Vehicle Lower Structure Layout for Battery Side-Impact Protection
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Solution Overview
Problem
In conventional vehicle lower structures, during a lateral collision, the torque box crushes and shifts towards the electricity storage device, causing the floor panel to deform and potentially contact the electricity storage device, leading to increased risk of damage.
Innovation Solution
A vehicle lower structure design that includes a protector positioned to face the lower end of the torque box, which absorbs the impact and prevents the floor panel from deforming towards the electricity storage device, along with a configuration that reduces water ingress during high-pressure washing or flooded road conditions by strategically placing the protector on the lower side of the housing case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the torque box is positioned to connect the rocker and front suspension member, then the structural connection is improved, but the floor panel deforms toward the electricity storage device during lateral collision
Solution Approach 1:
The patent introduces a floor panel as an intermediary component between the torque box and the electricity storage device. This floor panel acts as a mediator that absorbs and distributes the deformation forces during lateral collision, preventing direct contact between the deformed torque box/floor assembly and the electricity storage device, thus resolving the contradiction between structural connection strength and safety reliability
Solution Approach 2:
The patent segments the structural components by positioning the electricity storage device separately from the torque box connection area, with the floor panel creating spatial separation. This segmentation allows the torque box to deform independently without directly affecting the electricity storage device, maintaining both structural integrity and safety
2Reliability
If the protector is positioned to face the lower end of the torque box, then the protection of electricity storage device is improved, but the water ingress risk during high-pressure washing increases
Solution Approach 1:
The patent applies local quality by making the protector selectively functional - it provides collision protection to the torque box lower end while having openings or design features that allow water to pass through or flow around it, thus providing localized protection where needed without creating a water trap that would increase ingress risk
Solution Approach 2:
The patent converts the potential harm of water accumulation behind the protector into a benefit by designing the protector with water drainage capabilities. The structure that provides collision protection also incorporates features that channel water away, transforming what could be a harmful water trap into a beneficial drainage system
Data Source
AI summary
A vehicle lower structure includes an electricity storage device, a rocker, a front suspension member, a torque box, a floor panel, and a protector. The front suspension member is disposed on a front side of the electricity storage device. The torque box lies side-by-side with the electricity storage device in a horizontal direction. The torque box connects the rocker and the front suspension member to each other. The floor panel is disposed on an upper side of the electricity storage device and connected to the torque box. The protector is disposed on the electricity storage device. The protector is disposed so as to face a lower end of the torque box in the horizontal direction.