Raised Floor Pan Architecture for Hybrid and EV Battery Packaging
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Solution Overview
Problem
Manufacturers face challenges in producing motor vehicles with different drive concepts (combustion, electric, hybrid) using uniform components, particularly in accommodating batteries and fuel tanks without compromising interior space and production flexibility.
Innovation Solution
Adopting an architecture based on electric drive vehicles, with a raised floor panel subassembly to accommodate batteries, and utilizing uniform components across drive concepts, including adaptable deep-drawing tools and modular subassemblies to optimize space and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a raised floor panel subassembly is used to accommodate batteries, then battery capacity is maximized, but interior space is reduced
Solution Approach 1:
The patent raises the floor panel subassembly in the vertical dimension to create space for batteries underneath the passenger compartment, rather than expanding horizontally into the interior space. This dimensional shift allows battery accommodation while preserving passenger volume.
Solution Approach 2:
The vehicle structure is segmented into distinct functional zones: the raised floor panel subassembly forms a separate platform for battery placement, while the passenger compartment maintains its original volume. This segmentation allows independent optimization of both battery capacity and interior space.
2Ease of manufacture
If uniform components are used across different drive concepts, then production costs are reduced, but adaptability to different drive concepts is limited
Solution Approach 1:
The floor panel subassembly is designed as a universal component that serves multiple functions: it provides structural support, creates a platform for battery placement, and can be adapted to accommodate different drive concepts (combustion, electric, hybrid) without requiring complete redesign. This multi-functionality enables cost-effective production across vehicle variants.
Solution Approach 2:
The system incorporates adaptable elements within the uniform floor panel subassembly, such as configurable mounting points and modular battery compartments, that can be dynamically adjusted or configured for different drive concepts while maintaining the overall uniform structure.
3Quantity of substance
If the floor panel subassembly is raised to accommodate batteries, then battery capacity increases, but the floor panel subassembly complexity increases
Solution Approach 1:
The floor panel subassembly is segmented into modular components that can be independently manufactured and assembled, reducing overall complexity. The raised section forming the battery compartment is treated as a separate modular unit.
Solution Approach 2:
The raised floor panel subassembly is designed to perform multiple functions simultaneously: structural support, battery platform, and access point to underfloor components. This multi-functionality reduces the need for additional separate components, thereby managing complexity.
Data Source
AI summary
In a group of motor vehicles of one vehicle type, hybrid-drive motor vehicles are derived from the electric-drive motor vehicles. By using the architecture of electric-drive motor vehicles for the hybrid-drive motor vehicles, the architecture has a floor pan subassembly that sits in a higher position in comparison to that in motor vehicles having an internal combustion engine drive. An installation space for housing a battery on the underside of the floor pan subassembly is made available, which, in comparison to the motor vehicle in the prior art, allows significantly larger batteries to be housed.