Composite Frame Carrier Ribs for EV Battery Crash Protection
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Solution Overview
Problem
Existing vehicle frames, particularly those with hybrid or electric drive systems, face challenges in protecting batteries from damage during collisions, which can lead to fires or explosions, and require structural reinforcements that are lightweight and customizable without significantly increasing vehicle weight.
Innovation Solution
A carrier system for vehicle frames comprising a periphery with outer and inner edges and ribs, produced through extrusion, co-extrusion, or pultrusion, which reinforces the frame to absorb collision energy and protect batteries, allowing for various material and shape customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If structural reinforcements are added to vehicle frames to protect batteries and improve crash performance, then safety and crash resistance are improved, but vehicle weight increases
Solution Approach 1:
The patent employs composite materials consisting of a polymer matrix combined with reinforcing fibers (glass, carbon, or aramid) to create a carrier that provides high strength and stiffness while maintaining low weight. This composite structure delivers superior crash protection and battery safety without significantly increasing vehicle weight, directly resolving the contradiction between safety improvement and weight control.
2Reliability
If traditional structural reinforcements are used, then crash protection is provided, but customization options for materials, shape, and rib arrangement are limited
Solution Approach 1:
The carrier is designed with a segmented rib structure where multiple ribs can be arranged in different patterns and orientations within the polymer matrix. This segmentation allows for customized rib arrangements tailored to specific crash scenarios and vehicle requirements, providing both crash protection and design flexibility.
Solution Approach 2:
The patent enables local customization of the carrier by varying rib density, thickness, and orientation in different regions of the polymer matrix. This local quality approach allows optimal crash protection in critical areas while maintaining customization options for materials, shape, and structural characteristics.
3Reliability
If multiple reinforcement components are used to achieve desired crash performance, then safety is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges multiple reinforcement functions into a single integrated carrier component. The polymer matrix combined with embedded ribs creates a unified structure that provides both structural support and crash protection, eliminating the need for separate reinforcement components and reducing overall device complexity.
Solution Approach 2:
The composite material structure integrates the polymer matrix and reinforcing ribs into a single functional unit that achieves desired crash performance through material composition rather than complex multi-component assembly, simplifying the overall device structure.
Data Source
AI summary
The present teachings generally relate to a carrier and method of making the carrier, the carrier comprising: a periphery having: an outer edge, arranged distally along a transverse axis of the carrier, configured to be oriented away from a frame enclosure of a vehicle, an inner edge, arranged distally along the transverse axis, configured to be oriented toward the frame enclosure of the vehicle, and distal ends arranged opposite each other along a longitudinal axis of the carrier; one or more series of ribs having: a cross-sectional pattern, and an orientation along the longitudinal axis, the transverse axis, or both.