EV Subframe Diagonal Load Paths for Battery Crash Protection
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Solution Overview
Problem
Existing vehicle frames for long-range battery electric vehicles (BEVs) are not adequately designed to support larger batteries, leading to potential damage during collisions and increased repair costs, as they may deform and expose the battery to intrusion.
Innovation Solution
The proposed vehicle frame design includes a subframe with diagonal members to transfer longitudinal loads, a truss-embedded cross-member, and a forward-bent cross-member to distribute loads laterally, reducing deformation and protecting the battery during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the vehicle frame is extended laterally and/or longitudinally to support a larger battery, then the travel range of the BEV is increased, but the frame becomes more vulnerable to deformation and battery damage during collisions
Solution Approach 1:
The frame is divided into front frame and mid frame sections, allowing each segment to be optimized independently. The front frame can be designed with specific crash absorption characteristics while the mid frame provides structural support for the battery, resolving the contradiction between extended length for range and structural integrity for reliability
Solution Approach 2:
Diagonal members are added to transfer longitudinal loads to lateral rockers, converting force vectors from the vulnerable longitudinal direction to the more stable lateral direction. This dimensional load transfer protects the extended frame structure from deformation while maintaining the extended geometry needed for large battery capacity
2Strength
If diagonal members are added to transfer longitudinal loads laterally, then the frame resistance to deformation is improved, but the device complexity increases
Solution Approach 1:
The diagonal members are integrated with existing frame components such as rockers and rails, combining multiple functions into unified structural elements. This merging approach enhances load resistance while minimizing the increase in overall structural complexity by reusing existing components rather than adding entirely separate systems
Data Source
AI summary
Vehicle frames for battery powered electric vehicles are disclosed. An example apparatus disclosed herein includes a vehicle subframe including a first rail and a first rocker on a first side of the vehicle subframe, and a second rail and a second rocker on a second side of the vehicle subframe, the first side opposite the second side, a first diagonal member coupled between the first rail and the second side of the vehicle subframe, the first diagonal member to transfer a first longitudinal load from the first rail to the second side, and a second diagonal member coupled between the second rail and the first side of the vehicle subframe, the second diagonal member to transfer a second longitudinal load from the second rail to the first side.