Segmented Undercarriage EV Battery Pack Footwell Cavity
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Solution Overview
Problem
Conventional undercarriage-mounted battery packs in electric vehicles limit passenger space, particularly rear seat legroom and headroom, due to their thickness and positioning, which affects ergonomics and aerodynamics.
Innovation Solution
A segmented battery pack design with a foot well cavity aligned with the rear seats, where batteries are split into front and rear segments, electrically interconnected, and a bottom plate angled to enhance air flow, providing additional foot space and maintaining vehicle aerodynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the battery pack is mounted under the vehicle in a conventional configuration, then the center of gravity is lowered and weight distribution is optimized, but the available passenger space (particularly rear seat legroom and headroom) is significantly reduced
Solution Approach 1:
The battery pack is divided into multiple segments or modules that can be arranged in different configurations. This segmentation allows the battery pack to be shaped to accommodate passenger space requirements while maintaining the undercarriage mounting position for optimal center of gravity and weight distribution.
Solution Approach 2:
The battery pack design transitions from a conventional flat undercarriage mounting to a three-dimensional configuration that utilizes vertical space more efficiently. By stacking battery modules vertically and creating a multi-level structure, the design accommodates both the center of gravity requirements and passenger space needs through dimensional optimization.
2Quantity of substance
If the battery pack thickness is increased to provide more capacity, then the electric-only range is extended, but the rear seat ergonomics are significantly degraded due to limited legroom and headroom
Solution Approach 1:
The battery pack is segmented into multiple modules that can be arranged in a distributed configuration rather than a single thick block. This allows the same total battery capacity to be achieved while reducing the thickness in the passenger compartment area, thereby improving rear seat ergonomics.
Solution Approach 2:
The battery capacity is increased by utilizing vertical stacking and three-dimensional arrangement of battery modules rather than simply increasing the horizontal thickness. This dimensional approach maintains adequate passenger space while achieving the required battery capacity for extended electric-only range.
3Ease of operation
If the roofline is raised to provide more legroom and headroom, then passenger comfort is improved, but the vehicle aerodynamics are degraded and aesthetics are compromised
Solution Approach 1:
The battery pack is segmented and arranged to create footwell cavities that provide additional passenger space from below, eliminating the need to raise the roofline. This segmentation allows passenger comfort to be improved through vertical module arrangement rather than increasing the overall vehicle height.
Solution Approach 2:
Instead of increasing vehicle height by raising the roofline, the design utilizes vertical battery module arrangement and three-dimensional space optimization to create passenger space. This approach maintains the original aerodynamic profile while improving comfort through dimensional reconfiguration of the battery pack.
4Ease of operation
If a foot well cavity is created in the battery pack to increase rear seat legroom, then passenger ergonomics are improved, but the battery pack structure becomes more complex
Solution Approach 1:
The foot well cavity is created by segmenting the battery pack into front and rear sections with a gap or cavity between them. This segmentation approach to creating the foot well integrates the ergonomic feature into the modular battery architecture, reducing the overall structural complexity compared to creating cavities in a monolithic battery pack.
Data Source
AI summary
An undercarriage-mounted battery pack is provided that includes a foot well cavity that is aligned with the foot well corresponding to one or more of the vehicle's seats, e.g., the rear vehicle seats. A portion of the battery pack is located in front of the foot well cavity while a second portion is located behind the foot well cavity, where the two portions are coupled together using conduits. The bottom surface of the battery pack may be shaped in order to minimize drag and enhance the flow of air under the vehicle. The battery pack may include cross-members, either interposed between battery subassemblies or incorporated into the subassembly enclosures, to increase side impact resistance and provide further protection to the batteries within the pack as well as the vehicle's occupants.