EV Center Frame Layout for Multi-Level Impact Load Dispersion
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Solution Overview
Problem
Conventional automobile structures with floor tunnels face challenges in suppressing cabin deformation during frontal or rearward impact loads, as the tunnel frames do not effectively disperse the impact load.
Innovation Solution
An electric-vehicle-body structure is designed with a floor panel and a center frame extending in the vehicle front-rear direction, along with a battery frame positioned lower than the floor panel, ensuring that impact loads are dispersed and absorbed across multiple points in the up-down direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a floor tunnel structure with tunnel frames is used, then the cabin structure is simplified and easier to manufacture, but the cabin deformation cannot be effectively suppressed during frontal or rearward impact loads
Solution Approach 1:
The floor structure is segmented into multiple independent reinforcement frames (first reinforcement frame, second reinforcement frame, third reinforcement frame) positioned at different locations. Each frame independently absorbs and disperses impact loads, preventing concentrated stress points while maintaining manufacturing simplicity. The segmentation allows each frame to function as a separate load-bearing element.
Solution Approach 2:
The reinforcement frames are positioned at different heights (first frame at floor panel level, second frame above floor panel, third frame below floor panel), creating a three-dimensional load distribution system. This vertical dimensionality allows impact loads to be dispersed across multiple elevation levels, effectively suppressing cabin deformation while maintaining structural integrity.
2Strength
If tunnel frames extending in the vehicle front-rear direction are provided, then the floor panel structure is strengthened, but the impact load is still locally applied and cabin deformation occurs
Solution Approach 1:
The reinforcement system is divided into multiple discrete frames positioned at different locations and heights rather than a single continuous tunnel frame. This segmentation distributes the impact load across multiple discrete points, preventing concentration at any single location while maintaining overall floor strength.
Solution Approach 2:
Reinforcement frames are distributed across three vertical levels (above floor panel, at floor panel level, below floor panel), creating a three-dimensional load distribution network. This vertical distribution prevents localized stress concentration by spreading impact forces across multiple elevation planes, effectively reducing harmful load concentration.
3Volume of moving object
If a tunnel portion largely bulging upward is used, then the exhaust pipe and propeller shaft can be housed, but the cabin deformation suppression during impact is compromised
Solution Approach 1:
The reinforcement system utilizes three vertical levels (above, at, and below the floor panel) to distribute impact loads, replacing the traditional single-level tunnel structure. This multi-level approach suppresses cabin deformation by dispersing forces across vertical dimensions, eliminating the need for a large upward-bulging tunnel while maintaining structural protection.
Solution Approach 2:
The large upward-bulging tunnel structure is extracted/replaced with a distributed reinforcement frame system at multiple heights. The essential function of housing exhaust pipes and propeller shafts is maintained through the framework, but the harmful characteristic of large upward bulge that compromises impact suppression is removed.
Data Source
AI summary
An electric-vehicle-body structure includes a floor panel constituting a floor of an occupant space, and a center frame disposed to be higher than and away from the floor panel at a vehicle-width-direction central portion of the occupant space and extending in a front-rear direction. A battery unit includes battery frames disposed at a lower position than the floor panel and extending in the front-rear direction. Such a positional relation is achieved in which the battery frames and the center frame overlap each other in a plan view.