Structural EV Battery Floor With Adhesive Beam Modules
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Solution Overview
Problem
Existing electric vehicle battery packs occupy excessive volume and weight, compromising range and crash safety, while traditional designs fail to optimize volumetric efficiency and structural integration.
Innovation Solution
A bottom structure comprising beam-shaped battery modules interconnected via adhesive connections, forming a stiff core with integrated cooling channels and thermal insulation, and connected to a top and bottom plate to create a lightweight, high-strength sandwich structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional standalone battery packs with safety cages are used, then crash safety and protection are improved, but volumetric efficiency deteriorates due to double structures occupying excessive volume
Solution Approach 1:
The patent merges the battery structure with the vehicle body structure by integrating beam-shaped battery modules that form both the battery housing and the vehicle floor structure. This eliminates the separate safety cage, achieving both crash safety and improved volumetric efficiency through structural integration.
Solution Approach 2:
The battery modules serve multiple functions: they provide electrical energy storage, structural support for the vehicle floor, and crash safety protection. This multi-functionality resolves the contradiction by making the same structure serve both energy storage and safety purposes simultaneously.
2Quantity of substance
If larger footprint is used to compensate for lower volumetric efficiency, then more cell volume can be integrated, but stopping distance increases and weight increases
Solution Approach 1:
The patent transitions from a planar battery arrangement to a three-dimensional integrated structure where battery modules are positioned vertically and horizontally to form the vehicle floor. This dimensional integration allows maximum cell volume within the available footprint without increasing the vehicle's external dimensions.
3Stability of the object's composition
If beam-shaped battery modules interconnected via adhesive are used, then volumetric efficiency and stiffness are improved, but impact resistance in transverse direction may be reduced
Solution Approach 1:
The patent divides the battery pack into discrete beam-shaped modules that are interconnected. This segmentation allows for optimized adhesive bonding surfaces that provide both stiffness through rigid connection and impact resistance through distributed stress absorption across multiple bonding interfaces.
4Weight of stationary object
If structural integration is maximized to improve volumetric efficiency, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates adhesive bonding surfaces and connection features directly into the battery module manufacturing process before assembly. This preliminary integration of connection elements during module production simplifies the overall assembly process and reduces manufacturing complexity despite the high degree of structural integration.
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
Enhances volumetric efficiency, improves crash safety, and increases critical buckling load, while reducing uncontrolled heat transfer and weight, thus optimizing vehicle performance.
Implementation Method 1
the modules being interconnected along their longitudinal sides via an adhesive
Implementation Method 2
the cover plate of the battery modules can be adhesively connected to the battery cells and may include cooling channels extending in the length direction
Implementation Method 3
cooling channels extending in the length direction
Implementation Method 4
The adhesive connection of the vertical short sides of the cells acts as a thermal insulator between the battery cells and the interconnecting members, so that uncontrolled heat transfer from the battery cells to environment is reduced
Data Source
AI summary
A bottom structure for an electric vehicle including at least a first and second beam-shaped battery modules extending in a length direction. Each module is formed by a number interconnected cells and has two longitudinal sides, two transverse sides and a top side covered by a cover plate. The modules are mutually interconnected along their longitudinal sides via an adhesive.