Vehicle Frame Cross Member Structure for Side-Impact Buckling Avoidance
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Solution Overview
Problem
Vehicle frames in electrified vehicles face increased likelihood of damage during impacts due to the additional space requirements of EV batteries, which can compromise the structural integrity and lead to buckling during side impacts.
Innovation Solution
Incorporating a cross member with varying strength sections, where the inner section is stronger and thicker than the outer sections, and a structural bracket to redirect the impact forces, allowing the outer sections to absorb kinetic energy and deform inelastically, thereby preventing the inner section from buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cross member is designed with uniform strength throughout, then the manufacturing is simpler and cost is lower, but the inner section may buckle during side impacts causing damage to critical components
Solution Approach 1:
The cross member is designed with non-uniform wall thickness, where the inner section has greater wall thickness than the outer sections. This local quality variation provides enhanced buckling resistance precisely where the battery and critical components are located, while maintaining simpler geometry elsewhere. The bracket is similarly designed with varying thickness to redirect impact forces away from the inner cross member section.
2Stability of the object's composition
If the outer sections of the cross member are made stronger to prevent overall deformation, then structural integrity is improved, but the kinetic energy from impacts cannot be absorbed effectively increasing the risk of inner section buckling
Solution Approach 1:
The cross member is segmented into distinct zones with different strength characteristics: outer sections with lower strength for energy absorption, and an inner section with higher strength for buckling resistance. The bracket acts as a separate structural element that redirects forces. This segmentation allows each zone to perform its specific function optimally during impact events.
Solution Approach 2:
The design intentionally allows the outer sections to deform and buckle during side impacts, converting the harmful impact energy into controlled deformation of the sacrificial outer sections. This prevents the energy from reaching the inner section, thereby protecting critical components. The bracket redirects additional impact forces away from the vulnerable inner area.
3Reliability
If a heavy bracket is added to redirect impact forces, then the protection of the battery is improved, but the overall vehicle weight increases
Solution Approach 1:
The bracket is designed with optimized thickness parameters that provide sufficient structural strength for force redirection while minimizing weight. The varying thickness design allows the bracket to be stronger where needed for force redistribution and thinner where less strength is required, achieving an optimal weight-to-protection ratio.
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
This design enhances the vehicle's ability to withstand side impacts by minimizing the deformation and buckling of the inner, critical components, thus protecting the battery and other central components from damage.
Implementation Method 1
allowing the outer sections to absorb kinetic energy and deform inelastically, thereby preventing the inner section from buckling
Data Source
AI summary
Vehicle frames with buckling avoidance features are disclosed. An example apparatus includes a cross member extending between a first side rail and a second side rail, a battery coupled to the cross member and the second side rail, and a bracket opposite to the battery, the bracket coupled to the first side rail and the cross member at a first location and a second location.