EV Body Load Paths Through Side Sills and Battery Case
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Solution Overview
Problem
Existing vehicle-body structures for electric automotive vehicles face challenges in balancing collision safety and weight reduction, particularly in effectively dispersing and absorbing large collision loads while minimizing weight increase.
Innovation Solution
The vehicle-body structure incorporates a dash panel, front side frames, side sills, first and second longitudinal load-transmitting members, and a battery case designed to disperse collision loads through multiple pathways, including the floor panel, side sills, and battery case, thereby optimizing member strength and weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the strength of the front side member is increased to deal with large collision load, then collision safety is improved, but vehicle-body weight increases
Solution Approach 1:
The patent divides the collision load transmission path into multiple segments: the front side member, the floor panel, and the battery case. By segmenting the load-bearing structure, the front side member does not need to bear the entire collision load alone, allowing for weight optimization while maintaining collision safety. The load is distributed through multiple structural components rather than concentrated in one member.
Solution Approach 2:
The patent introduces a vertical dimension to the load transmission path by utilizing the battery case as a load-bearing component. Traditionally, the battery case was only for energy storage, but this patent makes it structurally functional by having it bear collision loads from above through the floor panel, creating a multi-dimensional load distribution system that reduces the weight burden on the front side member.
2Strength
If the strength of the front side member is increased, then collision safety is improved, but local concentrated load requires additional reinforcement
Solution Approach 1:
The patent segments the load transmission function across multiple components (front side member, floor panel, battery case), which distributes the reinforcement requirements across these components rather than concentrating all reinforcement needs at the front side member. This reduces the number of additional reinforcement points needed in the vehicle body structure.
Solution Approach 2:
The floor panel is given a dual function: it serves as both a structural component for passenger protection and as a load transmission path for collision forces. By making the floor panel structurally functional, the patent eliminates the need for separate reinforcement structures, thereby reducing vehicle body complexity while maintaining collision safety.
3Strength
If under member and front extension portion are used as collision absorbing members, then collision load is absorbed in two stages, but weight reduction of vehicle body becomes difficult
Solution Approach 1:
The battery case, which traditionally only serves for energy storage, is made to serve dual purposes by also functioning as a collision load-bearing component. By making the battery case structurally functional, the patent eliminates the need for separate dedicated collision absorption structures, achieving weight reduction while maintaining collision absorption capability through the existing battery case structure.
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 structure effectively absorbs collision loads by dispersing them through the side sills and battery case, while optimizing the strength of individual members to achieve weight reduction without compromising safety.
Implementation Method 1
a pair of right-and-left first longitudinal load-transmitting members respectively extending from respective vehicle-rear portions of the right-and-left front side frames to the right-and-left side sills along an upper face of the floor panel
Implementation Method 2
a pair of right-and-left second longitudinal load-transmitting members respectively extending from the respective vehicle-rear portions of the right-and-left front side frames toward a vehicle-front portion of the battery case along a lower face of the floor panel
Implementation Method 3
the collision load is absorbed by its dispersion by both of the side sill and the battery case
Data Source
AI summary
A vehicle-body structure comprises a dash panel, a pair of right-and-left front side frames, a pair of right-and-left side sills, a pair of right-and-left first longitudinal load-transmitting members respectively extending from respective vehicle-rear portions of the right-and-left front side frames to the right-and-left side sills along an upper face of the floor panel, and a pair of right-and-left second longitudinal load-transmitting members respectively extending from the respective vehicle-rear portions of the right-and-left front side frames toward a vehicle-front portion of the battery case along a lower face of the floor panel.