A CRASH ENERGY DISTRIBUTION SYSTEM FOR A VEHICLE

Abstract

This disclosure provides a crash energy distribution system (100) to redirect or absorb impact forces during a vehicle crash, minimize their transfer to the vehicle's battery pack (102), and prevent cross members (110) or other frame components from intruding into the battery pack (102). The system (100) comprises a pair of first elements (106) positioned along the longitudinal sides of the vehicle to absorb impact forces during a side impact. Additionally, one or more second elements (108) are configured between the first elements (106) to transfer impact forces from the crash-side first element to the other first element.The second elements (108) are positioned within the cross members (110) of the vehicle, their ends being coupled to the respective first elements (106) by a series of damping elements (112) which absorb the impact forces and reduce their transmission to the battery pack (102).

Description

This disclosure relates to the field of vehicle safety. In particular, this disclosure relates to a crash energy distribution system for an electric vehicle, designed to prevent one or more cross members from penetrating the vehicle's battery pack during a collision. Modern vehicles, especially electric vehicles (EVs), increasingly rely on high-voltage battery packs as a core component of their powertrains. These battery packs are often located in the vehicle's underbody or chassis to optimize space and improve overall weight distribution. Due to the battery pack's critical role in powering the vehicle, its protection in accidents or collisions is essential to prevent both physical damage to the battery and the potential for hazardous situations such as fires caused by electrical short circuits. In a collision scenario, especially frontal, side, or rear impacts, significant forces are exerted on the vehicle's body structure. This impact energy is normally absorbed by various parts of the vehicle's crash safety system, such as crumple zones, crossmembers, and other structural components. However, in some cases, particularly high-energy impacts, the impact forces transmitted through the vehicle chassis or crossmembers can cause these components to penetrate critical areas such as the battery pack, compromising its integrity and potentially leading to catastrophic consequences such as battery leakage, thermal breakdown, or even fire. To reduce accident risks and improve vehicle safety, various energy absorption systems have been developed in the past. These include crumple zones, energy-absorbing materials, and strategically placed structural elements designed to absorb or disperse impact forces. For example, patent document KR19990017622A discloses a side seal for a vehicle comprising an inner plate whose lower edge is connected to both sides of a floor plate forming the floor of the vehicle compartment. The inner plate is curved inwards. A track is formed to connect to the upper and lower ends of the inner plate, creating a cavity. The track includes an outer plate, which is connected to the upper and lower edges of the inner plate via a force plate and curved outwards to form another cavity.This arrangement creates a cavity on the outer surface of the outer plate that absorbs the laminar load in a side impact. The side seal also incorporates a side damper, mounted inside the side damper to increase its stiffness by distributing the impact load across the vehicle body during a side collision. Furthermore, crossmembers, typically metal rods or beams, play a significant role in maintaining the vehicle's structural integrity and are often used to connect different sections of the vehicle frame. They are essential for maintaining the alignment and stability of the vehicle body during a collision. However, conventional crossmember arrangements do not account for the load-bearing capacity of the battery pack in electric vehicles. While effective in certain applications, the crossmembers can potentially pose a risk to the battery pack in the event of a side collision under severe impact. In some cases, the crossmembers can penetrate directly into the battery pack or exert excessive pressure on the battery pack housing, leading to damage or failure. Existing solutions to prevent such penetration generally focus on reinforcing the battery enclosure or adding external protective layers. However, these solutions often result in added weight or complexity, which can reduce the overall performance and efficiency of the vehicle. There is a significant need for an improved and reliable solution to address the aforementioned shortcomings and deficiencies in the current state of the art, particularly regarding the prevention of crossmembers or other frame components intruding into the battery pack during collisions, especially in electric vehicles. Such a solution should protect the battery pack from both direct physical damage and the risks associated with energy transfer through the vehicle chassis. A system capable of effectively redirecting, absorbing, or dissipating crash energy, thus preventing crossmembers from impacting the battery pack, would significantly improve the safety of electric vehicles and contribute to the overall vehicle safety in crash situations. A general objective of this disclosure is to provide a crash energy distribution system that redirects or absorbs impact forces in such a way as to prevent the intrusion of cross members or other frame components into the vehicle's battery pack. One objective of this disclosure is to provide a crash energy distribution system to improve battery protection without the need for excessive structural reinforcements or additional weight. Another objective of this disclosure is to provide a crash energy distribution system that ensures the integrity of the battery pack is maintained in a variety of accident scenarios. A further objective of this disclosure is to provide a crash energy distribution system that minimizes the risk of intrusion into the battery pack by effectively dispersing impact forces during a crash, thereby suppressing the transfer of impact forces to the vehicle's battery pack and reducing the risk of battery damage, thermal events, and failure. The components of the crash energy distribution system are lightweight and cost-effective, enabling easy integration into existing vehicle designs without significantly impacting production costs or vehicle performance. Another objective of this disclosure is to provide a crash energy distribution system that disperses or redirects impact forces acting laterally away from the battery pack of an electric vehicle, thereby reducing the transmission of these impact forces to the battery pack. Another objective of this disclosure is to provide a crash energy distribution system to improve the safety of electric vehicles by offering comprehensive protection for the battery pack in the event of an accident. Another objective of this disclosure is to provide a crash energy distribution system that can be easily adapted to different vehicle designs, accident scenarios and battery placements, and offers flexibility in its application across different electric vehicle models. Aspects of this disclosure relate to a crash energy distribution system for a vehicle designed to effectively redirect or absorb impact forces to prevent crossmembers or other frame components from intruding into the vehicle's battery pack, thereby improving safety during a collision. The system ensures the integrity of the battery pack in various crash scenarios and reduces the risk of intrusion, damage, thermal events, and failure by dispersing impact forces. Additionally, the system incorporates lightweight, cost-effective components that can be easily integrated into existing vehicle designs without significantly impacting production costs or performance. The system disperses or absorbs impact forces away from the battery pack, providing comprehensive protection and enhanced overall safety. In one aspect, the present disclosure provides a crash energy distribution system for a vehicle, comprising a pair of first links configured along two lateral sides of the vehicle to receive impact forces during a side impact, and one or more second links configured between the pair of first links to transfer the impact forces from one first link on the impact side to the other first link of the pair of first links. The one or more second links are positioned within one or more cross members of the vehicle. The ends of the one or more second links are coupled to the respective first links by a plurality of damping elements. In some embodiments, each of the first elements may include an energy absorption element and a stiffening beam positioned behind the energy absorption element. In some embodiments, the energy absorption element can be made of aluminum. The stiffening beam can be made of a high-strength steel alloy. In some embodiments, the plurality of damping elements can be attached between the corresponding stiffening beam and the one or more second elements. In some embodiments, the stiffening beam can be positioned adjacent to a corresponding side sill of the vehicle. The stiffening beam can extend in a longitudinal direction of the vehicle. In some embodiments, the energy absorption element may comprise a variety of protruding sections to absorb the impact forces before the impact forces are transferred to the stiffening beam. In some embodiments, the energy absorption element may comprise a plurality of internal chambers to absorb the impact forces transmitted from the side threshold and to enable the energy absorption element to distribute the impact forces to the stiffening beam. In some embodiments, the stiffening beam can comprise a base section and one or more stiffening projections extending outwards from the base section. The one or more stiffening projections contact the energy-absorbing element and the adjacent damping element to allow the transmission of the impact forces received to the adjacent damping element for absorption of that portion of the impact forces. In some embodiments, each of the multiple damping elements may include a spring-activated damper to absorb a proportion of the impact forces. In some embodiments, the vehicle may include a battery pack located below one or more cross members. The transfer of impact forces from the first member on the impact side of the vehicle to the other first member on the opposite side of the vehicle by the one or more second members located within the cross members prevents the cross members from bending and the subsequent penetration of the bent cross member into the battery pack. Various objectives, features, aspects and advantages of the inventive subject matter will become clearer from the following detailed description of preferred embodiments together with the accompanying drawing figures, in which identical numbers represent identical components. The accompanying drawings are included to provide a further understanding of this disclosure and are incorporated into and form part of this description. The drawings illustrate exemplary embodiments of this disclosure and, together with the description, serve to explain the principles of this disclosure. Fig. 1 shows an exemplary schematic representation of a crash energy distribution system for an electric vehicle according to one embodiment of this disclosure; and Fig. 2 shows an exemplary perspective view of a vehicle chassis equipped with the crash energy distribution system according to one embodiment of this disclosure. The following is a detailed description of embodiments of the disclosure illustrated in the accompanying drawings. The embodiments are described in such detail to clearly communicate the disclosure. However, the level of detail provided is not intended to limit the expected variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives that fall within the scope of the present disclosures as defined by the accompanying claims. During a collision, such as a frontal, side, or rear-end impact, an electric vehicle experiences significant forces on its body, which are normally absorbed by components like crumple zones, crossmembers, and other structural elements. However, in high-impact crashes, these forces can travel through the vehicle chassis or crossmembers, potentially damaging a battery pack mounted under the floor and causing serious problems like leaks, thermal breakage, or fires. To improve safety, various systems have been developed to absorb or dissipate impact forces, with crossmembers helping to maintain the vehicle's structure. However, the conventional crossmember design fails to adequately address the load-bearing capacity of the battery pack in electric vehicles.In side collisions, crossmembers can damage the battery pack or exert excessive pressure, leading to failure. Current solutions to prevent this typically involve reinforcing the battery or adding protective layers, but these techniques can add weight or complexity, which can reduce vehicle performance. The embodiments described here relate to a crash energy distribution system for an electric vehicle that disperses or absorbs impact forces to prevent crossmembers or other frame components from damaging the vehicle's battery pack, thereby improving collision safety. This system offers enhanced battery protection without adding excessive weight or structural reinforcements, balancing safety and performance. The system maintains the integrity of the battery pack in various crash scenarios and reduces the risk of damage, thermal issues, and failure through effective impact force management. The system utilizes lightweight, cost-effective components that can be easily integrated into existing vehicle designs without significantly impacting cost or performance.Additionally, the system helps to divert impact forces away from the battery pack and offers overall protection and flexibility for use in various vehicle designs and battery placements. Fig. 1 shows an exemplary schematic representation of a crash energy distribution system (referred to here as the “system”) 100, designed to disperse or absorb impact forces, thereby preventing crossmembers or other frame components from damaging the vehicle’s battery pack 102 during a collision. The system 100 also prevents the vehicle frame components from penetrating the battery pack 102, maintaining its integrity and improving the safety of the battery pack 102. The battery pack 102 is typically installed under the vehicle’s floor 104 and contains multiple battery cells connected in series and / or parallel configurations to store and supply electrical energy to various vehicle components. The crash energy distribution system 100 comprises at least one pair of first links 106 positioned along the lateral sides of the vehicle to absorb impact forces during a side impact. Each first link 106 comprises an energy absorption link 106-1 and a stiffening beam 106-2 located behind the energy absorption link 106-1 in the lateral / transverse direction of the vehicle. In one exemplary embodiment, the energy absorption element 106-1 can be made of an extruded lightweight metal or alloy such as aluminum. Alternatively, the energy absorption element 106-1 can be constructed of high-strength energy-absorbing foams, lightweight composites, or deformable materials that absorb impact forces while maintaining the structural integrity of the stiffening beam 106-2. In one exemplary embodiment, the energy absorption element 106-1 can have a series of projecting sections to absorb impact forces before they are transmitted to the stiffening beam 106-2. In another exemplary embodiment, the energy absorption element 106-1 can include multiple internal chambers that absorb the impact forces transmitted from the vehicle's side sill and allow the energy absorption element 106-1 to efficiently distribute the forces to the stiffening beam 106-2. The vehicle can include two side sills as part of the vehicle's body structure. These side sills can be spaced laterally and positioned below the door flanges, extending along the longitudinal direction of the vehicle. In an exemplary embodiment, the stiffening beam 106-2 can be constructed from a high-strength steel alloy and positioned adjacent to the corresponding side sill, extending longitudinally along the vehicle. The energy-absorbing element 106-1 ensures that crash energy from a collision is distributed across the stiffening beam 106-2, thereby preventing localized impact forces that could directly damage the vehicle frame components or the battery pack 102. The system 100 also includes second links 108, which are positioned between the first links 106 to transfer impact forces from one first link 106 on one side to the other during an accident or collision. The second links 108 are positioned within crossbeams 110 that extend transversely across the vehicle. The ends of each second link 108 are coupled to the respective first links 106 by one or more damping links 112, which are attached between the stiffening beam 106-2 and the corresponding second link 108. The damping links 112 can include spring-activated dampers or hydraulic shock absorbers that compress and decompress to absorb the transmitted impact forces, thereby reducing the transmission of these forces to the battery pack 102.The design of the first and second links 106, 108 ensures that during a collision the battery pack 102 remains protected from the majority of the impact forces, thereby reducing the likelihood of battery cell damage and the risk of thermal events and failure of the battery pack 102. In an exemplary embodiment, the stiffening beam 106-2 can resemble a leaf spring, with a base section and one or more stiffening projections extending outwards from the base section. The stiffening projections can contact both the energy-absorbing element 106-1 and the adjacent damping element 112, thereby effectively transferring the impact forces received by the stiffening projections to the damping element 112 for absorption. This configuration helps to prevent lateral impact forces from reaching the battery pack 102, protecting it from damage from all sides and improving the overall safety of the vehicle. Referring to Fig. 2, components of the system 100 can be mounted on the chassis 202 of the vehicle, with the battery pack 102 located below the cross members 110, which extend transversely across the chassis 202 of the vehicle. The battery pack 102 can include a housing located below the cross members 110. The housing can accommodate a plurality of battery cells and can be covered by a cushioning element to reduce the impact on the battery cells. In one exemplary embodiment, each cross member 110 can be located above the vehicle floor 104, with the battery pack 102 located below it. The cross members 110 can be positioned under both the front and rear seats of the vehicle. The cross members 110 can be made of an extruded lightweight metal or alloy. The second links 108 are positioned at the lateral ends of each crossbeam 110 in contact with the stiffening beams 106-2. During a side collision, the impact forces traveling through the first link 106 on the side of the vehicle involved in the accident are transferred by the second links 108 to the first link 106 on the opposite side. This transfer prevents the crossbeams 110 from bending and effectively stops them from penetrating the battery pack 102. Thus, the System 100 effectively redirects or absorbs impact forces during a crash, minimizing the transfer of these forces to the vehicle's battery pack. By preventing crossmembers or other frame components from penetrating the battery pack, particularly under side impact forces, the System 100 reduces the risk of battery damage, thermal events, and failure, improving safety for both vehicle occupants and bystanders. The System 100 significantly enhances overall crash safety and reduces the likelihood of battery-related incidents. While the foregoing describes various embodiments of the invention, other and further embodiments of the invention can be developed without deviating from its basic scope. The scope of the invention is defined by the following claims. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person with ordinary technical skills to make and use the invention when combined with the information and knowledge available to such a person. The present disclosure provides a crash energy distribution system that effectively redirects or absorbs impact forces to prevent cross members or other frame components from penetrating the vehicle's battery pack, thereby increasing safety in a collision. The present disclosure provides a crash energy distribution system that improves battery protection without requiring excessive structural reinforcements or adding significant weight, and offers a balance between safety and vehicle performance. The present disclosure provides a crash energy distribution system that ensures the integrity of the battery pack is maintained in a variety of accident scenarios and provides reliable protection under various accident conditions. The present disclosure provides a crash energy distribution system which, by effectively diverting impact forces during a crash, reduces the risk of intrusion into the battery pack, damage, thermal events and failures, thereby improving vehicle safety. The present disclosure provides a crash energy distribution system that includes lightweight and cost-effective components that allow for easy integration into existing vehicle designs without significantly impacting production costs or vehicle performance. The present disclosure provides a crash energy distribution system that effectively dissipates or redirects impact forces acting in a lateral direction, keeping them away from the battery pack and reducing the risk of damage to the battery during a crash. The present disclosure provides a crash energy distribution system that offers comprehensive protection for the battery pack and increases the overall safety of electric vehicles in the event of a crash. The present disclosure provides a crash energy distribution system that is configured to be easily adapted to different vehicle designs, accident scenarios and battery placements, offering flexibility for application in various electric vehicle models. LIST OF REFERENCE NUMBERS 100 Crash energy distribution system. 102 Battery pack. 104 Vehicle floor. 106 First element. 106-1 Energy absorbing element. 106-2 Stiffening beam. 108 Second element. 110 Cross member. 112 Damping element. 202 Vehicle chassis. QUOTES INCLUDED IN THE DESCRIPTION This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature KR 19990017622A

[0004]

Claims

A crash energy distribution system (100) for a vehicle, comprising: a pair of first elements (106) configured along two longitudinal sides of the vehicle to absorb impact forces during a side impact of the vehicle; and one or more second elements (108) configured between the pair of first elements (106) to transfer the impact forces from one crash-side first element to the other first element of the pair of first elements (106); wherein the one or more second elements (108) are positioned within one or more cross members (110) of the vehicle, and wherein ends of the one or more second elements (108) are coupled to the respective first elements (106) by a plurality of damping elements (112). The crash energy distribution system (100) according to claim 1, wherein each of the first elements (106) comprises an energy-absorbing element (106-1) and a stiffening carrier (106-2) positioned behind the energy-absorbing element (106-1). The crash energy distribution system (100) according to claim 2, wherein the energy-absorbing element (106-1) is made of aluminium and the stiffening support (106-2) is made of a high-strength steel alloy. The crash energy distribution system (100) according to claim 2, wherein the plurality of damping elements (112) are attached between the corresponding stiffening carrier (106-2) and the one or more second elements (108). The crash energy distribution system (100) according to claim 2, wherein the stiffening beam (106-2) is positioned next to a corresponding side sill of the vehicle and extends in the longitudinal direction of the vehicle. The crash energy distribution system (100) according to claim 2, wherein the energy-absorbing element (106-1) comprises a plurality of protruding sections to absorb the impact forces before the transfer of the impact forces to the stiffening beam (106-2). The crash energy distribution system (100) according to claim 5, wherein the energy-absorbing element (106-1) comprises a plurality of internal chambers to absorb the impact forces transmitted from the side sill and to enable the energy-absorbing element (106-1) to distribute the impact forces to the stiffening beam (106-2). The crash energy distribution system (100) according to claim 2, wherein the stiffening support (106-2) comprises a base section and one or more stiffening projections extending outwards from the base section, and wherein the one or more stiffening projections contact the energy-absorbing element (106-1) and the adjacent damping element (112) to enable the transfer of the impact forces thereby absorbed to the adjacent damping element to absorb part of the impact forces. The crash energy distribution system (100) according to claim 1, wherein each of the plurality of damping elements (112) comprises a spring-actuated damper to absorb part of the impact forces. The crash energy distribution system (100) according to claim 1, wherein the vehicle comprises a battery pack (102) arranged below one or more cross members (110), and wherein the transmission of the impact forces from the first element (106) on the crash side of the vehicle to the other first element (106) on the opposite side of the vehicle by one or more second elements (108) located inside the cross members (110) prevents bending of the cross member (110) and consequently the penetration of the bent cross member (110) into the battery pack (102).

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