Gas-Tight Underbody Battery Module for Space-Constrained EVs
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Solution Overview
Problem
The integration of large and heavy energy storage units, such as lithium-ion batteries, in partially or completely electrified vehicles is becoming increasingly difficult due to space and weight constraints, requiring innovative solutions for efficient and flexible underbody modules that ensure gas-tightness and protection against environmental elements.
Innovation Solution
An underbody module comprising side elements, transverse elements, and a floor element forming a gas-tight frame with a cover element that creates an arrangement space for energy storage, providing two tightness zones for protection against water, mud, and dust, and allowing for the safe accommodation of energy storage elements like high voltage batteries, while also being adaptable for other components like fuel tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy storage units are made larger to increase vehicle range, then the range requirement is improved, but the installation space requirement worsens
Solution Approach 1:
The patent moves the energy storage unit from the conventional passenger compartment or trunk area to the underbody space of the vehicle. By utilizing the vertical dimension and the space beneath the vehicle floor, the design accommodates larger battery capacity without increasing the vehicle's footprint or compromising passenger space, thus resolving the contradiction between range requirements and installation space constraints.
Solution Approach 2:
The underbody module is designed as a segmented, modular structure with the energy storage unit as a separate module that can be independently installed and removed. This segmentation allows for flexible configuration and optimization of the battery pack size and shape to fit the available underbody space efficiently, enabling larger energy storage capacity within the constrained installation area.
2Use of energy by moving object
If energy storage units are made larger to increase vehicle range, then the range requirement is improved, but the weight increases
Solution Approach 1:
The energy storage unit is merged with the underbody module structure, where the battery pack serves dual purposes: as the energy storage component and as part of the structural reinforcement of the underbody. This integration allows the battery to contribute to the overall structural strength of the vehicle, potentially reducing the need for additional structural materials and offsetting some of the weight added by the large battery capacity.
3Object-affected harmful factors
If the underbody module is made gas-tight to protect against environmental elements, then the protection level is improved, but the construction complexity increases
Solution Approach 1:
The cover element serving the energy storage unit is designed with multi-functionality: it provides gas-tight sealing protection against environmental elements, structural support for the battery pack, and integration with the underbody module framework. By combining multiple functions into a single component, the design achieves high protection levels without proportionally increasing construction complexity.
Solution Approach 2:
The underbody module design allows the energy storage unit to serve as part of the protective structure itself. The battery pack's outer casing and mounting structure are integrated into the gas-tight sealing system, meaning the energy storage unit contributes to its own protection rather than requiring entirely separate protective components, thereby reducing overall system complexity.
Data Source
AI summary
An underbody module for a motor vehicle includes a left side element and a right side element, wherein the side elements extend in a longitudinal direction and are connected on the end sides by transverse elements, as a result of which an upper contact surface and a lower contact surface are formed. A floor element is arranged on the upper contact surface. A cover element is arranged or can be arranged on the lower contact surface, as a result of which an arrangement space is formed or can be formed between the floor element and the cover element, wherein the floor element is arranged in a gas-tight manner.