EV Body Frame Layout for Battery Case Collision Load Dispersion
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Solution Overview
Problem
Existing vehicle-body structures for electric automotive vehicles face challenges in effectively dispersing and absorbing collision loads, particularly when large collision loads are applied, which can lead to increased deformation of critical components like the battery case.
Innovation Solution
A vehicle-body structure that includes a battery case positioned below the floor panel, with a pair of right-and-left front side frames and frame members extending forward from the battery case. This structure features plural connection portions spaced apart in the vehicle longitudinal direction to stabilize the frame members and ensure straight transmission of collision loads to the battery case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the collision load is absorbed by deforming the under member and the front extension portion, then the collision load is absorbed in two stages, but the collision load comes to be intensively applied to the front side member when the large collision load is inputted, so that the deformation becomes larger
Solution Approach 1:
The connection between the frame member and front side frame is segmented into multiple connection portions spaced apart in the vehicle longitudinal direction, allowing the collision load to be distributed across multiple connection points rather than concentrated at a single point, thereby reducing deformation of the front side member
Solution Approach 2:
The connection portions are arranged not only in the vehicle longitudinal direction but also extend in the vehicle width direction, creating a spatial distribution of connection points that disperses the collision load across multiple dimensions, preventing intensive application to the front side member
2Device complexity
If the frame member is connected to the front side frame at a single point, then the structure is simple, but the frame member becomes unstable and may incline in the vehicle width direction or vertical direction when collision load is applied
Solution Approach 1:
Multiple connection portions are provided at different locations along the frame member, with each connection portion having a specific function in stabilizing the frame member against inclination in different directions (vehicle width direction and vertical direction), providing localized support where needed
Solution Approach 2:
The connection portions are distributed in three-dimensional space, extending in both the vehicle longitudinal and width directions, creating a spatial configuration that provides multi-directional stability to the frame member without requiring excessive structural complexity
3Strength
If the collision load is transmitted straight to the front portion of the battery case, then dispersion and absorption of the collision load can be properly attained, but the battery case may deform under large collision loads
Solution Approach 1:
The transmission path of the collision load to the battery case is segmented through multiple connection portions spaced apart in the vehicle longitudinal direction, allowing the load to be gradually transmitted and absorbed along the transmission path rather than applied directly to the battery case, thereby reducing deformation of the battery case
Data Source
AI summary
A vehicle-body structure comprises right-and-left front side frames and right-and-left frame members respectively extending forward from a vehicle-front portion of a battery case below the right-and-left front side frames. Plural right-side connection portions to connect the right-side frame member to the right-side front side frame are provided to be spaced apart from each other in a vehicle longitudinal direction.