EV Floor Structure With Porous Thermal Layer for Battery Overheat
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Solution Overview
Problem
In electric-powered motor vehicles, the risk of battery overheating leading to excessive heat transmission to the acoustical trim lining, potentially causing ignition and toxic smoke emission, poses a challenge for thermal protection while maintaining interior volume, load-bearing capacity, and acoustic protection.
Innovation Solution
A fibrous and porous thermal protection layer is introduced between the acoustical trim lining and the floor plate, comprising thermal protection fibers made from fusible materials and structural fibers with a higher melting point, which absorbs heat by melting and maintains structural integrity and acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal protection layer is added between the battery and the acoustical trim lining, then thermal protection is improved, but the interior volume of the vehicle is reduced
Solution Approach 1:
The patent employs a porous thermal protection layer with controlled porosity (30-70%) that provides effective thermal insulation while maintaining a thin profile. The porous structure allows heat absorption through capillary action and phase change of the filling material (paraffin, salt hydrate, or graphite particles), achieving thermal protection with minimal thickness to preserve interior volume.
Solution Approach 2:
The patent utilizes phase change materials (paraffin, salt hydrate) or heat-absorbing particles (graphite) that undergo parameter changes at specific temperatures. These materials absorb excessive heat through melting or phase transition, dynamically adjusting their thermal properties to protect the lining while maintaining a compact layer thickness.
2Reliability
If a thermal protection layer is added between the battery and the acoustical trim lining, then thermal protection is improved, but the load-bearing capacity is impaired
Solution Approach 1:
The patent creates a composite structure combining a porous matrix material (open-cell foam, fibrous material, or sintered metal) with heat-absorbing filling material. This composite design provides both thermal protection through phase change and sufficient mechanical strength to support the acoustical trim lining and withstand vehicle floor loads.
Solution Approach 2:
The patent applies different materials with specific properties to different regions of the thermal protection layer. The porous matrix provides structural support in load-bearing zones, while the filling material (paraffin, salt hydrate, graphite) concentrated in specific areas provides targeted thermal absorption where heat flux is highest.
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 thermal protection layer effectively limits heat transmission to the lining, preventing ignition and maintaining the vehicle's interior space, load-bearing capacity, and acoustic protection, even under conditions of battery overheating.
Implementation Method 1
thermal protection fibers based on at least one fusible material... fusion corresponds to an endothermic phase change; consequently, part of the heat released by the battery is devoted to fusion of the protection fibers, thereby limiting the amount of heat transmitted to the lining
Implementation Method 2
fusion corresponds to an endothermic phase change; consequently, part of the heat released by the battery is devoted to fusion of the protection fibers
Implementation Method 3
the fibrous and porous nature of the protection layer gives it sound-absorbing properties in addition to those provided by the lining
Data Source
AI summary
The invention relates to a floor structure (1) for an electric-powered motor vehicle successively comprising, from bottom to top: a battery (2) arranged in a tray (3), a floor plate (5) facing said battery and an acoustic trim lining (6) arranged on said plate, said structure further comprising a fibrous and porous thermal protection layer (7) arranged between said lining and said plate, said protection layer comprising thermal protection fibers based on at least one fusible material and structural fibers of one or more types, said fibers being infusible or based on material having a melting point greater than the maximum melting point of said protection fibers.