Multi-Layer Thermal Barrier for EV Battery Pack Integration
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Solution Overview
Problem
Existing battery mounting systems in electric vehicles do not effectively integrate the battery pack to utilize its rigidity and strength while minimizing impact on vehicle occupant comfort and safety, and fail to adequately isolate the battery pack from the passenger compartment for noise, thermal, and vibration damping.
Innovation Solution
A multi-layer thermal barrier is interposed between the battery pack enclosure and the passenger cabin floor, comprising a compressible elastic material and a thermally insulating material, providing noise isolation, thermal insulation, and vibration damping, and including a moisture barrier to enhance passenger comfort and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery pack is mounted directly to the vehicle floor panel, then structural integration and impact resistance are improved, but noise, heat, and vibration are transmitted to the passenger compartment
Solution Approach 1:
A multi-layer thermal barrier is introduced as an intermediary component between the battery pack enclosure and the passenger cabin floor panel. This barrier includes a compressible elastic material layer and a thermally insulating material layer, which together provide thermal isolation, noise isolation, and vibration damping while maintaining structural integration.
Solution Approach 2:
The thermal barrier employs composite material construction with at least two distinct layers: a compressible elastic material providing mechanical compliance and noise isolation, and a thermally insulating material providing thermal barrier properties. This composite structure addresses multiple harmful transmissions simultaneously.
2Temperature
If a thermal barrier is added between the battery pack and passenger compartment, then thermal isolation and noise isolation are improved, but the complexity of the mounting system increases
Solution Approach 1:
The thermal barrier is designed to perform multiple functions simultaneously: thermal insulation, noise isolation, vibration damping, and moisture barrier protection. By consolidating these functions into a single multi-layer component, the system complexity is minimized while achieving comprehensive protection.
Solution Approach 2:
Multiple protective functions (thermal barrier, acoustic barrier, vibration damper, moisture barrier) are merged into a single integrated thermal barrier assembly that is interposed between the battery pack and passenger compartment, simplifying the overall mounting system.
3Stability of the object's composition
If the battery pack is fully integrated into the vehicle floor structure, then structural strength and rigidity are improved, but passenger comfort is reduced due to noise and vibration
Solution Approach 1:
The compressible elastic material layer is positioned specifically at the interface between the battery pack enclosure and the passenger cabin floor panel, providing localized vibration damping and noise isolation precisely where needed to protect passenger comfort while maintaining overall structural rigidity.
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 integrates the battery pack into the vehicle structure, enhancing performance and impact resistance, while providing significant noise isolation, thermal isolation, and vibration damping, ensuring passenger comfort and safety by minimizing the transfer of noise, heat, and vibration to the passenger compartment.
Implementation Method 1
the multi-layer thermal barrier provides noise isolation, thermal isolation and vibration damping
Implementation Method 2
a first layer formed from a compressible and conformable elastic material
Implementation Method 3
a second layer formed from a conformable thermally insulating material
Data Source
AI summary
An integration assembly for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the assembly utilizing a multi-layer thermal barrier interposed between the battery pack enclosure and the passenger cabin floor panel, where the multi-layer thermal barrier provides noise isolation, thermal isolation and vibration damping, and where the multi-layer thermal barrier is compressed when the battery pack enclosure is mounted to the vehicle. The multi-layer thermal barrier is comprised of a first layer formed from a compressible and conformable elastic material and a second layer formed from a conformable thermally insulating material. The multi-layer thermal barrier may also include a moisture barrier layer that encases the first and second layers, for example a moisture barrier layer fabricated from a plastic. A sealant may be used to seal and bond the moisture barrier layer to the battery pack enclosure.