Vehicle Front Structure Load Path Design for EV Crashworthiness

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Solution Overview

Problem

The increased capacity of high voltage batteries in electric vehicles requires structural improvements to achieve crashworthiness and stiffness, particularly in vehicle front structures to effectively distribute impact loads and enhance safety during frontal impacts.

Innovation Solution

A vehicle front structure design that includes a suspension housing between front side and fender apron members, with reinforcing members and connecting portions to form multiple load paths, enhancing the distribution of impact loads and increasing torsional stiffness, while sealing cavities and coupling flanges to reinforce the suspension housing and dash panel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the capacity of high voltage battery is increased to extend range, then the range of electric vehicle is improved, but the volume of battery is increased by approximately 1.5 times or more, requiring structural improvement to achieve crashworthiness and stiffness

Engineering Contradiction:

Improvebattery capacityVSAvoidcrashworthiness and stiffness

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The front structure is divided into multiple components (front side members, fender aprons, suspension housings, and reinforcing members) that work together to distribute impact loads. The first and second reinforcing members are segmented components that can be independently positioned to optimize structural strength while accommodating the larger battery volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcing members extend in the longitudinal direction of the vehicle, adding structural strength in the depth dimension rather than just increasing width or height. This allows the structure to handle the increased battery volume without compromising front-end crashworthiness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If reinforcing members and connecting portions are added to form multiple load paths, then impact load distribution is improved, but device complexity increases

Engineering Contradiction:

Improveimpact load distributionVSAvoidstructure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The first reinforcing member integrates multiple functions: it connects the front side member to the fender apron, provides structural reinforcement, and forms part of the load path system. The connecting portions are integrated into the reinforcing member structure, combining connection and reinforcement functions into single components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcing members serve multiple purposes: they distribute impact loads through multiple paths, increase torsional stiffness, and provide structural support for the suspension housing and dash panel. This multi-functionality reduces the need for separate components, managing complexity while improving strength.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11724743B2Vehicle front structure

Publication Date: 2023.08.15 HYUNDAI MOTOR CO LTD

AI summary

A vehicle front structure includes a suspension housing disposed between a front side member and a fender apron upper member, a first reinforcing member extending in a longitudinal direction of a vehicle and coupled to the suspension housing, and a first connecting portion attached to the first reinforcing member and connecting the fender apron upper member and the front side member.