Vehicle Crash Structure With Diverging Load Paths for Battery Packaging
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Solution Overview
Problem
Existing vehicle architectures face challenges in accommodating traction batteries and power electronics due to increased cabin height or restricted headroom, necessitating a redesign to enhance crash protection and component positioning.
Innovation Solution
A vehicle crash structure incorporating a longitudinal energy absorption member and load bearing element with diverging portions that divert longitudinal loads, allowing for flexible component placement and protection, including a load bearing element with arms and a support leg to redirect forces around the battery and electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the traction battery is placed underneath the rear passenger seats, then the battery can be accommodated in the vehicle, but the cabin height must be increased or rear passenger headroom is restricted
Solution Approach 1:
The patent extends the battery housing laterally beyond the vehicle cabin boundaries, utilizing space in the transverse dimension rather than increasing vertical cabin height. The load bearing element supports the battery housing to extend laterally outward from the vehicle body, allowing battery placement without compromising cabin headroom.
2Adaptability or versatility
If the battery is positioned further forward or rearward, then component placement flexibility is improved, but crash protection and load path management become more challenging
Solution Approach 1:
The load bearing element acts as an intermediary structure between the battery housing and the vehicle body structure. It provides a dedicated mounting interface that manages load paths and crash forces independently of the bulkhead panel position, enabling flexible battery placement while maintaining crash protection through controlled load transfer paths.
3Strength
If the load bearing element is attached to the bulkhead panel, then structural support is provided, but component placement flexibility is reduced
Solution Approach 1:
The mounting structure is segmented into separate functional elements: the load bearing element that attaches to the bulkhead panel for structural support, and the battery housing that can be positioned independently. This segmentation allows the housing to be placed at different longitudinal positions while the load bearing element maintains fixed structural attachment points.
Data Source
AI summary
The present invention relates to a vehicle crash structure including a longitudinal energy absorption member and a load bearing element. The load bearing element includes a first and second end and a first and second load bearing arm. Each of the load bearing arms extend between the first and second ends of the load bearing element. The first end of the load bearing element is attached to one end of the longitudinal energy absorption member. The second end of the load bearing element is attached to a cross member of a vehicle body structure located between a bulkhead panel of the vehicle body structure and the longitudinal energy absorption member. The longitudinal energy absorption member and the load bearing element define a load path for a longitudinal load during a crash. The first and second load bearing arms define a first and second diverging portion of the load path, respectively.