Fuel Cell Vehicle Layout with Underfloor Battery and Hydrogen Tanks
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Solution Overview
Problem
The compact arrangement of fuel cell stacks, hydrogen tanks, and batteries in electric vehicles reduces interior and trunk space, leading to decreased marketability.
Innovation Solution
A fuel cell electric vehicle design that accommodates a motor, fuel cell stack, battery assembly, and hydrogen tanks in a way that maximizes space, with the motor and fuel cell stack in a powertrain room, a battery assembly at the rear, and hydrogen tanks below, using an integrated DC-DC converter to connect batteries and motors efficiently, and strategically mounting components to minimize space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components (fuel cell stack, hydrogen tank, battery, motor) are mounted in the vehicle, then the vehicle can function as a fuel cell electric vehicle, but the interior space and trunk space are reduced
Solution Approach 1:
The patent relocates the battery assembly from the interior space to the under-vehicle space (below the first row seat), utilizing the third dimension (vertical space below the vehicle body) rather than horizontal interior space. The hydrogen tanks are positioned in the rear under-vehicle area, also utilizing vertical and rear spatial dimensions. This dimensional relocation allows all necessary components to be mounted while preserving interior and trunk space for passenger and cargo use.
2Area of stationary object
If components are arranged to maximize interior and trunk space, then space utilization is improved, but component placement becomes more complex
Solution Approach 1:
The patent divides the vehicle into distinct functional zones: the PE room (powertrain room) at the front containing the motor and fuel cell stack, the battery assembly zone in the under-vehicle space below the first row seat, and the hydrogen tank zone in the rear under-vehicle area. This segmentation of spatial zones simplifies the overall arrangement by assigning specific components to specific zones, reducing the complexity of component placement while maximizing usable space.
3Device complexity
If the battery assembly is mounted inside the vehicle body, then electrical connections are simplified, but interior space is reduced
Solution Approach 1:
The patent introduces an integrated DC-DC converter as an intermediary component positioned between the high-voltage battery and the low-voltage battery. This intermediary device manages the electrical power conversion and distribution, allowing the high-voltage battery to be mounted in the under-vehicle space while maintaining efficient electrical connections through the converter. The IDC serves as a mediating element that resolves the spatial-electrical connection trade-off.
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 design effectively increases interior and trunk space, improves marketability by reducing the need for compact component placement, and allows for cost and weight reduction through shorter high-voltage cables and efficient power conversion.
Implementation Method 1
an inlet duct that passes through the battery case and the vehicle body and is connected to an interior may be formed to protrude upward from the battery case so as to cool the high-voltage battery by sucking air inside the vehicle; and an outlet duct that discharges the cooled air of the high-voltage battery to a lower side of the vehicle may be formed to extend to an outside of the battery case
Data Source
AI summary
A fuel cell electric vehicle includes: a motor, a fuel cell stack and an integrated controller, which are accommodated in a PE room provided in a front of a vehicle body; a battery assembly including a high-voltage battery electrically connected to the motor and the fuel cell stack, and a low-voltage battery for supplying electric power to a vehicle electrical part; an IDC that is mounted between the PE room and the battery assembly, and electrically connects the high-voltage battery to the motor and the fuel cell stack; and a plurality of hydrogen tanks that is mounted at a rear of the battery assembly and below the vehicle body. In particular, the battery assembly is mounted at a rear of the PE room and below the vehicle body, and the IDC converts power of the high-voltage battery to be supplied to the low-voltage battery.