EV Battery Frame Impact Load Reduction Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing impact load reduction structures for electric vehicles do not effectively mitigate the rapid increase of impact loads transmitted to batteries during collisions, as they often result in a large impact load being directly applied to the batteries due to the secure fixation of the vehicle body frame to the protrusion supporting the batteries.
Innovation Solution
An impact load reduction structure comprising a battery frame and a load reduction frame, where the load reduction frame is positioned to extend in the front-rear direction and has a lower rigidity than the battery frame, allowing it to come into contact with the battery frame only during collisions, thereby reducing the direct transmission of impact loads. The load reduction frame is designed to support the battery frame from the front side, reducing the initial impact load and preventing forward movement of the battery frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vehicle body frame is securely fixed to the protrusion supporting the batteries, then the batteries are reliably supported, but a large impact load is directly transmitted to the batteries during collision
Solution Approach 1:
A load reduction frame is introduced as an intermediary component between the vehicle body frame and the battery frame. This intermediate structure absorbs and distributes impact loads, preventing direct transmission to the batteries while maintaining reliable support during normal operation
Solution Approach 2:
The rigidity of the load reduction frame is specifically designed to be lower than that of the battery frame. This parameter difference allows the load reduction frame to deform preferentially during impact, absorbing energy and reducing the peak load transmitted to the batteries
2Strength
If a rigid battery frame is used to support heavy batteries, then the batteries are securely held, but the impact load is rapidly transmitted to the batteries during collision
Solution Approach 1:
The load reduction frame is designed with lower rigidity parameters compared to the battery frame. This creates a progressive deformation mechanism where the softer load reduction frame yields first during impact, extending the impact duration and reducing peak forces reaching the rigid battery frame
Solution Approach 2:
The load reduction frame acts as a pre-designed cushioning element positioned between the vehicle body and battery frame. It is specifically engineered to deform and absorb impact energy before the force reaches the batteries, providing protective cushioning in advance of actual collision events
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 configuration effectively reduces the impact load transmitted to the batteries in the early stages of a collision by distributing the load through the load reduction frame, which deforms preferentially, thereby suppressing the forward movement of the battery frame and reducing the overall impact load on the batteries.
Implementation Method 1
the load reduction frame, which deforms preferentially, thereby suppressing the forward movement of the battery frame and reducing the overall impact load on the batteries
Data Source
AI summary
An impact load reduction structure includes a battery frame and a load reduction frame. The battery frame is fixed to a vehicle body frame of an electrically-powered vehicle and supports a battery. The load reduction frame is disposed so as to extend in a front-rear direction on a front side of the battery frame. A rear section of the load reduction frame is disposed facing a front section of the battery frame with a predetermined gap therebetween such that the load reduction frame comes into contact with the battery frame when the electrically-powered vehicle is involved in a collision.