Stacked Modular Battery Housing for Electric Vehicle Drive
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Solution Overview
Problem
Existing battery housings for electric vehicle drives are expensive due to active cooling requirements and are difficult to seal, especially when installed in the underfloor area, and require complex construction to ensure tightness and stability during accidents.
Innovation Solution
A battery housing design where multiple interconnected battery modules are arranged in separate, identical, stackable housings, each with a smaller footprint, allowing for easier manufacturing and improved tightness, with a protective housing that can be partially open and optimized for stability and rigidity, using plastic materials and plug-in connector elements for enhanced shear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single large battery housing is used to accommodate multiple battery modules in different layers, then the battery can be installed in the underfloor area, but the housing becomes difficult to seal and requires considerable constructive effort to ensure tightness and stability
Solution Approach 1:
The patent divides the battery housing into multiple separate housings, each accommodating a single layer of battery modules. These modular housings are stacked vertically and interconnected through connecting elements. This segmentation transforms one difficult-to-seal large housing into several easier-to-seal smaller housings, directly resolving the sealing difficulty while maintaining the required volume for battery installation.
2Volume of moving object
If a single large battery housing is used to accommodate multiple battery modules in different layers, then the battery can be installed in the underfloor area, but the housing requires considerable constructive effort to ensure stability and rigidity during accidents
Solution Approach 1:
The patent segments the battery housing into multiple stacked modular units, each with its own connecting elements. This creates a distributed structural system where failure in one module does not compromise the entire battery assembly. The modular design with standardized connecting elements provides sufficient stability and rigidity while reducing the constructive effort required compared to a single large housing.
Solution Approach 2:
The patent employs composite construction with housing bodies made from at least two different materials, combining the advantages of each material to achieve optimal strength-to-weight ratio and accident resistance. This composite approach enhances the structural integrity of each modular housing unit and their connections.
3Volume of moving object
If a single large battery housing is used to accommodate multiple battery modules, then the battery can be installed in the underfloor area, but the manufacturing cost increases due to complex construction and sealing requirements
Solution Approach 1:
The patent divides the battery housing into multiple identical or similar modular housings that can be manufactured using the same tooling and processes. This standardization significantly reduces manufacturing costs compared to producing one large complex housing, while the modular assembly approach maintains the required volume for battery installation.
Solution Approach 2:
The patent designs the modular housing units to be universal and interchangeable, with standardized connecting elements and dimensions. This universality allows for economies of scale in manufacturing and simplifies assembly, directly reducing the overall manufacturing cost while achieving the required battery housing volume.
4Area of stationary object
If battery modules are arranged in at least two layers in the vertical direction, then the battery can be installed in the front area or front structure/crumple zone, but separate interconnected battery housings are required for each layer
Solution Approach 1:
The patent segments the battery system into multiple modular housings arranged in vertical layers, enabling flexible installation in the front area or crumple zone. While this creates multiple housing components, the standardized modular design actually reduces overall system complexity compared to a single large housing, as each module is simpler and more interchangeable.
Solution Approach 2:
The patent utilizes the vertical dimension by arranging battery modules in stacked layers, allowing the battery to fit in the front area or crumple zone where horizontal space may be limited. This vertical stacking with standardized modular housings provides flexible configuration while maintaining manageable complexity through standardization.
Data Source
AI summary
A battery for an electric drive of a motor vehicle, having a number of battery modules, which are arranged one above the other in the respective layers and accommodated in an assigned housing. The battery is optimized regarding production engineering aspects, and is also optimized regarding the requirements of tightness and accident properties, each of the layers of the battery modules arranged one above the other is accommodated in a respectively assigned, separate battery housing, which are arranged one above the other in a stack and connected to one another.