EV Floor Structure With Cross Members for Rigidity and Side Impact
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Solution Overview
Problem
The flat type center floor structure in electric vehicles faces issues with reduced rigidity due to increased parts, leading to excessive vibration and potential damage during side collisions, particularly affecting the battery assembly and occupant safety.
Innovation Solution
A floor structure for electric vehicles that includes cross members, seat mounting units, and reinforcement members, utilizing aluminum extruded materials to enhance coupling rigidity, minimize vibration, and improve side impact performance by connecting seats and battery assemblies securely through pipe nuts and bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flat type center floor structure is used to increase battery capacity and secure wide indoor space, then the vehicle interior space is improved, but the rigidity of the vehicle body deteriorates causing excessive vibration
Solution Approach 1:
The floor structure is divided into multiple segments including a tunnel portion with left and right floor panels, and multiple cross members (first, second, third cross members) connecting them. This segmentation provides structural reinforcement while maintaining the flat overall profile needed for battery installation and interior space.
2Length of stationary object
If the flat type center floor structure is used to reduce cross-section height, then the vehicle height is reduced, but the rigidity deteriorates leading to excessive vibration
Solution Approach 1:
Instead of increasing vertical height to improve rigidity, the design adds structural elements in the horizontal plane - multiple cross members connecting left and right floor panels through the tunnel portion. This provides rigidity through lateral bracing while maintaining low cross-section height.
3Object-affected harmful factors
If the crash load is concentrated on the side sill during side collision, then the side impact resistance is improved, but the side sill suffers rotational deformation causing damage to battery assembly and occupant
Solution Approach 1:
The side impact protection structure is segmented into multiple reinforcement members (first and second reinforcement members) positioned at different locations within the side sill. This distributes the crash load across multiple points rather than concentrating it on the side sill alone, preventing rotational deformation.
Solution Approach 2:
The floor structure uses composite construction with floor panels connected to cross members and reinforcement members, creating a composite structural system that distributes and manages crash loads more effectively than a single-material structure.
Data Source
AI summary
An embodiment floor structure for an electric vehicle includes a cross member connected to an upper portion of a floor panel of the electric vehicle along a vehicle width direction, wherein the floor panel is configured to be connected to a pair of side sills that are disposed on each side of the electric vehicle, respectively, and extend in a front-to-rear direction of the electric vehicle, and a seat mounting unit installed on the cross member, wherein the seat mounting unit comprises a lower mounting bracket connected to an upper portion of the cross member and an upper mounting bracket connected to an upper portion of the lower mounting bracket.