Subframe Window for Crash-Protected Energy Source Placement

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Solution Overview

Problem

High inert mass energy sources in electric or hybrid vehicles pose a risk during crashes, potentially causing damage to vehicle components and passenger safety due to uncontrolled movement and penetration into the passenger compartment.

Innovation Solution

A subframe with a window that exceeds the dimensions of the energy source and its components, allowing them to dip into a crash-protected area during a collision, thereby guiding the energy away from critical zones and minimizing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the energy source is positioned in front of the subframe in the crash direction, then the energy source can be accommodated in the vehicle structure, but it creates a risk of uncontrolled movement and penetration into the passenger compartment during a crash

Engineering Contradiction:

Improveaccommodation space for energy sourceVSAvoidcrash damage risk to passenger compartment

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the energy source from its fixed position in front of the subframe and relocates it to a dedicated crash-protected accommodation space within the subframe structure. This separation removes the harmful factor (energy source) from the crash path, preventing penetration into the passenger compartment while maintaining proper vehicle integration

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The subframe acts as an intermediary structure between the energy source and the passenger compartment. By providing a crash-protected accommodation space within the subframe, it mediates the crash forces and prevents direct transmission to critical zones, solving the contradiction between energy source placement and passenger safety

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If additional deformation elements are added between the energy source and subframe to absorb crash energy, then crash energy absorption is improved, but the device complexity and structural weight increase

Engineering Contradiction:

Improvecrash energy absorptionVSAvoidstructural complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The subframe is designed to serve multiple functions simultaneously: it provides structural support for the energy source, creates a crash-protected accommodation space, and absorbs crash energy through its own deformation characteristics. This multi-functionality eliminates the need for separate deformation elements, reducing structural complexity while maintaining energy absorption capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the crash protection function with the existing subframe structure by creating an integrated accommodation space. The subframe itself becomes the protective structure, combining support and protection functions into a single element, thereby avoiding additional complex components

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a frame-shaped structure is provided around the energy source to guide crash energy, then the energy source is protected, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveenergy source protectionVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective frame-shaped structure is merged with the subframe itself. The subframe's inherent structural design provides the protective enclosure for the energy source, combining the protection function with the existing support structure rather than adding a separate frame, thereby reducing manufacturing complexity and cost

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If special collision panels and load-bearing frames are added to protect the energy source, then crash protection is improved, but the vehicle weight and structural complexity increase

Engineering Contradiction:

Improvecrash protectionVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The subframe is designed to simultaneously provide load-bearing support and crash protection through its integrated accommodation space. This multi-functional design eliminates the need for separate collision panels and additional load-bearing frames, reducing overall vehicle weight while maintaining protective capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The protective function is extracted from separate components (collision panels, additional frames) and integrated into the subframe structure itself. The subframe becomes the sole protective element, removing redundant weight while maintaining reliability

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS9925856B2Arrangement in a motor vehicle

Publication Date: 2018.03.27 DR ING H C F PORSCHE AG

AI summary

An arrangement in a motor vehicle includes a subframe. An energy source is arranged in a region of the subframe and components are assigned to the energy source. The energy source and the components are positioned in front of the subframe in a crash direction. The subframe has a window which exceeds the external dimensions of at least one of the energy source or the components and is configured to allow the at least one of the energy source or the components to dip into the window.