EV Tunnel Floor Structure for Battery Impact Protection
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Solution Overview
Problem
Electric vehicles require enhanced structural protection for their batteries to prevent damage and potential fires during collisions, while maintaining performance and safety without compromising other vehicle features.
Innovation Solution
A tunnel structure is integrated into the electric vehicle's floor, featuring a hollow enclosure with planar panels and ridges that extend from the front to the rear, coupled with cross members, to efficiently transfer impact forces and provide increased stiffness and protection for the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional structural features are added to protect the battery, then safety is improved, but vehicle performance is compromised
Solution Approach 1:
The floor structure is segmented into multiple functional zones: a first portion with increased thickness for battery protection, a second portion for structural support, and a third portion for heat dissipation. This segmentation allows each zone to be optimized for its specific function without compromising overall vehicle performance.
Solution Approach 2:
The floor structure implements local quality by varying thickness and material properties in different regions. The first portion has increased thickness specifically where battery protection is needed, while other portions maintain original specifications to preserve vehicle performance characteristics.
2Reliability
If the floor structure thickness is increased for battery protection, then safety is improved, but vehicle weight increases
Solution Approach 1:
Instead of uniformly increasing floor thickness throughout the vehicle, the invention segments the floor structure so that only the first portion (where battery protection is critical) has increased thickness. This localized approach provides necessary protection while minimizing overall weight increase.
Solution Approach 2:
The floor structure applies local quality by concentrating increased thickness and reinforcement only in the region directly above the battery pack, while maintaining standard thickness in other areas to avoid unnecessary weight addition.
3Reliability
If structural features are added to improve safety, then battery protection is enhanced, but manufacturing complexity increases
Solution Approach 1:
The invention merges multiple functions into a single integrated floor structure: protection, support, and heat dissipation are all incorporated into one component rather than requiring separate structural elements. This reduces overall manufacturing complexity while maintaining enhanced safety.
Solution Approach 2:
The floor structure is designed with multi-functionality, serving as both a protective barrier for the battery, a structural support element, and a heat dissipation pathway. This universal design eliminates the need for multiple separate components, simplifying manufacturing.
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 tunnel structure effectively distributes impact forces, enhancing the vehicle's body stiffness and protecting the battery by transferring energy efficiently, thereby reducing the risk of damage and improving safety during collisions.
Implementation Method 1
efficiently transfer and dissipate impact forces
Implementation Method 2
transfers a fourth portion of the force received by the bottom portion to the front cross member and the rear cross member
Data Source
AI summary
A tunnel structure in an electric vehicle for providing a protected battery storage location and for increasing the stiffness of a vehicle's body structure. The tunnel structure may include a floor portion coupled to the floor of the vehicle, a front portion coupled to the vehicle firewall, and a paneled portion extending between the front portion and the floor portion. The tunnel structure may also include a plurality of panels and ridges that extend from the front portion toward a rear edge of the floor portion. The specific arrangement of the panels and ridges can improve the transfer of energy in the event of a collision.