EV Cabin Floor Stiffener Reduces Vibration Noise

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Solution Overview

Problem

The cabin floor of electric vehicles experiences vibrations due to lack of rigidity, leading to audible noise that discomforts occupants, and existing sound deadening materials like soft foam are prone to moisture damage and increased vehicle weight.

Innovation Solution

A rigid stiffener is positioned between the cabin floor and the battery pack, made of impermeable materials like rigid polyurethane foam, conforming to the shape of the cabin floor to enhance stiffness and reduce noise, eliminating the need for separate moisture barriers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If soft foam sound deadening material is used to reduce cabin floor vibrations, then vibration reduction is achieved, but the material is prone to moisture damage and increases vehicle weight

Engineering Contradiction:

Improvecabin floor vibrationsVSAvoidmoisture resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent changes the physical state and material properties from soft foam to rigid material, transforming the vibration damping mechanism while improving moisture resistance and structural integrity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining rigid stiffener material with moisture-resistant properties, integrating multiple functions (vibration reduction, stiffness enhancement, and moisture protection) into a single material system

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If soft foam sound deadening material is used to reduce cabin floor vibrations, then vibration reduction is achieved, but vehicle weight increases

Engineering Contradiction:

Improvecabin floor vibrationsVSAvoidvehicle weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent changes the density and structural parameters of the vibration damping material, using a rigid structure that provides equivalent or superior vibration control with reduced mass compared to soft foam

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If the cabin floor structure is made more rigid to reduce vibrations, then vibration reduction is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvecabin floor vibrationsVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent divides the stiffener into modular sections with standardized interfaces, allowing independent manufacturing and assembly of individual components while achieving overall structural rigidity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates mounting features and alignment elements during the stiffener manufacturing process itself, preparing the component for easy installation without requiring complex post-assembly operations

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10476061B1Electric vehicle cabin floor structure

Publication Date: 2019.11.12 SERES AUTOMOBILE CO LTD

AI summary

Provided herein are apparatus, systems, and methods for reducing noise in an electric vehicle. The apparatus can include a cabin floor, a battery pack, and a stiffener positioned between the cabin floor and the battery pack. The cabin floor can include a recess that that defines a volume in the cabin floor. The battery pack is coupled to the cabin floor, and includes a plurality of battery cells generating a voltage and a current. The stiffener includes a first stiffener surface that faces the cabin floor, a second stiffener surface that faces the battery pack, and a first stiffener element that extends out of the first stiffener surface and conforms to a shape of the recess. The first stiffener element is positioned on the first stiffener surface to align with a position of the recess in the cabin floor.