Integrating HV Battery Support into Vehicle Body Structure
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Solution Overview
Problem
Existing methods for protecting high-voltage energy storage in electric vehicles during crashes and sealing against water/moisture ingress are inefficient, requiring multiple components and interfaces, which increase costs and complexity.
Innovation Solution
A method that integrates the battery support structure into the vehicle body, using the body structure to provide mounting points and seal the space in an upward direction, with a separate installation protection structure sealing the space downwardly after component installation, reducing the number of parts and interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate battery support structure with outer frame, inner longitudinal profiles, and transverse struts is used to protect HV energy storage and provide sealing, then safety and sealing are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the battery support structure with the vehicle body structure by integrating the HV energy storage into the vehicle tunnel. The body structure itself provides the protective framework and sealing, eliminating the need for a separate battery support structure with outer frames, longitudinal profiles, and transverse struts. This integration maintains safety and sealing while significantly reducing structural complexity.
Solution Approach 2:
The vehicle body structure is designed to serve multiple functions: it provides structural support for the vehicle, creates the vehicle tunnel space, and simultaneously serves as the protective support structure and sealing barrier for the HV energy storage. This multi-functionality eliminates the need for dedicated battery protection components.
2Reliability
If a complete battery housing with cover and base is used to seal the HV energy storage space, then sealing against water and moisture is improved, but manufacturing costs and installation complexity increase
Solution Approach 1:
The patent extracts the sealing function from a complete battery housing assembly and assigns it to the vehicle body structure. The body structure's floor panel and side sills provide the sealing barrier, while the battery modules are installed directly in the vehicle tunnel without requiring a separate housing cover and base assembly. This reduces manufacturing costs by eliminating unnecessary housing components.
3Volume of moving object
If battery modules are arranged exclusively in the vehicle tunnel with local sealing, then space utilization is improved, but the number of interfaces and installation complexity increase
Solution Approach 1:
The patent combines the sealing interfaces into a single integrated body structure rather than creating multiple separate interfaces between battery housing components and the vehicle. The body structure provides continuous sealing along the vehicle tunnel, reducing the number of interfaces and simplifying installation while maintaining optimal space utilization.
Data Source
AI summary
A method for producing an electrically driveable vehicle which has a sealed space for accommodating a high-voltage (HV) energy storage. A body structure delimits the space for accommodating the HV energy storage at least in an upward direction and which sealingly closes off the space at least in the upward direction and which has attachment points for the direct or indirect connection of at least one energy storage module. At least one energy storage module is connected to the body structure. A space for accommodating the HV energy storage is open at least in partial regions. An installation protection structure delimits the space for accommodating the HV energy storage in the downward direction and which sealingly closes off the space at least in the downward direction. The body structure is connected to the installation protection structure, whereby the space for accommodating the HV energy storage is sealingly closed.