Diagonal Vehicle Deformation Structure for EV Driveline Protection
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Solution Overview
Problem
Electrically propelled vehicles face higher collision energy due to lower front mass, necessitating improved structures to protect sensitive components and absorb energy during collisions.
Innovation Solution
A vehicle deformation structure comprising a pair of front, rear, and intermediate frame elements, along with diagonally extending frame elements, forming a box-shaped structure that absorbs collision energy by deforming primarily in the longitudinal front zone while maintaining the rear zone intact, using suspension members for attachment to vehicle frame components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrically propelled vehicles use conventional front mass for collision absorption, then collision energy absorption is insufficient, but adding mass increases vehicle weight and reduces efficiency
Solution Approach 1:
The vehicle front structure is segmented into multiple functional zones: a deformable front zone for energy absorption and an intact rear zone for component protection. The frame elements are divided into front frame elements, intermediate frame elements, and rear frame elements, each serving specific deformation and protection functions.
Solution Approach 2:
The patent introduces diagonal frame elements that extend between front and rear frame elements at angles, adding a diagonal dimension to the traditionally vertical and horizontal frame structure. This creates three-dimensional deformation patterns that enhance energy absorption efficiency without requiring additional mass.
2Loss of energy
If the entire vehicle deformation structure deforms during collision, then energy absorption is maximized, but protection of sensitive components in the rear zone is reduced
Solution Approach 1:
The deformation structure is segmented into a front deformable zone and a rear protected zone. The front frame elements and intermediate frame elements are designed to deform preferentially, while the rear frame elements and enclosed components remain relatively intact. This spatial segmentation allows simultaneous energy absorption and component protection.
Solution Approach 2:
Different parts of the structure have different deformation characteristics. The front zone is designed with lower stiffness to deform easily and absorb energy, while the rear zone is designed with higher stiffness to protect sensitive components. The diagonal frame elements create localized deformation patterns that concentrate energy absorption in specific areas.
3Ease of manufacture
If a simple frame structure is used, then manufacturing is easier, but collision energy absorption capability is insufficient
Solution Approach 1:
The complex deformation structure is divided into modular frame elements (front, intermediate, rear) and diagonal elements that can be manufactured separately and assembled. This segmentation maintains manufacturing simplicity while achieving complex three-dimensional deformation behavior for enhanced energy absorption.
Solution Approach 2:
The addition of diagonal frame elements creates a three-dimensional lattice structure that provides enhanced stiffness and energy absorption pathways without significantly complicating manufacturing. The diagonal elements can be integrated using standard welding or joining techniques.
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 structure effectively protects electric driveline components by absorbing collision energy, maintaining the rear zone integrity, and providing enhanced stiffness and defined attachment points for load transfer.
Implementation Method 1
the energy resulting from such collision should preferably be absorbed by a vehicle deformation structure
Implementation Method 2
the generated energy during a collision is thus absorbed primarily by the longitudinal front zone
Implementation Method 3
the diagonally extending frame elements will, deform in a transversal direction away from each other. Thus, the volume formed inside the longitudinal front zone will be protected
Data Source
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AI summary
Vehicle deformation structure (100) for protecting vehicle electric driveline components during a collision, the vehicle deformation structure comprising a pair of diagonally extending frame elements (402, 404), wherein a first diagonally extending frame element (402) extends between the first end portion (106) of the first front frame element (102) and the second end portion (210) of the first rear frame element (202), and a second diagonally extending frame element (404) extends between the first end portion (108) of the second front frame element (104) and the second end portion (212) of the second rear frame element (204), wherein the first diagonally extending frame element (402) is attached to the first intermediate frame element (302) at a position (502) between the first (306) and second (310) end portions of the first intermediate frame element (302), and the second diagonally extending frame element (404) is attached to the second intermediate frame element (304) at a position (504) between the first (308) and second (312) end portions of the second intermediate frame element (304).