Dual Dash Cross Member Layout for Flat-Floor EV Crash Load Dispersion
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Solution Overview
Problem
In electric vehicles with a large battery pack positioned below the floor panel, the lack of reinforcements along the floor panel makes it difficult to disperse collision loads effectively, leading to unintended deformation, necessitating a strong joining of the dash cross member and center tunnel.
Innovation Solution
The implementation of a dual dash cross member configuration, where the first dash cross member is divided into right and left portions by the center tunnel and the second dash cross member extends to curve along the center tunnel, providing a strong and extensive connection over a long distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a large battery pack is disposed below the floor panel, then the floor panel can be made flat, but it becomes difficult to provide reinforcements along the floor panel
Solution Approach 1:
The second dash cross member extends along the outline of the center tunnel in a three-dimensional path, moving from a two-dimensional reinforcement approach to a three-dimensional structural solution. This allows the cross member to connect to the center tunnel at multiple points along its length, providing structural support without requiring reinforcements on the floor panel surface.
2Shape
If reinforcements are not provided along the floor panel, then the floor panel remains flat, but collision load is primarily applied to the center tunnel
Solution Approach 1:
The second dash cross member merges with the center tunnel structure by extending along its outline and connecting at multiple points. This integration creates a combined structural system where the dash cross member and center tunnel work together to resist collision loads, distributing the force along the entire length of the connection rather than concentrating it at a single point.
Solution Approach 2:
The second dash cross member follows the curved outline of the center tunnel, adapting its shape to match the tunnel's geometry. This curved configuration allows the cross member to wrap around and connect to the center tunnel along its entire perimeter, creating a stronger, more distributed connection that effectively resists collision loads while maintaining the flat floor panel.
3Strength
If the dash cross member and center tunnel are strongly joined, then collision load can be effectively dispersed, but the structure becomes more complex
Solution Approach 1:
The dash cross member system is segmented into two distinct members: the first dash cross member that connects to the side faces of the center tunnel, and the second dash cross member that extends along the outline of the center tunnel. This segmentation allows each member to perform a specific function in load dispersion, creating a systematic approach to strength distribution without excessive overall complexity.
Data Source
AI summary
A vehicle including a vehicle body that includes: a floor panel; a dash panel; a first and a second dash cross members extending in a right-left direction of the vehicle along the dash panel; and a center tunnel extending from the dash panel rearward in the vehicle along the floor panel. The first dash cross member includes a right side portion extending from a right side face of the center tunnel to a right end of the dash panel and a left side portion extending from a left side face of the center tunnel to a left end of the dash panel. The second dash cross member is located above the first dash cross member and continues from the right end to the left end of the dash panel, and at least a part of the second dash cross member extends to curve along the center tunnel.