Vehicle Front Structure Battery Case Load Transmission
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Solution Overview
Problem
Existing vehicle front portion structures fail to efficiently transmit collision loads from the suspension member to the battery case during a front collision, leading to suppressed load transmission and potential damage to the battery case.
Innovation Solution
A vehicle front portion structure featuring a battery case installed beneath the vehicle floor, with front side members, side rails, first connecting members, and second connecting members that facilitate efficient load transmission from the suspension member to the battery case, including offset rear ends and a lightweight, rigid second connecting member design with ribs for enhanced load distribution and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat plate brackets connect the lower surface of the battery case and the lower surface of the suspension member, then the structure is simple to manufacture, but the component of force in the vehicle longitudinal direction cannot be transmitted from the rear end surface of the suspension member to the front end surface of the battery case
Solution Approach 1:
The connecting member transitions from a flat plate configuration to a three-dimensional structure with upper and lower connection portions positioned at different heights. This spatial arrangement enables the member to bridge the gap between the lower surface of the suspension member and the front end surface of the battery case, allowing effective transmission of longitudinal collision forces while maintaining manufacturing feasibility.
Solution Approach 2:
The connecting member acts as an intermediary element that mediates the force transmission between the suspension member and the battery case. By positioning its upper connection portion near the lower surface of the suspension member and its lower connection portion at the front end surface of the battery case, it creates an effective load path that transmits collision forces in the vehicle longitudinal direction.
2Reliability
If the connecting member has a complex three-dimensional structure to improve load transmission, then the collision load can be transmitted effectively, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The connecting member is segmented into distinct functional portions: an upper connection portion for connecting to the suspension member, a lower connection portion for connecting to the battery case, and a longitudinal connection portion linking these two portions. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural efficiency and manufacturability.
Solution Approach 2:
Different portions of the connecting member are designed with locally optimized properties. The upper connection portion is positioned and shaped to interface with the suspension member's lower surface, while the lower connection portion is configured for the battery case's front end surface. This local optimization enables effective load transmission without requiring excessive overall structural complexity.
Data Source
AI summary
A vehicle front portion structure includes: a battery case that is installed beneath a floor of a vehicle; front side members that extend in a vehicle longitudinal direction further toward a vehicle front side than the battery case; side rails that structure portions of a suspension member that is disposed further toward the vehicle front side, and that extend in the vehicle longitudinal direction; first connecting members that connect the battery case and the front side members; and second connecting members that connect a vehicle longitudinal direction front end portion of the battery case and vehicle longitudinal direction rear ends of the side rails, that face the battery case in the vehicle longitudinal direction as seen in a plan view and in a side view, and that face the side rails in the vehicle longitudinal direction as seen in a plan view and in a side view.