Front Cross Member Geometry for EV Battery Protection
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Solution Overview
Problem
Electric vehicles face challenges due to the bulkiness and weight of batteries, which pose safety risks during collisions and require innovative structural designs to protect both the batteries and passengers, while also considering the need for efficient energy transfer and storage.
Innovation Solution
A passenger compartment support system for electric vehicles featuring a front cross beam with bent portions, crash beams, and a rigid tunnel that absorbs impact forces by crumpling and redirecting them away from the passenger compartment, utilizing lightweight yet strong materials like aluminum and carbon fiber to enhance safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batteries are made larger and more numerous to increase energy storage capacity, then the energy storage capability of the electric vehicle is improved, but the vehicle weight increases and the batteries become more susceptible to damage during collisions
Solution Approach 1:
The patent implements a multi-layer protective structure including a front cross member with energy-absorbing crash beams, a battery protection plate positioned between the batteries and front cross member, and reinforced firewall. This beforehand cushioning structure is designed to absorb and redirect collision forces before they reach the batteries, protecting them from damage while maintaining large battery capacity for energy storage
Solution Approach 2:
The battery protection plate serves as an intermediary element positioned between the batteries and the front cross member. This intermediary component redirects collision forces away from the batteries and toward the reinforced firewall and floor structure, thereby protecting the energy storage components while allowing the vehicle to maintain high energy storage capacity
2Object-affected harmful factors
If the vehicle structure is reinforced to protect batteries from collision damage, then the safety of the batteries is improved, but the overall vehicle weight increases
Solution Approach 1:
The patent applies local quality by reinforcing only the specific areas where battery protection is needed, such as the front cross member with crash beams, the battery protection plate, and the firewall. Other parts of the vehicle structure maintain their original design, avoiding unnecessary weight increase while providing targeted protection to the batteries
Solution Approach 2:
The patent employs composite material structures in the protective components, combining different materials with complementary properties to achieve high strength-to-weight ratio. This allows the vehicle to maintain enhanced battery protection while minimizing the overall weight increase from the reinforced structure
3Strength
If the front cross member is designed with bent portions to redirect collision forces, then the energy absorption capability is improved, but the structural complexity increases
Solution Approach 1:
The patent implements curvature in the front cross member design, with left and right portions bent rearward relative to the medial portion. This curved geometry enables the structure to redirect collision forces away from the batteries in a controlled manner, improving energy absorption capability while maintaining a relatively simple overall structural form that can be manufactured using conventional processes
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
The system effectively absorbs and redirects collision forces, protecting the passenger compartment and batteries from damage, while allowing for easy battery replacement and improving the vehicle's stability and cornering capabilities.
Implementation Method 1
absorbing at least a portion of a force from the collision at a front crash beam by crumpling a portion of the front crash beam
Implementation Method 2
receiving a collision at a front end of the electric vehicle and absorbing at least a portion of a force from the collision
Implementation Method 3
transferring a remaining portion of the force from a rear edge of the front crash beam to a medial portion of a front cross beam
Data Source
AI summary
A passenger compartment support for an electric vehicle includes a front cross beam forming a portion of a firewall configured to separate a passenger compartment of the vehicle from a motor compartment of the vehicle. The cross beam has a left portion, a medial portion, and a right portion. The left and right are bent rearward relative to the medial portion. The left portion is coupled with a left structure of the electric vehicle and the right portion is coupled with a ride structure of the electric vehicle. A right crash beam is coupled with and generally orthogonal to a right medial portion. A left crash beam is coupled with and generally orthogonal to a left medial portion. A floor structure is coupled with a bottom of the cross beam. A rigid tunnel is coupled to a rear of the cross beam and a top of the floor structure.