High-Voltage Battery Hanging Cell Layout for Safer Vehicle Integration
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Solution Overview
Problem
Conventional high-voltage batteries in motor vehicles face issues with installation space, safety, and maintenance due to the need for a gap between the battery and the vehicle structure, which can lead to outgassing and heat development inside the vehicle during accidents.
Innovation Solution
A high-voltage battery design with a frame that mounts battery cells 'hanging' upside down, where electrical contacts face downwards and cell bases face upwards, integrated into the vehicle with the floor panel serving as the cover, eliminating the need for a separate battery cover and allowing for improved safety and reduced installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap is maintained between the battery and vehicle structure, then chafing and corrosion are prevented, but installation space is increased and collision-free installation is compromised
Solution Approach 1:
The battery cells are mounted inverted (hanging upside down) with electrical contacts facing downward and cell bottoms facing upward, reversing the conventional orientation. This inversion allows the floor panel to serve as the battery cover, eliminating the need for a separate cover and reducing the required gap between battery and vehicle structure.
Solution Approach 2:
The floor panel is dual-functional: it serves both as the vehicle floor and as the battery cover. This merging of functions eliminates the need for a separate battery cover component and reduces the space required for battery installation while maintaining protective functions.
2Reliability
If a separate battery cover is used, then battery protection is provided, but device complexity and cost increase
Solution Approach 1:
The floor panel is dual-functional: it serves both as the vehicle floor and as the battery cover. This merging of functions eliminates the need for a separate battery cover component and reduces the required gap between battery and vehicle structure.
Solution Approach 2:
The floor panel performs multiple functions: it is both the vehicle floor structure and the battery cover. This multi-functionality reduces the total number of components needed and simplifies the overall battery assembly structure.
3Ease of manufacture
If battery cells are mounted conventionally with contacts upward, then installation is simplified, but outgassing and heat development affect vehicle interior safety
Solution Approach 1:
The battery cells are mounted inverted (hanging upside down) with electrical contacts facing downward and cell bottoms facing upward, reversing the conventional orientation. This inversion directs any outgassing and heat development away from the vehicle interior toward the underbody protection, improving safety while maintaining installation simplicity.
4Ease of repair
If the entire battery unit is designed for complete removal, then maintenance access is enabled, but installation and removal time increase
Solution Approach 1:
The battery assembly is segmented into individual battery cells or modules that can be accessed and removed independently from the frame. The cross members and seal allow selective access to battery components without requiring removal of the entire battery unit, reducing maintenance time while maintaining full accessibility.
Data Source
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AI summary
A motor vehicle with a high-voltage battery, wherein the high-voltage battery comprises a frame (1) laterally bounding the high-voltage battery, wherein a plurality of battery cells (2) are arranged in the frame (1), wherein a floor plate (3) of the motor vehicle forms the cover of the high-voltage battery covering the frame (1) at its top, and the battery cells (2) are mounted "hanging" in the frame (1) such that the electrical contacts of the battery cells (2) are directed downwards and the cell bottoms are directed upwards, and a method for mounting a high-voltage battery in such a motor vehicle.