Spring Sheet Coupling for EV Battery Housing Vibration Isolation
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Solution Overview
Problem
Existing motor vehicle designs face challenges in effectively reducing vibrations and noise in the passenger compartment due to the interaction between the energy store housing structure and the passenger compartment floor structure, while also needing to manage tolerances during assembly.
Innovation Solution
A resilient coupling element, typically made of spring steel, is used to connect the energy store housing structure and the passenger compartment floor structure, providing reversible elastic deformation to reduce vibrations and irreversible plastic deformation to compensate for assembly tolerances, thereby optimizing vibration behavior and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a resilient coupling element is used to reduce vibrations and noise, then acoustic performance is improved, but the device complexity increases
Solution Approach 1:
The resilient coupling element acts as an intermediary component between the energy store housing structure and the passenger compartment floor structure. It mediates the mechanical connection while filtering out vibrations and noise, thus improving acoustic performance without requiring direct modification of the main structures.
Solution Approach 2:
The coupling element utilizes material parameter changes through elastic and plastic deformation. The elastic modulus and deformation characteristics are specifically selected to provide vibration damping while maintaining structural integrity, resolving the contradiction between acoustic performance and structural requirements.
2Object-affected harmful factors
If the coupling element uses elastic deformation to reduce vibrations, then acoustic performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coupling element is designed to operate in the elastic deformation range where material properties are well-defined and predictable. By selecting materials with appropriate elastic moduli and designing geometries that ensure elastic behavior under service loads, the patent achieves vibration reduction while maintaining feasible manufacturing tolerances.
3Ease of operation
If the coupling element is designed to compensate assembly tolerances, then ease of assembly is improved, but the reliability of vibration reduction may be compromised
Solution Approach 1:
The coupling element is pre-designed with inherent elastic compliance that automatically compensates for assembly tolerances. The elastic deformation capability is built into the component geometry and material selection, allowing for easy assembly while maintaining consistent vibration reduction performance across different assembly conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coupling element effectively reduces low-frequency vibrations and noise in the passenger compartment, compensates for assembly tolerances, and ensures safe installation forces, enhancing the overall stiffness and acoustic performance of the vehicle body.
Implementation Method 1
The coupling element can be reversibly elastically deformable below a predetermined level of exerted force in order to effect a reduction in noise
Implementation Method 2
The coupling element can be irreversibly plastically deformable above a predetermined level of exerted force in order to enable the compensation of tolerances
Data Source
AI summary
A resilient coupling element for a motor vehicle, which is to be placed between an energy store housing structure and a passenger compartment floor structure, is made of a spring sheet or plate. A motor vehicle having an energy store housing structure and a passenger compartment floor structure, includes the coupling element of the aforementioned kind being effective between the energy store housing structure and the passenger compartment floor structure.