Asymmetric Vehicle Frame Beads for High-Voltage Component Protection
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Solution Overview
Problem
Battery-powered electric vehicles face challenges in protecting high-voltage components from damage during frontal collisions, which can lead to electrical shorts and battery shutdown, and existing solutions complicate vehicle design and maintenance.
Innovation Solution
A vehicle frame with asymmetric bead patterns on its rails to control deformation and minimize contact between high-voltage components and other parts during collisions, using longitudinally and vertically extending beads to enhance structural rigidity and controlled deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high-voltage components are packaged under the hood for ease of access, then ease of service is improved, but protection during frontal collision deteriorates
Solution Approach 1:
The patent applies asymmetry by configuring different bead patterns on the left and right longitudinal rails. The rail containing the high-voltage component has an asymmetric bead pattern designed to limit deformation more effectively on the side where the component is mounted, while the opposite rail has a different bead pattern optimized for its position. This asymmetric configuration allows the vehicle to maintain ease of access to high-voltage components under the hood while providing enhanced collision protection specifically tailored to the component's location.
2Object-affected harmful factors
If protection locations are chosen for collision safety, then protection during frontal impact is improved, but ease of access and serviceability deteriorates
Solution Approach 1:
The patent applies local quality by providing different bead patterns on different rails based on their specific functional requirements. The rail containing the high-voltage component has a bead pattern specifically optimized to limit deformation at the component's mounting location, while the opposite rail has a different bead pattern. This localized optimization ensures that each rail provides appropriate protection and support for its specific contents, maintaining both collision protection and serviceability.
3Object-affected harmful factors
If complex front-end structure is used to protect high-voltage components, then protection during frontal collision is improved, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by designing the bead patterns on the longitudinal rails to serve multiple purposes: they provide structural support for the vehicle frame, enable controlled deformation during collision to protect high-voltage components, and maintain ease of access to components under the hood. The asymmetric bead patterns are integrated into the existing rail structure, eliminating the need for separate protection mechanisms and reducing overall device complexity while achieving collision protection.
Data Source
AI summary
A vehicle including a frame that includes a first longitudinally extending rail and a second longitudinally extending rail, wherein one of the first longitudinally extending rail and the second longitudinally extending rail includes a component mounted thereto. The first and second longitudinally extending rails each include a bead pattern that limits deformation of the respective rail during a frontal impact to the vehicle, and the bead pattern of the one of the first longitudinally extending rail and the second longitudinally extending that includes the component mounted thereto is different from the bead pattern of the other of the first longitudinally extending rail and the second longitudinally extending rail that does not have the component mounted thereto to limit an amount of deformation thereof during the frontal impact to the vehicle to minimize movement of the component in a direction toward a high-voltage component attached to the one rail.