Torque Box Battery Protection Structure for Front Side Member Crashes
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Solution Overview
Problem
Existing vehicle designs with batteries under a floor panel face challenges in providing sufficient space for the batteries due to limited connection strength between front side members and cross members, which can lead to separation during collisions, compromising the ability of the front side members to absorb collision energy effectively.
Innovation Solution
A configuration where the front side members are directly connected to torque boxes without interposing special members, with the proximal end portion of the front side member firmly joined to the torque box's inner surface, enhancing connection strength and allowing deformation to absorb collision energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extension side members are interposed between front side members and cross members, then connection strength is improved, but space for batteries in the vehicle length direction is reduced
Solution Approach 1:
The proximal end portion of the front side member is nested within the internal space of the torque box and joined to the inner surface of the torque box. This nesting configuration allows the front side member to be firmly connected to the torque box without requiring additional extension side members, thereby maintaining connection strength while maximizing battery space.
2Volume of moving object
If front side members are directly connected to cross members without extension side members, then space for batteries is increased, but connection strength is reduced causing separation during collision
Solution Approach 1:
The proximal end portion of the front side member is nested within the internal space of the torque box and joined to the inner surface of the torque box. This nesting configuration allows the front side member to be firmly connected to the torque box without requiring additional extension side members, thereby maintaining connection strength while maximizing battery space.
3Reliability
If extension side members are used to connect front side members to cross members, then connection reliability is improved, but device complexity is increased
Solution Approach 1:
The front side member is directly integrated with the torque box through joining the proximal end portion to the inner surface of the torque box. This merging eliminates the need for separate extension side members, reducing structural complexity while maintaining connection reliability through the firm join between the front side member and torque box.
4Strength
If front side members are firmly connected to torque box, then collision energy absorption is improved, but manufacturing complexity is increased
Solution Approach 1:
The proximal end portion of the front side member is nested within the internal space of the torque box and joined to the inner surface of the torque box. This configuration ensures firm connection for effective collision energy absorption through deformation of the front side member. The joining can be performed using conventional welding or joining techniques, maintaining ease of manufacture.
Data Source
AI summary
A vehicle includes a floor panel, a battery, a rocker, a torque box, and a front side member. The torque box extends inward in the vehicle width direction from a front end of the rocker along a front edge of the floor panel. The torque box includes a front wall and a rear wall that face each other in the vehicle length direction. The front wall and the rear wall define an internal space extending in the vehicle width direction. The front side member extends forward in the vehicle length direction from the torque box, and includes a proximal end portion at a rear end of the front side member. The proximal end portion is located in the internal space of the torque box, and is joined to an inner surface of the torque box in the internal space.