Through-Mount Battery Module Fixing for Rigid EV Floor Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery mounting structures in electric vehicles lack sufficient rigidity, requiring additional reinforcement members or panels to secure the battery module to the seat cross member, which increases weight and cost, and compromises riding comfort and interior space.
Innovation Solution
A through mount fixed type battery apparatus that uses a battery through fixing part and a member double fixing part to robustly couple the battery module to the seat cross member via CO2 welding, MIG welding, or axial force coupling, eliminating the need for reinforcement members and forming a robust structure by positioning coupling portions at the upper and lower ends of the cross section, thereby enhancing rigidity and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery mounting hardware is coupled only to the lower end of the seat cross member, then the battery module can be fixed under the floor panel, but the structure lacks sufficient rigidity requiring additional reinforcement members or panels
Solution Approach 1:
The mounting structure transitions from single-point lower-end coupling to multi-dimensional coupling by extending fasteners through the entire seat cross member from lower end to upper end, creating upper and lower coupling portions that distribute forces across multiple dimensions and eliminate the need for additional reinforcement
Solution Approach 2:
The coupling structure is divided into distinct upper coupling portion and lower coupling portion, with the fastener passing through intermediate portions of the seat cross member, creating segmented coupling points that collectively enhance overall structural rigidity without requiring separate reinforcement components
2Strength
If reinforcement members or panels are added to the central surface of the floor panel, then structural rigidity is improved, but vehicle weight increases
Solution Approach 1:
The mounting structure merges the fastener, seat cross member, and battery module into an integrated assembly where the fastener passes through the seat cross member to create upper and lower coupling portions, consolidating multiple functions into a single structure that provides rigidity without additional reinforcement members
3Strength
If reinforcement panels are installed on the floor panel, then rigidity is enhanced, but interior space and riding comfort are compromised
Solution Approach 1:
The solution extracts and eliminates the need for separate reinforcement panels from the floor panel structure by implementing through-mount fastening that creates upper and lower coupling portions, removing unnecessary components that would occupy interior space and affect riding comfort
4Reliability
If multiple battery mounting hardware are used to uniformly form fixed positions, then the battery module is securely fixed, but the structure becomes more complex
Solution Approach 1:
The fastener design serves multiple functions simultaneously: it creates upper coupling portions, lower coupling portions, and passes through intermediate portions of the seat cross member, providing universal multi-functional coupling that secures the battery module without requiring separate components for each function
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 solution provides increased rigidity and improved riding comfort by minimizing the need for additional reinforcement, reducing weight and cost, and enhancing the all-electric range while maintaining interior space, comparable to conventional internal combustion engine vehicles.
Implementation Method 1
a mounting bolt configured to pass through the battery module, the floor panel, and the seat cross member
Implementation Method 2
any one of a CO2 welding-coupling, a MIG welding-coupling, and an axial force coupling above the floor panel
Implementation Method 3
any one of a CO2 welding-coupling, a MIG welding-coupling, and an axial force coupling above the floor panel
Data Source
AI summary
An electric vehicle includes a floor panel, a seat cross member positioned at the floor panel, the seat cross member including an upper bracket and a lower bracket that define an internal structure therebetween, and a battery apparatus. The battery apparatus includes a battery module disposed below the floor panel, and a through mount member that is coupled to a through mounting position of the battery module and passes through the internal structure of the seat cross member. The through mount member is coupled to the seat cross member by any one of CO2 welding-coupling, metal inert gas (MIG) welding-coupling, or an axial force coupling to thereby fix the battery module to the floor panel.