Frame-Shaped Crash Energy Management Structure for Vehicle Battery Protection
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Solution Overview
Problem
Existing crash energy management structures for vehicles are complex and do not effectively protect energy source containment units, such as battery packs or fuel cells, especially in rear or frontal collisions, where the risk of intrusion and damage is high due to their design and structural complexity.
Innovation Solution
A simpler crash energy management structure comprising a frame-shaped design with a transverse portion and inclined ends, connected by a second member, forming an additional load path between the energy source containment unit and the vehicle's end, which distributes impact forces and can bend to absorb energy, reducing the risk of intrusion and damage during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex crash energy management structure with multiple members is used, then the protective strength is improved, but the structural complexity increases
Solution Approach 1:
The patent merges multiple structural members into a single integrated crash energy management structure. This single structure includes a first member with transverse and inclined portions, and a second member connecting the inclined portions, forming a frame-shaped structure that combines the functions of multiple separate members into one unified component, thereby reducing structural complexity while maintaining protective strength
Solution Approach 2:
The crash energy management structure is segmented into distinct functional portions: a transverse portion for load distribution, inclined portions for energy absorption through deformation, and connecting members for structural integrity. This segmentation allows each portion to be optimized for its specific function while forming a simplified overall structure
2Reliability
If a rigid crash energy management structure is used to prevent energy source containment unit movement, then the protection effectiveness is improved, but the energy absorption capability deteriorates
Solution Approach 1:
The patent incorporates dynamic characteristics into the crash energy management structure by designing the first member with inclined portions that are intended to deform during a crash. This allows the structure to transition from a static rigid form to a dynamic energy-absorbing mechanism, where controlled deformation occurs to absorb impact energy while still preventing the energy source containment unit from moving forward excessively
3Ease of manufacture
If multiple separate components are assembled into the protective housing, then the manufacturing flexibility is improved, but the assembly complexity increases
Solution Approach 1:
The patent combines multiple structural functions into a single crash energy management structure that can be manufactured as one integrated component. This reduces the number of separate parts that need to be assembled into the protective housing, thereby reducing assembly complexity while maintaining the flexibility to manufacture the structure in various configurations
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 proposed structure effectively distributes crash loads, reduces the risk of energy source containment unit intrusion, and provides mechanical protection by acting as an additional load path and energy absorber, suitable for both rear and frontal collisions, and can be adapted for various vehicle configurations.
Implementation Method 1
the crash energy management structure is operable to bend about the predetermined bending location when an impact load is applied to the first end of the side rails
Implementation Method 2
The side rails are operable to bend about the predetermined bending location when an impact load is applied to the first end of the side rails
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a crash energy management structure (3) intended to be mounted at the rear or front portion of a vehicle (1) for protecting an energy source containment unit (5) of the vehicle in case of a crash. The crash energy management structure comprises: - a first member (11), comprising a transverse portion (15) extending in the transverse direction of the vehicle, the first member further having an inclined portion (17, 19) at each end of the transverse portion (15), - a second member (13), being parallel to the transverse portion (15) of the first member (11) and connecting the inclined portions (17, 19) or additional portions of each side of the first member (11) such that a frame-shaped structure (21) is formed, wherein the frame-shaped structure (21) is adapted to be positioned between the energy source containment unit (5) of the vehicle (1) and a rear or front end of the vehicle (1), with the first member (11) being closer to the end of the vehicle (1) than the second member (13). The invention further relates to a vehicle (1) comprising an energy source containment unit (5) and a crash energy management structure (3) as described above.