Front Crash Structure Behind Cooling Module for HV Battery Protection
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Solution Overview
Problem
Battery-electric commercial vehicles face inadequate protection for high-voltage components like traction batteries during collisions, particularly when colliding with trailers, as the lower edge of the trailer's rear end often impacts above the vehicle's ladder frame level, risking damage and potential ignition from flammable electrolytes.
Innovation Solution
A crash structure comprising a crash strut oriented perpendicular to the frame longitudinal members, mounted behind the cooling module, with receiving elements to secure it, providing robust protection by absorbing impact energy and minimizing intrusion, while ensuring no other components are interposed between the crash structure and the high-voltage components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the engine compartment is divided into front and rear sections with the cooling module in front and engine in rear, then the engine can be cooled effectively, but the structural complexity increases and space utilization is reduced
Solution Approach 1:
The patent combines the cooling module and engine into a single integrated housing structure, eliminating the need for separate front and rear compartment divisions. The housing contains both the cooling module (with radiator and coolant reservoir) and engine components in a unified structure, simplifying the overall compartment layout while maintaining effective cooling through direct thermal coupling between engine and radiator.
2Reliability
If conventional front structures are used without integrated crash management, then manufacturing is simpler, but safety performance during frontal collisions is insufficient
Solution Approach 1:
The housing incorporates energy-absorbing elements and deformation zones designed to absorb impact energy during frontal collisions before it reaches the engine and coolant reservoir. The structure includes crush zones that deform in a controlled manner to dissipate collision energy, protecting critical components and occupants.
Solution Approach 2:
The housing is divided into distinct functional zones: a cooling module housing section, an engine mounting section, and intermediate sections with energy-absorbing structures. This segmentation allows each zone to be optimized for its specific function while maintaining overall structural integrity and safety performance.
3Ease of manufacture
If the housing is designed as a single integrated component, then assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
While the housing appears as a single integrated structure, it is manufactured as separate modular sections (cooling module housing, engine housing, intermediate sections) that are subsequently assembled together. This approach reduces the complexity of manufacturing each individual section while maintaining the benefits of an integrated design, and allows for easier quality control and repair.
Data Source
Figure 1a~1b
Figure 2a~2d
Figure 3a~3d
AI summary
The invention relates to a front-end structure (10) for a motor vehicle and to a motor vehicle with a corresponding front-end structure (10). The front-end structure (10) has two frame longitudinal members (11, 12), each with a front end (11a, 12a). Preferably, the front-end structure (10) includes a cooling module (13) which is mounted at the respective front ends (11a, 12a) of the frame longitudinal members (11, 12) and which extends transversely to the frame longitudinal members (11, 12). Furthermore, the front-end structure (10) has a crash structure (14), preferably in the form of a buffer, which is deformable upon impact and reduces impact forces, and which extends above and transversely to the frame longitudinal members (11, 12). Preferably, the aforementioned crash structure (14) is arranged behind the cooling module (13).