with a curved, arch-like geometry instead of flat surfaces. This curvature enables the structure to dissipate impact energy more effectively by distributing forces along the curved path, while still being manufacturable using standard forming processes.
Solution Approach 2:
The patent changes the geometric parameters of the bottom part by introducing curved support elements with specific arch shapes. This parameter change enhances the protective capability during impacts while maintaining manufacturing feasibility through standard forming operations.
4Reliability
If support elements are closely spaced to improve protection, then protection capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The curved, arch-like geometry of the support elements provides enhanced protection capability with improved energy dissipation during impacts. This geometric feature allows adequate protection with fewer, more strategically positioned support elements, reducing structural complexity.
Solution Approach 2:
By optimizing the geometric parameters of the support elements (curvature radius, arch height), the patent achieves effective protection with a reduced number of elements, thereby simplifying the overall structure and reducing manufacturing complexity.
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
This design effectively dissipates energy during impacts, providing enhanced protection for battery modules with reduced weight and cost, allowing for greater energy absorption before potential damage, while maintaining vehicle ground clearance.
Implementation Method 1
This design effectively dissipates energy during impacts, providing enhanced protection for battery modules with reduced weight and cost, allowing for greater energy absorption before potential damage
Data Source
AI summary
A battery housing for an electric-motor-driven vehicle comprising a tub-like housing part having a plurality of support elements arranged at a distance from each other, and having a bottom part supported on the support elements. The bottom part is convexly curved toward the outside of the housing part in the longitudinal and/or transverse extent in the span of the bottom part between each pair of adjacent support elements arranged at a distance from each other, and is connected in the direction of the curvature to the support elements between which the span of the arch extends.