EV Front Subframe Multi-Cell Extrusion for Pole Crash Absorption
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Solution Overview
Problem
Electric vehicles lack effective crash absorption mechanisms, particularly when colliding with narrow objects like poles, due to the absence of an internal combustion engine in the front section, which increases the risk of injury and damage.
Innovation Solution
A front subframe with a crash absorbing member featuring a first extruded aluminum profile, comprising multiple cells and intermediate walls, is integrated into the vehicle's chassis to absorb impact forces, providing improved crash performance and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the front section is left empty without an ICE engine, then electric vehicle design flexibility is improved, but crash absorption capability deteriorates
Solution Approach 1:
The crash absorbing member acts as an intermediary structure placed in the front section where the ICE engine would traditionally be located. This mediator component provides the necessary crash absorption function that would otherwise be provided by the engine, allowing the front section to remain flexible for electric vehicle design while maintaining safety capabilities.
Solution Approach 2:
The patent changes the structural parameters of the front section by introducing a multi-cell extruded profile with varying cross-sectional shapes along its length. This allows the front section to achieve crash absorption performance through carefully controlled geometric parameters rather than relying on the mass and structural properties of an ICE engine.
2Object-affected harmful factors
If a heavy crash absorption structure is used, then crash safety is improved, but vehicle weight increases
Solution Approach 1:
The crash absorbing member is manufactured as an extruded profile that can incorporate different materials or material distributions across its cross-section. This composite approach allows optimization of strength-to-weight ratio by placing materials strategically in different cells and wall sections, achieving high crash safety without excessive weight.
Solution Approach 2:
Instead of increasing weight in the longitudinal dimension to improve crash absorption, the patent utilizes the transverse and vertical dimensions by creating a multi-cell extruded profile with complex cross-sectional geometry. This dimensional approach allows crash forces to be distributed across multiple walls and cells, achieving safety performance through geometric complexity rather than mass increase.
3Object-affected harmful factors
If a complex crash absorption system is implemented, then crash performance is improved, but manufacturing cost increases
Solution Approach 1:
The single extruded profile structure serves multiple functions simultaneously: it provides crash absorption, structural support, and potential mounting points for other components. The multi-cell design with different cross-sectional shapes handles various crash scenarios (pole collisions, angled impacts, direct frontal impacts) all within one universal component, reducing the need for multiple separate parts and assembly operations.
Solution Approach 2:
The patent merges the functions of multiple crash absorption components into a single integrated extruded profile. Instead of using separate beams, braces, and absorption elements that would require multiple manufacturing steps and assembly operations, the design combines all these functions into one continuously extruded structure, simplifying manufacturing while maintaining comprehensive crash performance.
Data Source
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AI summary
A front subframe (50, 50') for an electric vehicle (100) having a crash absorbing member being a portion of the front subframe, the crash absorbing member (1) is adapted to absorb forces from a front crash for an electric vehicle, the crash absorbing member is adapted to be located in a front section (120) at a front end (140) of the vehicle chassis (130) at a bottom portion of the electric vehicle and connected to the portion of the vehicle chassis (130) via the subframe, said crash absorbing member (1) comprising a first extruded profile (10), having a main extension direction in a transverse direction (y) of the vehicle (100), whereby the extrusion direction of the first extruded profile (10) extends substantially in the transverse direction (y) of the vehicle (100), and wherein further said first extruded profile (10) comprises at least two cells (C1, C2) being defined by outer walls (11) and at least one intermediate wall (12) separating the at least two cells (C1, C2), wherein said at least one intermediate wall (12) has a main extension direction in the transverse direction (y) and a second extension direction which extends substantially in a vertical direction (z) in respect of the vehicle (100).