Sub-Frame Engagement Bracket That Redirects Crash Motion Below the Battery
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Solution Overview
Problem
The challenge in electric vehicles is that during collisions, the sub-frame is pushed rearward and strikes the high-capacity battery mounted on the bottom surface, potentially causing damage and fire, necessitating a reduction in battery size to accommodate collision protection, which reduces cruising distance and degrades marketability.
Innovation Solution
An engagement structure for the sub-frame that includes an inclined portion in the engagement bracket, guiding the sub-frame to move downward and rearward during collisions, preventing it from striking the battery, with reinforcement features to enhance stiffness and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a high-capacity battery is mounted on the bottom surface to increase cruising distance, then the battery capacity is increased, but the sub-frame may strike the battery during collision causing safety issues
Solution Approach 1:
The engagement bracket is designed with an inclined portion that redirects the sub-frame's rearward movement from a horizontal path into a downward vertical path during collision. This dimensional change in movement trajectory allows the sub-frame to pass below the battery without striking it, resolving the contradiction between battery capacity and collision safety.
2Object-affected harmful factors
If a protector is installed at the front end of the battery and space is secured to prevent sub-frame collision, then battery safety is improved, but the battery size must be reduced which decreases cruising distance
Solution Approach 1:
The inclined portion is pre-configured in the engagement bracket to automatically redirect the sub-frame downward upon collision occurrence. This preliminary structural arrangement eliminates the need for additional protectors or space allocations, maintaining full battery size while ensuring collision protection through the redirected movement path.
3Stability of the object's composition
If the sub-frame is rigidly connected to the side member to prevent separation during collision, then structural stability is improved, but ride and handling performance and NVH performance are degraded
Solution Approach 1:
The engagement bracket employs different structural characteristics in different regions: the inclined portion provides a controlled degree of movement freedom to maintain ride and handling performance, while the overall bracket structure ensures sufficient connection stability to prevent sub-frame separation during collision. This local differentiation of structural properties resolves the contradiction between stability and performance.
Data Source
AI summary
An embodiment engagement structure includes an engagement bracket including an upper end configured to be engaged with a side member of a vehicle and connected to a region in which the side member is to be engaged with a sub-frame, wherein the engagement bracket comprises an inclined portion inclined downward toward a rear side of the vehicle.