Inclined Bracket Guide for Electric Vehicle Front Frame Crash Stroke
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Solution Overview
Problem
Existing vehicle body front structures for electric vehicles with battery packs beneath the floor face challenges in maintaining crash stroke during frontal collisions due to interference with the battery frame, requiring costly redesigns to adjust angles or positions.
Innovation Solution
A vehicle body front structure with a bracket system where the rear part is fixed to the battery pack and the front part is fixed to the vehicle body floor, featuring an inclined design that allows the vehicle body frame to slide and drop downward, preventing interference and allowing adjustable abutment without altering the battery pack's design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the slant part is provided directly on the front part of the battery frame, then the crash stroke can be maintained, but the cost increases due to redesign of the battery frame
Solution Approach 1:
The invention separates the crash management function from the battery frame by introducing a dedicated subframe with a guide face. The subframe is divided into functional segments: the guide face for controlling frame movement, the mounting portion for battery attachment, and the connection points to the vehicle body. This segmentation allows the crash stroke control feature to be adjusted independently without redesigning the entire battery frame, thus maintaining reliability while reducing manufacturing cost.
Solution Approach 2:
The subframe acts as an intermediary component between the battery frame and the vehicle body. It introduces a guide face that mediates the interaction during frontal collision, controlling the movement of the vehicle body frame relative to the battery pack. This intermediary structure enables crash stroke management without requiring modifications to the battery frame itself, resolving the contradiction between maintaining crash performance and avoiding costly redesigns.
2Manufacturing precision
If the battery frame is redesigned to adjust the angle or position of the slant part, then the crash stroke can be optimized, but the manufacturing complexity increases
Solution Approach 1:
The invention segments the angle adjustment function from the battery frame to the subframe. The guide face on the subframe is designed with specific angular orientations (e.g., 30-60 degrees from horizontal) to control the crash stroke, while the battery frame maintains its original simple box-shaped structure. This segmentation allows precise angle control for crash management without increasing battery frame design complexity.
Solution Approach 2:
The subframe serves as an intermediary that carries the geometric features (guide face angles) necessary for crash stroke control. By placing the angular geometry on the subframe rather than the battery frame, the invention enables precise manufacturing of crash parameters while keeping the battery frame design simple and unchanged.
3Reliability
If the vehicle body frame abuts against the battery frame during collision, then the crash stroke decreases, but adding protective structures increases device complexity
Solution Approach 1:
The invention converts the potentially harmful direct contact between the vehicle body frame and battery frame into a beneficial controlled interaction. The guide face on the subframe is designed to receive the abutting vehicle body frame and guide it downward along a controlled path. This transforms the harmful interference that would reduce crash stroke into a beneficial mechanism that maintains crash stroke by controlling the frame's movement trajectory during collision.
Solution Approach 2:
The subframe with its guide face acts as an intermediary structure between the vehicle body frame and the battery pack. During collision, it mediates the interaction by controlling the movement of the vehicle body frame, preventing direct interference with the battery pack while maintaining the intended crash stroke. This intermediary approach maintains reliability without requiring complex protective structures around the battery pack.
Data Source
AI summary
In a vehicle body front structure for an electric vehicle, including a battery pack mounted beneath a vehicle body floor, a bracket and a rear end part of a vehicle body frame are each inclined downward from an upper front to a rear. When viewed in a fore-and-aft direction, at least part of the bracket overlaps the rear end part. Therefore, the rear end part, moving rearward due to frontal collision, abuts against the bracket, and the frame slips and drops downward from the upper front to the lower rear along the bracket, thus preventing any decrease in crash stroke of the frame due to interference with the battery pack at the end stage of collision. Since abutment relationship with the rear end part can be adjusted merely changing angle of inclination or position of the bracket, the cost is very low.