EV Dash Reinforcement Structure for Flat-Floor Body Strength
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Solution Overview
Problem
The transition from internal combustion engine vehicles to electric vehicles has resulted in a loss of vehicle body strength due to the deletion of the tunnel structure, which previously reinforced the vehicle body, and the need to accommodate batteries in the lower vehicle body space, making it challenging to maintain structural integrity and internal space while ensuring collision protection.
Innovation Solution
A reinforcement structure for electric vehicles that includes a closed cross-section dash lower reinforcement with internal ribs, a connection pipe to the battery, and strategically positioned cross members and floor members to distribute impact loads, formed from materials like aluminum or steel, maintaining a flat lower structure and minimizing reinforcement member usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the tunnel structure is deleted to accommodate batteries in the lower vehicle body, then internal space is expanded, but vehicle body strength is reduced
Solution Approach 1:
The lower dash portion is divided into upper and lower panels that form a closed cross-section structure, with the dash lower reinforcement member segmented into specific portions (first portion, second portion, third portion) positioned at different locations to provide targeted strength enhancement without requiring a complete tunnel structure
Solution Approach 2:
The reinforcement structure combines the lower dash portion panels with the dash lower reinforcement member to create a composite closed cross-section structure that provides both structural strength and space efficiency, allowing the battery to be mounted in the lower vehicle body while maintaining vehicle body strength
2Device complexity
If the tunnel structure is deleted to accommodate batteries, then structural complexity is reduced, but collision protection capability is weakened
Solution Approach 1:
The dash lower reinforcement member is pre-positioned within the closed cross-section formed by the lower dash portion panels before collision occurs, creating a prepared load-bearing structure that actively manages collision forces from the outset rather than relying on the deleted tunnel structure
Solution Approach 2:
The reinforcement structure utilizes the vertical dimension by positioning the dash lower reinforcement member between the lower dash portion upper panel and lower panel, creating a three-dimensional load distribution system that enhances collision protection without adding horizontal structural complexity
3Strength
If reinforcement members are increased to maintain vehicle body strength, then strength is improved, but device complexity increases
Solution Approach 1:
The dash lower reinforcement member serves multiple functions simultaneously: it forms part of the closed cross-section structure, provides collision protection, supports the battery mounting structure, and connects to the front side member and center floor member, eliminating the need for separate dedicated reinforcement components
Solution Approach 2:
The reinforcement structure merges the lower dash portion upper panel, lower panel, and dash lower reinforcement member into an integrated closed cross-section assembly that provides both structural strength and battery mounting functionality in a single unified structure rather than requiring multiple separate reinforcement members
Data Source
AI summary
A reinforcement structure for an electric vehicle includes a lower dash portion lower panel, a lower dash portion upper panel forming a closed cross-section with the lower dash portion lower panel in a vehicle body length direction and a dash lower reinforcement provided inside the closed cross-section.