Front Vehicle-Body Structure With Overlapping Torque Box and Battery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle-body structures limit the capacity of battery units due to interference with torque boxes, reducing their size in the forward direction, which affects their overall capacity and heat dissipation.
Innovation Solution
A vehicle-body structure that includes a torque box with a closed cross-sectional structure, coupled to the floor panel and side sills, allowing the battery unit to expand forward while overlapping with the torque box, ensuring stability and heat dissipation through a gap between the battery case and the floor panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the battery unit is increased in size in the forward direction, then the battery capacity is improved, but the battery unit interferes with the torque box
Solution Approach 1:
The battery unit is designed to overlap with the torque box in the vertical direction rather than extending forward in the horizontal direction. This dimensional transition allows the battery to utilize the vertical space above the torque box, thereby increasing battery capacity without causing horizontal interference with the torque box structure.
Solution Approach 2:
The battery unit is positioned to overlap with and effectively nest around the torque box in the vertical direction. The torque box is located below the battery unit, allowing the battery to utilize the space above the torque box while the torque box maintains its structural function below, creating a nested spatial arrangement that resolves the interference issue.
2Reliability
If the battery unit is arranged to avoid the torque boxes, then the torque box function is ensured, but the battery capacity is reduced
Solution Approach 1:
Instead of arranging the battery unit to avoid the torque boxes in the horizontal plane, the invention transitions to the vertical dimension by positioning the battery unit above the torque box. This allows both the torque box to maintain its structural function below and the battery to achieve maximum capacity by utilizing the vertical space, thereby ensuring both reliability and volume.
3Volume of moving object
If the battery unit overlaps with the torque box, then the battery capacity is increased, but the structural integrity may be compromised
Solution Approach 1:
The vehicle body structure is segmented into distinct vertical zones: the torque box occupies the lower zone for structural support, while the battery unit occupies the upper zone for energy storage. This vertical segmentation allows both components to coexist without compromising structural integrity, as each operates in its designated spatial zone with proper load paths maintained.
Solution Approach 2:
The overlapping arrangement is achieved in the vertical dimension rather than the horizontal dimension. The battery unit is positioned above the torque box, creating a vertical overlap that increases battery capacity while maintaining horizontal clearance. This dimensional separation preserves the structural integrity of the torque box while allowing maximum battery volume.
Data Source
AI summary
A front vehicle-body structure including a floor panel; side sills that extend along side edges of the floor panel; front side frames that extend forward from a front side of the floor panel, the front side frames being spaced apart from each other; and a torque box attached to the floor panel, the torque box and the floor panel coupling a rear end part of the front side frames to a front end part of the side sills, wherein a battery unit has a rectangular shape and is below the floor panel and extends along the floor panel, a step part having a lower height than an upper surface of the battery unit is at a front end part of the battery unit, and the torque box is on the step part such that the front end part of the battery unit vertically overlaps with the torque box.