Underfloor EV Battery Connection Element Integration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electric vehicle designs face challenges in optimizing the installation space, cost, and weight of battery connections, particularly in underfloor arrangements, while ensuring efficient electrical and thermal management and electromagnetic compatibility.

Innovation Solution

The integration of a connection element with recesses in the body members allows for efficient insertion and secure mounting of the battery, incorporating both electrical and thermal connections, and forming a Faraday cage for electromagnetic shielding, with the protective plate sealing the battery space from external influences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery is arranged in an underfloor arrangement with separate connection elements, then the electrical and thermal management functions are achieved, but the installation space and weight increase

Engineering Contradiction:

Improveelectrical and thermal management functionVSAvoidinstallation space and weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The connection element integrates multiple functions (electrical connection, thermal management connection, mechanical mounting) into a single component that is directly formed as part of the battery housing. This merging eliminates the need for separate connection parts, reducing installation space and overall weight while maintaining all necessary functions for electrical connection and thermal management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection element serves multiple purposes simultaneously: it provides electrical connection contacts, thermal management fluid pathways, and mechanical mounting structure. This multi-functional design allows a single component to replace what would traditionally require multiple separate parts, optimizing space utilization and reducing weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If the connection element is integrated into the body with recesses, then the assembly simplicity and electromagnetic compatibility are improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveassembly simplicity and electromagnetic compatibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The body is designed with recesses that segment the integration of connection elements, allowing each connection element to be independently positioned and secured. This segmentation simplifies assembly by providing predefined mounting locations while the recesses themselves are formed as integral parts of the body structure to maintain electromagnetic compatibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection element is formed as a composite structure combining conductive materials for electrical connection with structural materials for mechanical strength and mounting functionality. This composite approach enables a single manufacturing process to produce a multi-functional component that meets both electrical and mechanical requirements.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If the protective plate closes the battery space, then the environmental sealing is improved, but the access for battery installation is restricted

Engineering Contradiction:

Improveenvironmental sealingVSAvoidaccess for battery installation

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The recesses in the body are pre-formed to accommodate connection elements before the protective plate is installed. This preliminary preparation of mounting locations allows the protective plate to be closed afterward without restricting access during the assembly process, as all connection elements are already positioned and secured in their recesses.

Inventive Principle:

Principle #10Preliminary action

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 configuration significantly reduces installation space, weight, and costs, while enabling simple assembly and enhanced electromagnetic compatibility, leading to improved acoustic and environmental sealing.

Implementation Method 1

the body, the connection element or the connection elements and the protective plate may form a Faraday cage

Methodology Applied

Scientific EffectFaraday cage: Faraday Cage

Data Source

PatentUS11565579B2Electric vehicle having a battery in an underfloor arrangement

Publication Date: 2023.01.31 DR ING H C F PORSCHE AG

AI summary

An electric vehicle (1) has a battery (2) in an underfloor arrangement. The battery (2) is arranged in a battery space (4) that is delimited by body members (5, 6, 7, 8) of a body (3). The battery space (4) also is delimited at a bottom side of the electric vehicle (1) by way of a protective plate (9). The battery (2) has a connection element (10, 11) at least on a side oriented toward one of the body members (7, 8), and the body member (7, 8) has a recess (12, 13) in which the connection element (10, 11) is arranged.