EV Front Body Structure for Pole Collision Intrusion Reduction
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Solution Overview
Problem
Electric vehicles face increased pole collision intrusion due to the absence of an engine and fewer accessory components, which reduces the ability to absorb impact loads effectively in head-on collisions.
Innovation Solution
A vehicle-body front structure for electric vehicles featuring a battery casing with a front-side battery frame, side frames extending forward, a cross member between the side frames, and reinforcement members extending from the cross member to the battery frame, which absorbs and transmits impact loads to inhibit deformation and reduce intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the engine and accessory components are removed in electric vehicles, then the vehicle structure is simplified and weight is reduced, but the ability to absorb impact loads in pole collisions deteriorates
Solution Approach 1:
The front structure is segmented into multiple functional components: the battery frame serves as the primary load-bearing structure, while the cross member and reinforcement member create a hierarchical support system. This segmentation allows the structure to absorb impact loads through controlled deformation of individual components while maintaining overall structural integrity.
Solution Approach 2:
The cross member and reinforcement member are positioned beforehand to create a cushioning effect against pole intrusion. The cross member extends forward from the battery frame to intercept poles before they reach critical components, while the reinforcement member provides additional structural support to prevent excessive deformation during impact.
2Object-affected harmful factors
If the cross member is positioned forward to intercept poles, then pole intrusion is reduced, but the structural complexity increases
Solution Approach 1:
The cross member serves multiple functions simultaneously: it acts as a structural support element connecting the side frames, provides a forward intercepting barrier against pole intrusion, and creates a load path to transmit impact forces to the battery frame. This multi-functionality reduces the need for additional dedicated components.
Solution Approach 2:
The reinforcement member is merged with the cross member structure, extending from the cross member to the battery frame to create an integrated support system. This merging consolidates the load-bearing and intrusion-prevention functions into a unified structural arrangement rather than separate components.
3Strength
If the side frames extend to vehicle-width-direction outer sides, then offset collision impact absorption is improved, but the space for other components is reduced
Solution Approach 1:
The side frames are positioned to extend toward the vehicle-width-direction outer sides specifically in the front portion to optimize offset collision resistance where it is most needed. The frames connect to the battery frame at strategic locations, creating local structural reinforcement without requiring the entire front structure to occupy excessive space.
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 structure effectively reduces pole intrusion in pole collisions by transmitting impact loads to the battery frame, enhancing the absorption of impact forces and maintaining structural integrity.
Implementation Method 1
a reinforcement member which extends toward vehicle rear from the cross member toward the front-side battery frame... transmit the impact load to the front-side battery frame
Implementation Method 2
the cross member is supported from the rear by the reinforcement member... deformation of the cross member is inhibited
Data Source
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AI summary
[Problem] In an electric vehicle, an entrance amount of a pole in a pole collision is reduced. [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 forward from the front-side battery frame 32, a cross member 19 which is suspended between the left and right side frames 11 and 12, and reinforcement members 19A and 19B which extend toward vehicle rear from the cross member 19 toward the front-side battery frame 32.