Interlocking Vehicle Beam Assembly Notched Connection
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Solution Overview
Problem
Vehicle frame designs face challenges in maximizing battery storage volume while minimizing side impact intrusion and maintaining structural integrity, as cross members can reduce vertical package space and occupy interior space, and existing solutions do not effectively balance load transfer and intrusion prevention.
Innovation Solution
An interlocking beam assembly with a notched connection configuration between beams, where one beam has hollow sections with notches and the other beam is attached orthogonally, allowing for increased package space and improved load path bridging, which can be welded or attached using fasteners, to enhance load transfer and reduce intrusion distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cross members are added to prevent side impact intrusion, then side impact intrusion is reduced, but vertical package space and interior space are reduced
Solution Approach 1:
The second beam is nested within the hollow section of the first beam, with the beam extending into the cavity of the hollow section. This nesting arrangement allows the beams to occupy the same spatial envelope, preventing side impact intrusion while maximizing battery storage volume without requiring additional exterior space.
2Strength
If rigid attachment is used to ensure structural integrity, then load transfer is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The attachment features integrate the first and second beams into a unified load-bearing structure. The notched hollow section and extending beam are formed as integrated components that work together to transfer axial loads, achieving rigid attachment while simplifying the overall manufacturing process through consolidation of parts and attachment operations.
Data Source
AI summary
An interlocking beam assembly for a frame assembly of a vehicle that includes an upper beam and a lower beam. The upper beam includes an upper hollow section integrally formed with a lower hollow section and a common wall shared by the upper and lower hollow sections. A notch is disposed in the lower hollow section of the upper beam at a select portion along a length of the upper beam. The notch is defined at cut edges along a bottom wall and side walls of the lower hollow section. A lower beam is configured to extend substantially perpendicular to the upper beam and attach in the notch in the upper beam between the cut edges of the side walls in a manner that bridges load paths across the notch in the upper beam.