EV Frame Energy Absorption Pocket for Frontal Impact Protection
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Solution Overview
Problem
Electric and hybrid electric vehicles face challenges in protecting high voltage components during frontal impacts, as traditional crush zones are ineffective, leading to increased body cabin deformation and reduced drivable range due to the need for lighter protection structures.
Innovation Solution
A frame structure with a rear sub-frame and reinforcement brackets that form an energy absorption pocket under the vehicle, allowing controlled deformation and temporary restraint of the rear sub-frame to absorb impact energy, thereby protecting high voltage components and maintaining body cabin clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crush zone structures are used to protect high voltage components, then safety is improved, but vehicle mass increases reducing drivable range
Solution Approach 1:
The frame structure is divided into modular components including front sub-frames, rear sub-frames, side frame under-members, and reinforcement brackets. This segmentation allows each component to be optimized for its specific function while collectively providing protection, reducing the need for excessive mass in any single protective element.
Solution Approach 2:
The frame structure incorporates controlled deformation capabilities through energy absorption pockets that temporarily restrain the rear sub-frame during impact. This dynamic response allows the structure to adapt to impact forces, providing protection when needed while maintaining lighter mass during normal operation.
2Reliability
If high voltage components are positioned outside traditional crush zones, then component safety is improved, but drivable range is reduced due to smaller battery arrays
Solution Approach 1:
The frame structure uses controlled deformation and temporary restraint mechanisms that activate only during impact events. This allows high voltage components to be positioned in traditional crush zones during normal operation, maximizing available space for larger battery arrays, while providing protection when needed through dynamic structural response.
3Weight of moving object
If traditional load paths are removed to reduce mass, then vehicle efficiency is improved, but body cabin deformation increases during impact
Solution Approach 1:
The frame structure includes pre-configured energy absorption pockets and reinforcement brackets positioned to engage during impact. These preliminary structural arrangements ensure that when impact occurs, the deformation is channeled through controlled paths that protect the body cabin, even with reduced traditional load paths.
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 solution effectively reduces the mass of the safety cage while maintaining safety standards, allowing high voltage components to be placed in traditional crush zones and enabling larger batteries for increased range without compromising safety.
Implementation Method 1
at least one member is adapted to be deformed beyond its elastic limit
Implementation Method 2
The reinforcement bracket is provided for facilitating formation and controlling the deformation shape of an energy absorption pocket
Data Source
AI summary
A frame structure is adapted to absorb energy from frontal impacts and extends under a front portion of the body frame. The frame structure includes a rear sub-frame located below and in front of a pair of side frame under-members, and a reinforcement bracket attached to the pair of side frame under-members to facilitate formation and control a deformation shape in an energy absorption pocket in the side frame under-member during a frontal impact for temporarily restraining the rear sub-frame before releasing the rear sub-frame to slide past the reinforcement bracket. The energy absorption pocket is formed in the side frame under-member forward of and outboard of the reinforcement bracket during a frontal impact prior to the rear sub-frame be released from B-point bolt connections to the side frame under-members.