Front Subframe Pivot Layout to Protect EV Batteries in Collisions

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Solution Overview

Problem

Conventional electric vehicles lack effective energy absorption and battery protection during collisions, as the rigidly mounted electric motor and front subframe can cause the battery assembly to be damaged due to insufficient energy absorption and potential collision with the battery.

Innovation Solution

A vehicle impact energy absorption system that separates the electric motor from the front subframe and allows the subframe to rotate upward during a collision, using pivotally connected support arms and brackets to prevent collision with the battery assembly and maximize energy absorption by deforming the subframe and distributing impact energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electric motor is rigidly mounted between the chassis and front subframe, then the motor is securely fixed, but the front subframe cannot rotate upward during impact, causing it to collide with the battery assembly and reducing energy absorption

Engineering Contradiction:

Improvemotor fixation reliabilityVSAvoidbattery collision risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The support arm is changed from a rigid fixed connection to a pivotable connection with the front subframe. This allows the support arm to rotate upward during frontal impact, enabling the front subframe to lift away from the battery assembly and preventing harmful collisions while maintaining normal operational stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mounting system is divided into separate components: the support arm, support bracket, pivot pin, and front subframe. This segmentation allows independent movement of the front subframe relative to the chassis during impact, decoupling the motor fixation from the impact response of the front subframe.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the electric motor and front subframe are rigidly connected, then structural stability is improved, but the energy absorption capacity of the front subframe is significantly reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidenergy absorption amount

Core Design Contradiction:

Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The pivotable connection between the support arm and front subframe transforms the rigid static structure into a dynamic system. During frontal impact, the front subframe can rotate upward around the pivot pin, converting linear impact energy into rotational motion and significantly increasing energy absorption capacity while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection parameter between the support arm and front subframe is changed from fixed to pivotable. This parameter change allows the system to adapt its mechanical properties during impact, enabling energy absorption through rotation while maintaining stability during normal operation.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If the battery assembly size increases to extend vehicle range, then the energy capacity is improved, but the battery assembly protrudes toward the front, increasing the risk of collision with the front subframe during impact

Engineering Contradiction:

Improvebattery capacityVSAvoidcollision risk with front subframe

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The pivotable support arm enables the front subframe to rotate upward during impact, creating dynamic separation between the front subframe and battery assembly. This prevents collision even when the battery assembly is positioned forward to maximize capacity.

Inventive Principle:

Principle #15Dynamics

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 system effectively protects the battery assembly by preventing collision and maximizing impact energy absorption, ensuring safer and more efficient energy distribution during vehicle impacts.

Implementation Method 1

The support arm may be pivotally connected to the support bracket through a pivot pin

Methodology Applied

Scientific EffectPivoting: Hinge

Implementation Method 2

maximizing the distribution and absorption of impact energy

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS11840278B2Vehicle impact energy absorption system

Publication Date: 2023.12.12 HYUNDAI MOTOR CO LTD

AI summary

An embodiment vehicle impact energy absorption system includes a pair of front side members, a battery assembly disposed under a center floor of a vehicle, a front subframe disposed below the pair of front side members and located in front of the battery assembly, the front subframe being connected to the pair of front side members through a pair of support arms and a pair of support brackets, wherein each support arm of the pair of support arms is provided on the front subframe, and each support bracket of the pair of support brackets is provided on each front side member of the pair of front side members, respectively, and an electric motor mounted on the front subframe.