Vehicle Front Structure Charging Port Support Member
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Solution Overview
Problem
The existing vehicle body front structures for electric vehicles with charging port devices extend the front bumper beam overhang, hindering a compact design.
Innovation Solution
A vehicle body front structure with a support member that includes a mounting plate and bent pieces to minimize overhang, featuring a lateral member with a high-stiffness mount base and a frangible part to absorb impact, allowing secure mounting of the charging port device without increasing the front overhang.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support member extends from the upper cross member forward, then the charging port device can be mounted securely, but the front overhang length increases
Solution Approach 1:
The support member is repositioned to extend in the lateral direction between longitudinal members rather than extending forward from the upper cross member. This dimensional change in the support structure allows the charging port device to be securely mounted while minimizing the front overhang length, as the support is now provided by the lateral extension between longitudinal members at positions forward of the bulkhead rather than by forward extension from the bulkhead itself.
2Length of moving object
If the support member is positioned to minimize overhang, then compact design is achieved, but mounting strength may be reduced
Solution Approach 1:
The support member is configured with different structural characteristics at different locations: the first portion extends laterally between longitudinal members to provide secure mounting points, while the second portion extends forward to support the charging port device. This local differentiation allows the support structure to provide both strong mounting capability at the lateral ends and adequate forward support while minimizing overall overhang.
Solution Approach 2:
The support member is constructed as a composite structure combining a first portion and a second portion with different functional characteristics. The first portion provides lateral support between longitudinal members while the second portion provides forward support for the charging port device, creating a composite support system that achieves both compact overhang and sufficient mounting strength.
3Device complexity
If the fixing point is located outside the projection plane of the mounting surface, then structural simplicity is maintained, but bending moment increases reducing mounting strength
Solution Approach 1:
The fixing point of the support member to the longitudinal members is pre-positioned within the projection plane of the mounting surface in advance. This preliminary positioning of the fixing point ensures that when the charging connector is connected and disconnected, the bending moment acting on the support member is minimized, thereby maximizing mounting strength without requiring complex structural modifications.
4Strength
If the bent piece is added to the support member, then bending stiffness is improved, but manufacturing complexity increases
Solution Approach 1:
A bent piece is provided on a peripheral edge of the mounting plate of the support member. This curved or bent geometric feature increases the bending stiffness of the support member, providing enhanced structural rigidity. While this does increase manufacturing complexity compared to a flat mounting plate, the bent piece can be formed through standard sheet metal bending processes during manufacturing.
Data Source
AI summary
A vehicle body front structure provided with a charging port device to which a charging connector is selectively connected is provided. The vehicle body front structure includes: a pair of longitudinal members extending in a fore and aft direction on either side of a vehicle body; a bulkhead including an upper member extending laterally and having lateral ends connected to the respective longitudinal members; a lateral member extending laterally behind the bulkhead, and having lateral ends connected to the respective longitudinal members; and a support member having a front part fixed to the upper member and a rear part fixed to the lateral member to support the charging port device.