Front Reinforcement Plate for Electric Vehicle Impact Resistance
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Solution Overview
Problem
Existing passenger compartment front reinforcement parts designed for thermal motor vehicles are insufficient to provide adequate mechanical strength for electric or hybrid motor vehicles subjected to frontal impacts due to their greater mass.
Innovation Solution
An assembled passenger compartment front reinforcement part comprising a plate with an upper and lower flange and an intermediate part, reinforced with a stiffener having an upper and intermediate portion at right angles, which is welded to a stamped pad, and featuring specific fixing lugs for enhanced structural integrity, with a thickness of 1.2 mm to 1.4 mm for increased resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing reinforcement parts designed for thermal motor vehicles are used, then the device complexity is reduced and ease of manufacture is improved, but the mechanical strength is insufficient for electric or hybrid motor vehicles
Solution Approach 1:
The reinforcement part is divided into multiple segments: a plate with upper and lower parts, an intermediate part, and a stiffener with upper and intermediate portions. This segmentation allows each component to be optimized independently for strength while maintaining overall structural integrity, resolving the contradiction between mechanical strength and device complexity.
Solution Approach 2:
The stiffener is strategically positioned and configured with specific geometric features (upper portion, intermediate portion at right angles) to provide localized reinforcement where impact forces are most severe. This local quality enhancement improves mechanical strength without requiring uniform thickening of the entire structure, thus avoiding excessive complexity.
2Strength
If the thickness of the reinforcement part is increased to 1.2 mm to 1.4 mm, then the mechanical strength is improved, but the weight of the component increases
Solution Approach 1:
The patent specifies a thickness parameter range of 1.2 mm to 1.4 mm for the reinforcement part, optimizing the balance between mechanical strength and weight. This parameter change ensures sufficient impact resistance for electric vehicles with greater mass while avoiding excessive weight gain that would occur with thicker materials.
Solution Approach 2:
The reinforcement part utilizes a composite structure combining a plate, intermediate part, and stiffener elements with different geometric configurations. This composite approach provides enhanced mechanical strength through structural design rather than simply increasing material thickness, thereby controlling component weight.
3Reliability
If multiple welding points and attachment lugs are added to the stiffener, then the reliability of the reinforcement structure is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The stiffener is equipped with pre-configured attachment lugs (first, second, third, and fourth attachment lugs) and welding tabs that are formed during the stamping process. These preliminary actions prepare the structure for reliable assembly through welding, ensuring consistent positioning and reducing the need for high-precision adjustments during manufacturing.
Solution Approach 2:
The intermediate part of the stiffener includes a welding tab that acts as an intermediary element for joining the stiffener to the plate and other components. This intermediary feature facilitates reliable welding connections while accommodating normal manufacturing tolerances, thereby maintaining structural reliability without requiring excessive manufacturing precision.
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 solution significantly enhances the mechanical resistance of electric or hybrid motor vehicles during frontal impacts by providing a robust reinforcement structure that effectively absorbs and distributes impact forces, ensuring better protection of the passenger compartment.
Implementation Method 1
The intermediate portion is provided with a welding tab configured for welding onto a stamped pad of an elongation portion of the intermediate portion
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The subject of the present invention is an assembled cabin-side front reinforcing part (5) intended to protect a cabin of an electric or hybrid motor vehicle from a frontal impact. The assembled cabin-side front reinforcing part (5) comprises a plate (6) which comprises an upper portion (61) provided with an upper flange (611) and a lower portion (62) provided with a lower flange (621), between which an intermediate portion (63) is formed. The assembled cabin-side front reinforcing part (5) is provided with a means (8, E) for reinforcing the mechanical strength of the assembled cabin-side front reinforcing part (5).