Vehicle Floor Battery Module Layout for Crash-Stable EV Packs
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Solution Overview
Problem
Existing traction battery designs in vehicle floors lack sufficient crash stability and structural integrity, particularly in the transverse direction, during vehicle collisions, while maintaining efficient cooling and accessibility for maintenance.
Innovation Solution
A self-supporting battery module arrangement with crash-stable housings and a battery control module integrated into the vehicle floor, utilizing longitudinal supports and a bar-like control module housing to enhance structural rigidity, combined with active cooling and gap design to prevent module collision, and optionally using aluminum die-cast or extrusion profiles for additional reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If battery modules are directly fastened to transverse supports for structural support, then structural integrity is improved, but accessibility for maintenance and repair deteriorates due to reduced space for maneuvering
Solution Approach 1:
The battery system is divided into modular battery modules that can be independently accessed and maintained. Each module is separated by gaps that provide access pathways, allowing maintenance personnel to reach individual modules without disassembling the entire structure.
Solution Approach 2:
The patent introduces a third dimension of access by creating vertical gaps and horizontal spacing between modules. This multi-dimensional spacing system allows maintenance access from multiple directions (above, below, and between modules) without compromising the structural support function.
2Productivity
If battery modules are arranged closely together to maximize space utilization, then productivity is improved, but crash stability deteriorates due to reduced structural rigidity
Solution Approach 1:
The patent applies different qualities to different regions: battery modules have high structural rigidity for crash stability, while the gaps between modules provide the necessary spacing for both stability and maintenance access. The module housings are specifically designed with reinforced structures in critical areas.
Solution Approach 2:
The battery module housings utilize composite construction combining rigid materials for crash stability with integrated cooling channels. The housing structure integrates multiple functions (structural support, thermal management, and module containment) into a unified composite component that optimizes both space utilization and crash stability.
3Strength
If a complex frame construction is used to provide crash protection, then strength is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the battery module housings themselves. Each housing serves as both the structural container for battery cells and the primary crash protection element. The housings are directly fastened to the vehicle floor, eliminating the need for separate complex framing structures.
Solution Approach 2:
The battery module housings are designed as multi-functional components that simultaneously provide: structural support for crash protection, thermal management through integrated cooling channels, electrical isolation, and mechanical mounting interfaces. This universal design reduces overall system complexity.
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 enhanced crash stability and structural integrity in both longitudinal and transverse directions, while ensuring effective cooling and ease of maintenance, by distributing crash forces effectively and minimizing deformation risks to battery modules.
Implementation Method 1
The module housing can be configured so as to be perfusable by a cooling liquid and can thus be part of an active cooling circuit
Implementation Method 2
the battery modules can also be cooled by an actively cooled cooling plate below and/or above the battery modules
Data Source
AI summary
A traction battery vehicle floor has a plurality of self-supporting battery modules arranged in a horizontal plane (X,Y). The battery modules are fastened in a supporting manner directly to two lateral vehicle floor longitudinal supports. Adjacent to the frontmost and/or rearmost battery module, an electrical battery control module having a self-supporting battery control module housing is arranged in the battery module horizontal plane (X, Y). The two transverse ends of the battery control module housing are each structurally connected to the corresponding longitudinal support in a supporting manner.