Front Floor Cross Member Layout for Side-Impact Energy Absorption
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Solution Overview
Problem
Existing front floor reinforcement structures in vehicles, particularly electric and hybrid vehicles with battery packs in the tunnel, do not effectively utilize the front floor panel for energy absorption during side impacts, limiting the vehicle's crash protection capabilities.
Innovation Solution
A front floor reinforcement structure featuring a front floor cross member with a non-deformable portion near the side sill and a deformable portion near the tunnel, where the non-deformable portion has greater resistance to plastic deformation than the deformable portion, and both have specific material properties and configurations to enhance energy absorption by stretching the front floor panel during a side impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the front floor cross member is designed with uniform high resistance to plastic deformation throughout, then anti-intrusion capability is improved, but energy absorption capability deteriorates
Solution Approach 1:
The front floor cross member is divided into a non-deformable portion (near side sill) and a deformable portion (near tunnel), with different resistance to plastic deformation values. The non-deformable portion has higher resistance to maintain anti-intrusion capability, while the deformable portion has lower resistance to enable energy absorption through controlled deformation.
Solution Approach 2:
Different portions of the front floor cross member are assigned different material properties: the non-deformable portion near the side sill has high resistance to plastic deformation for structural support, while the deformable portion near the tunnel has lower resistance to allow controlled deformation and energy absorption during impact.
2Strength
If the front floor panel is made with high resistance to plastic deformation, then structural strength is improved, but energy absorption capability deteriorates
Solution Approach 1:
The resistance to plastic deformation of the front floor panel is optimized to a specific range (500-1500 MPa) that balances structural strength and energy absorption. This parameter adjustment allows the panel to maintain adequate strength while enabling stretching deformation that absorbs impact energy.
3Weight of moving object
If vehicle weight is reduced, then manufacturing costs and fuel consumption are improved, but crash protection capability deteriorates
Solution Approach 1:
The resistance to plastic deformation of the front floor panel is optimized to a specific range (500-1500 MPa) that balances structural strength and energy absorption. This parameter adjustment allows the panel to maintain adequate strength while enabling stretching deformation that absorbs impact energy.
Solution Approach 2:
The front floor panel is given multiple functions: it serves as both a structural component providing crash protection and an energy absorption element through controlled stretching deformation. This multi-functionality reduces the need for additional dedicated safety components, potentially reducing overall vehicle weight.
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
This design increases the energy absorbed during a side impact by utilizing the front floor panel's stretching deformation, potentially reducing vehicle weight, manufacturing costs, and enhancing safety while maintaining anti-intrusion and energy absorption roles.
Implementation Method 1
the resistance to plastic deformation of the deformable portion being greater than the resistance to plastic deformation of said front floor panel
Implementation Method 2
the resistance to plastic deformation of the non-deformable portion being greater than the resistance to plastic deformation of the deformable portion
Implementation Method 3
the energy absorbed by the front floor reinforcement structure during a side impact will be increased thanks to the stretching deformation of a large surface area of the front floor panel
Data Source
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AI summary
The invention deals with the design and the production method of a front floor reinforcement structure (1) for a vehicle (3) having a battery pack (5) in the tunnel (7) designed to improve the energy absorption of the vehicle during a side impact by involving the front floor panel (11) in the energy absorption during the side impact. The front floor reinforcement structure (1) comprises a front floor cross member (13) having a non-deformable portion (14) located on the end of the front floor cross member (13) closest to the side sill (9) and a deformable portion (16) located on the end of the front floor cross member (13) closest to the tunnel (7). The resistance to plastic deformation of the non-deformable portion (14) is greater than the resistance to plastic deformation of the deformable portion (16), which is itself greater than the resistance to plastic deformation of the front floor panel (11).