EV Front Body Structure for Head-On and Offset Impact Absorption
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Solution Overview
Problem
Existing vehicle-body front structures struggle to effectively absorb impact loads in both head-on and offset collisions, as inclined pipe frames in current designs collapse outwardly during head-on collisions, limiting their ability to absorb the increased impact load.
Innovation Solution
A vehicle-body front structure for electric vehicles featuring a battery casing with a front-side battery frame, side frames extending forward, and support portions on the vehicle-width-direction outer sides to absorb impact loads, along with cross members and a frame bracket for enhanced rigidity and collision resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the left pipe frame and the right pipe frame are inclined toward vehicle-width-direction outer sides to absorb impact load in offset collision, then the impact load can efficiently be absorbed in offset collision, but both pipe frames are deformed to collapse to the vehicle-width-direction outer sides in head-on collision, making it difficult to absorb the largely rising impact load
Solution Approach 1:
The side frames are divided into multiple sections with different structural characteristics. The front portion has an inclined configuration for offset collision absorption, while the rear portion connects to the battery casing for head-on collision resistance. This segmentation allows each section to optimize its function for specific collision types.
Solution Approach 2:
Different portions of the side frames have different structural properties. The front sections are designed with inclination and lower rigidity to absorb offset collision energy through controlled deformation, while the rear sections near the battery casing have higher rigidity and different orientation to resist head-on collision forces and protect the battery.
2Ease of operation
If the left pipe frame and the right pipe frame are inclined toward vehicle-width-direction outer sides, then the extending direction agrees with impact load input direction in offset collision, but the pipe frames collapse to the vehicle-width-direction outer sides in head-on collision
Solution Approach 1:
The side frames are designed with dynamic deformation characteristics. In offset collision, the inclined front portions deform dynamically to absorb energy. In head-on collision, the rear portions connected to the rigid battery casing maintain structural stability and prevent catastrophic collapse, allowing the structure to adapt its response based on collision type.
Solution Approach 2:
The battery casing acts as an intermediary structure that receives and redistributes impact loads from the side frames. In head-on collision, it provides a stable platform that prevents the side frames from collapsing outward, while in offset collision, it allows controlled deformation of the side frames to absorb energy.
Data Source
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AI summary
[Problem] An impact load is enabled to be sufficiently absorbed in both of a head-on collision and an offset collision. [Means for Solution] A vehicle-body front structure A for an electric vehicle includes a front-side battery frame 32 which extends in a vehicle width direction, a pair of left and right side frames 11 and 12 which extend from the front-side battery frame 32 to be positioned on vehicle-width-direction outer sides toward front, a left-side support portion 41 which is mounted on the front-side battery frame 32 and supports the left side frame 11 from the vehicle-width-direction outer side, and a right-side support portion 42 which is mounted on the front-side battery frame 32 and supports the right side frame 12 from the vehicle-width-direction outer side.