Closed-Section Dash Panel Reinforcement for EV Battery Crash Protection
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Solution Overview
Problem
The reduction of the engine compartment in electric vehicles due to battery placement necessitates a structure to absorb or transfer collision loads effectively, as the sub-frame can hit the battery during a frontal collision, causing damage and potential fire.
Innovation Solution
A reinforced dash panel structure with closed cross sections, a dash tunnel member, and a battery protector that guides the sub-frame away from the battery during a collision, enhancing rigidity and preventing the sub-frame from hitting the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the battery capacity is increased to extend traveling distance, then the traveling distance is improved, but the vehicle weight increases and the battery is positioned closer to the front end, increasing collision risk
Solution Approach 1:
The patent introduces a battery protection structure as an intermediary component between the sub-frame and the battery. This protective structure includes a first protection member and a second protection member that form a protective space, preventing direct contact between the sub-frame and battery during collisions while allowing the battery to be positioned forward for extended range
2Ease of operation
If the sub-frame is positioned to support engine components, then the engine components are properly mounted, but the sub-frame can hit the battery during frontal collision causing damage and potential fire
Solution Approach 1:
The protection structure is segmented into multiple components: a first protection member extending from the dash panel to protect the upper portion, and a second protection member extending from the floor panel to protect the lower portion. This segmentation allows the sub-frame to maintain its mounting function while being redirected along a safe path that avoids the battery
Solution Approach 2:
The protection members act as intermediaries that intercept and redirect the sub-frame during collision. The first and second protection members form a protective space that guides the sub-frame away from the battery, preventing direct impact while maintaining the sub-frame's structural support function
3Volume of stationary object
If the engine compartment is reduced to accommodate the battery, then the battery space is secured, but the structure for absorbing or transferring collision load to the rear cannot be adopted
Solution Approach 1:
The patent applies local reinforcement to specific areas rather than redesigning the entire engine compartment. The first protection member is attached to the dash panel at the upper portion, and the second protection member is attached to the floor panel at the lower portion, providing localized collision load management while preserving the reduced engine compartment space for battery accommodation
Data Source
AI summary
A structure for reinforcing a lower portion of a dash panel of a vehicle, which reinforces the rigidity of the lower portion of the dash panel that partitions an engine compartment and a passenger compartment of the vehicle, preventing a sub-frame from hitting a battery in the event of a collision, includes a dash panel provided at a front end portion of a cabin room in the vehicle in a width direction of the vehicle, a dash center cross upper member including an upper end portion connected to the front of the dash panel and extending downwardly from the upper end portion to a lower portion thereof at an interval from the dash panel, and a dash center cross lower member including a front end portion connected to the dash center cross upper member and a rear end portion connected to a lower end portion of the dash panel, in which the dash panel, the dash center cross upper member, and the dash center cross lower member form a closed cross section.