Vehicle Rear Bracket Design for Collision Load Transfer
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Solution Overview
Problem
Conventional vehicle rear structures inefficiently transfer collision loads forward in the vehicle body and have insufficient joint strength due to the placement of the battery frame below the inclined members, leading to forces being generated in peeling directions at the brackets.
Innovation Solution
A vehicle rear structure design that includes a battery case with a rear load transfer member and brackets extending from the load transfer member to the bottom surface of the battery case, enhancing the transfer of collision loads forward and improving joint strength by directing forces in shearing directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery frame is disposed below the inclined members, then the structure is compact, but the collision load is not transferred forward efficiently and the joint strength of the brackets is insufficient
Solution Approach 1:
The bracket extends downward from the inclined member to connect with the battery frame, changing the force transfer direction from horizontal to vertical. This dimensional change allows the bracket to transfer collision loads effectively while maintaining compact structure.
Solution Approach 2:
The bracket acts as an intermediary component between the inclined member and the battery frame, mediating the force transfer. By positioning the bracket to extend downward and connect to the battery frame, it efficiently transmits collision loads from the upper structure to the battery frame without compromising joint strength.
2Device complexity
If the bracket connects to the rear wall of the battery frame, then the structure is simple, but forces are generated in peeling directions reducing joint strength
Solution Approach 1:
Instead of connecting horizontally to the rear wall, the bracket extends downward to connect with the lower portion of the battery frame. This vertical connection orientation changes the force direction from peeling (horizontal) to compressive (vertical), significantly improving joint strength while maintaining structural simplicity.
3Length of stationary object
If the bracket extends horizontally to the battery frame, then the load transfer path is short, but forces are generated in peeling directions
Solution Approach 1:
The bracket extends downward in the vertical dimension rather than horizontally, creating a longer effective load transfer path. This vertical extension allows the bracket to engage with the lower portion of the battery frame, transferring collision loads through compression rather than peeling forces, thereby improving joint strength.
Data Source
AI summary
A vehicle rear structure includes: a battery case to house a battery; a rear side frame, a rear crossmember, and a gusset, which are included in a rear load transfer member which is disposed rearward of the battery case and transfers forward a collision load at the time of collision; and a bracket to transfer the collision load from the rear load transfer member to the battery case. The bracket extends from the rear load transfer member to below the battery case and is joined to a bottom surface of the battery case in an up-down direction.