EV Battery Case-Floor Structure for Space-Efficient Body Integration
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Solution Overview
Problem
Conventional methods of manufacturing electric vehicles by separately producing the vehicle body and battery case result in inefficient use of limited space, reduced battery capacity, and compromised stability due to excessive overlap and simple external bolting.
Innovation Solution
The vehicle body is integrated with the battery case by configuring the floor panel as the upper panel and side sills as sidewalls, forming a unified structure through extrusion molding, eliminating the need for separate components and enhancing connectivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the body of the vehicle and the battery case are separately manufactured and assembled, then the manufacturing process is simple and flexible, but the space where panels overlap is excessive, making it impossible to efficiently use the limited space of the vehicle
Solution Approach 1:
The patent merges the battery case with the vehicle body structure by making the floor panel serve dual functions: as the vehicle body floor and as the upper panel of the battery case. The side sills are configured to extend downward from the floor panel to form the sidewalls of the battery case, eliminating the need for a separate battery case structure and reducing overlapping panel spaces.
Solution Approach 2:
The floor panel is designed to perform multiple functions simultaneously: it serves as the vehicle body floor for passenger compartment support and as the upper panel of the battery case for battery module protection. The side sills serve both as vehicle body structural components and as sidewalls of the battery case, achieving multi-functionality that maximizes space utilization.
2Ease of manufacture
If the body of the vehicle and the battery case are separately manufactured and assembled, then the assembly process is flexible, but the connectivity between components is simple, resulting in reduced stability
Solution Approach 1:
The patent combines the battery case structure with the vehicle body structure through integral forming processes. The floor panel and side sills are configured to form both the vehicle body and the battery case simultaneously, creating strong structural connectivity rather than simple external bolting, thereby enhancing overall vehicle stability.
3Ease of manufacture
If separate battery case and vehicle body are used, then the manufacturing process is straightforward, but the impact loads are not effectively dispersed, compromising safety
Solution Approach 1:
By merging the battery case with the vehicle body structure, the patent creates an integrated load-bearing system where impact forces are dispersed throughout the combined structure. The floor panel and side sills work together as a unified structural system, improving impact resistance compared to separate assembled components.
Data Source
AI summary
A battery case includes a floor panel of a vehicle, which forms a floor of a body of the vehicle and at the same time, forms an upper panel of a battery case, a side sill positioned at opposite sides of the floor panel, extending in a longitudinal direction of the vehicle, and extending downwardly from the floor panel in a height direction, and front and rear barriers extending downwardly from a front portion and a rear portion of the floor panel connected to the side sill to form a sidewall portion of the battery case together with the side sill by being connected to the side sill.