Aluminum Extruded Frame Cross-Section for Vertical Impact Absorption
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Solution Overview
Problem
Existing energy absorbing members made of aluminum alloy primarily address axial impact, failing to provide adequate collision resistance and lightweight properties in the vertical direction for battery cases in electric vehicles.
Innovation Solution
A frame member with a specific cross-sectional design featuring nodes and ribs in an aluminum-alloy extruded material, optimized for improved collision resistance and reduced weight by limiting the maximum number of ribs connected to each node and ensuring four or more nodes are unconnected, enhancing energy absorption in the vertical direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an aluminum alloy energy absorbing member is designed to absorb axial impact, then axial impact energy absorption is improved, but vertical direction collision resistance deteriorates
Solution Approach 1:
The invention transitions from axial impact absorption to lateral (vertical) impact absorption by changing the loading direction dimension. The frame member is specifically designed to absorb impacts applied perpendicular to its longitudinal axis, utilizing the cross-sectional geometry and rib-node structure to resist lateral forces during battery pack collisions.
2Weight of moving object
If the frame member structure is simplified to reduce weight, then weight reduction is achieved, but collision resistance deteriorates
Solution Approach 1:
The frame member cross-section is segmented into discrete nodes and ribs rather than using continuous solid structures. This segmentation allows the aluminum alloy extrusion to achieve high collision resistance through the distributed rib-node architecture while maintaining reduced weight compared to solid sections, as the ribs provide structural support only where needed to resist lateral impacts.
3Strength
If more ribs are added to connect nodes, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The invention optimizes the rib-node configuration parameters within the extrusion die design, specifically limiting the maximum number of ribs connected to any node to three or less and ensuring at least four nodes remain unconnected. These parameter constraints simplify the extrusion manufacturing process while maintaining adequate structural strength for lateral impact absorption.
Data Source
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AI summary
A frame member has an aluminum-alloy extruded material in which a plurality of nodes are set in a cross-sectional space of an outer peripheral wall and a plurality of ribs connecting the nodes are provided inside the outer peripheral wall, and the frame member has a cross-sectional shape in which a maximum number of the ribs connected to one of the nodes is three or less and there are four or more nodes that are not connected to the ribs.