Curved Floor-Pan Battery Pack for Aerodynamic Space Utilization
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Solution Overview
Problem
Existing vehicular battery packs with planar surfaces cause aerodynamic inefficiencies due to unevenness in the floor pan, leading to reduced rear aerodynamic load and inefficient space usage, particularly in high-performance vehicles.
Innovation Solution
A vehicular battery pack with a support structure featuring a curved floor pan design that houses cylindrical electrochemical cells arranged in parallel strips, maximizing space usage and maintaining aerodynamic downforce by preventing fluid detachment, combined with a method of assembling these cells to optimize both aerodynamics and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a planar floor pan is used to support battery modules, then space utilization is optimized, but aerodynamic performance deteriorates due to fluid detachment
Solution Approach 1:
The floor pan is designed with a curved configuration instead of a planar surface. The curvature radius varies along the longitudinal axis, creating a smooth transition that prevents fluid detachment while maximizing the volume available for battery module placement. This curved geometry simultaneously improves aerodynamics and space utilization.
Solution Approach 2:
The floor pan incorporates a variable curvature radius along its longitudinal axis, transitioning from a first curvature radius in the front portion to a second curvature radius in the rear portion. This dynamic geometric variation optimizes both aerodynamic flow characteristics and space utilization for battery modules at different locations.
2Object-affected harmful factors
If an angled floor pan is used to improve rear aerodynamic load, then aerodynamic performance improves, but space utilization deteriorates
Solution Approach 1:
Instead of using an angled floor pan configuration, the invention employs a curved floor pan with optimized curvature radii. This curved geometry maintains rear aerodynamic load by preventing fluid detachment while providing superior space utilization compared to angular configurations.
3Object-affected harmful factors
If cylindrical batteries are arranged with longitudinal axis perpendicular to floor pan, then aerodynamic performance improves, but manufacturing complexity increases
Solution Approach 1:
The floor pan curvature is designed to accommodate cylindrical batteries arranged parallel to each other with their longitudinal axes perpendicular to the floor pan. The varying curvature radius allows optimal positioning of batteries while maintaining aerodynamic performance and simplifying the manufacturing process compared to more complex curved arrangements.
Data Source
AI summary
A vehicular battery pack comprising a floor configured to define, at least in part, a floor pan of a road vehicle; cylindrical electrochemical cells, electrically connected to each other and arranged on the inner surface of the floor; each of the cylindrical electrochemical cells comprises a lateral surface having a circular cross-section extending along an axis of symmetry; the floor of the support structure has an at least partially curved conformation, which deflects distancing itself from the ground along the longitudinal axis in a direction opposite a normal travel direction of the road vehicle; wherein said electrochemical cells are arranged with said respective lateral surface in contact with the inner surface of the floor.