# US 12,179,841 B2 · Chassis collision structure for new energy vehicle

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- Number: US 12,179,841 B2
- Document ID: US12179841B2
- Status: Granted
- Kind: B2
- Application number: 17/765,369
- Filed: 2020-12-22
- Published: 2022-10-27
- Granted: 2024-12-31
- Earliest claimed: 2019-12-27
- Assignees: Great Wall Motor Company Limited
- Applicants: Great Wall Motor Company Limited
- Inventors: Yonghui Song; Weidong Ding; Yanmeng Song; Wei Wang; Ming Chi; Changjian Cai; Chao Ji
- Web page: https://patentgrep.com/patent/US12179841B2

## CPC

- B62D 21/11: with resilient means for suspension {, e.g. of wheels or engine; sub-frames for mounting engine or suspensions}
- B62D 21/155: {Sub-frames or underguards}
- B60K 1/04: of the electric storage means for propulsion
- B60L 3/0007: {Measures or means for preventing or attenuating collisions}
- B60L 50/66: {Arrangements of batteries}
- B60R 19/34: destroyed upon impact, e.g. one-shot type
- B62D 21/15: having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body (bumpers B60R19/02; shock absorbers in general F16F)
- B60K 2001/0438: {Arrangement under the floor}
- B60Y 2306/01: Reducing damages in case of crash, e.g. by improving battery protection
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY

## Abstract

The present disclosure provides a chassis collision structure of a new energy vehicle, comprising a front lower collision beam assembly, a front sub-frame assembly, a front battery pack bottom fender, a rear battery pack bottom fender, and a rear sub-frame assembly which are arranged sequentially along a direction from a head to a tail of a vehicle, wherein the front lower collision beam assembly is connected to a front end of the front sub-frame assembly; the front battery pack bottom fender is connected to a bottom of the front sub-frame assembly; the rear battery pack bottom fender is connected to a bottom of the rear sub-frame assembly; and connecting parts which are connected with a battery pack are arranged at one end of the front battery pack bottom fender and one end of the rear battery pack bottom fender, which are close to each other, respectively.

## Claims

### Claim 1

A chassis collision structure of a new energy vehicle, wherein the chassis collision structure of the new energy vehicle comprises a front lower collision beam assembly (1), a front sub-frame assembly (2), a front battery pack bottom fender (3), a rear battery pack bottom fender (6), and a rear sub-frame assembly (5) which are arranged sequentially along a direction from a head to a tail of the vehicle, wherein the front lower collision beam assembly (1) is connected to a front end of the front sub-frame assembly (2); the front battery pack bottom fender (3) is connected to a bottom of the front sub-frame assembly (2); the rear battery pack bottom fender (6) is connected to a bottom of the rear sub-frame assembly (5); and connecting parts which are connected with a battery pack (8) are arranged at one end of the front battery pack bottom fender (3) and one end of the rear battery pack bottom fender (6), which are close to each other, respectively;
wherein the rear battery pack bottom fender (6) comprises a bottom fender body which consists of a top fender (602) and a bottom fender (601) which are buckled fixedly from top to bottom; a plurality of rear battery pack connecting parts (7) are arranged on one side of the bottom fender body, and a plurality of rear sub-frame connecting parts which are connected with the rear sub-frame assembly (5) are constructed on the other side of the bottom fender body with respect to the rear battery pack connecting parts (7); and the rear battery pack connecting parts (7) and the rear sub-frame connecting parts are connecting holes which are formed in the bottom fender body.

### Claim 2 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the front lower collision beam assembly (1) comprises energy-absorbing boxes (102) which are arranged on two sides, and a front lower collision beam (101) which is connected with the energy-absorbing boxes (102) on the two sides; and a length (L) of the front lower collision beam (101), which is located between centers of the energy-absorbing boxes (102) on the two sides, is larger than 50% of an overall width of the vehicle.

### Claim 3 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the front sub-frame assembly (2) comprises longitudinal beams (201) of the sub-frame, which are arranged on the two sides, a front cross beam (202) of the sub-frame, which is connected between the longitudinal beams (201) of the sub-frame on the two sides and is close to a front end of the longitudinal beams (201) of the sub-frame, and a rear cross beam (203) of the sub-frame, which is close to a rear end of the longitudinal beams (201) of the sub-frame with respect to the front cross beam (202) of the sub-frame; body connecting parts are arranged on the longitudinal beams (201) of the sub-frame; and the front sub-frame assembly (2) further comprises two powertrain front mounting installation parts (209) which are arranged relatively on the two sides, and a powertrain rear mounting installation part (2010) which is arranged on the rear cross beam (203) of the sub-frame.

### Claim 4 (depends on 3)

The chassis collision structure of the new energy vehicle according to claim 3, wherein the body connecting parts on the longitudinal beams (201) of the sub-frame comprise a front connecting part (205) of body, a middle connecting part (2012) of body, and a rear connecting part (2016) of body which are arranged on the longitudinal beams (201) of the sub-frame along a length direction of the longitudinal beams (201) of the sub-frame; and the powertrain front mounting installation part (209) on each side is arranged close to a junction of the front cross beam (202) of the sub-frame and the longitudinal beam (201) of the sub-frame on the side, and is provided with a front cross beam installation position (20901) arranged at the front cross beam (202) of the sub-frame, and a longitudinal beam installation position (20902) arranged at the longitudinal beams (201) of the sub-frame; and the powertrain rear mounting installation part (2010) is located in the middle of the rear cross beam (203) of the sub-frame in a length direction.

### Claim 5 (depends on 4)

The chassis collision structure of the new energy vehicle according to claim 4, wherein a front installation position support (206) is fixedly connected to a position which is close to a front end of the longitudinal beams (201) of the sub-frame; each front connecting part (205) of body is a front installation drive pipe (2061) arranged on the front installation position support (206); the front installation drive pipe (2061) is located right above the corresponding longitudinal beams (201) of the sub-frame; and a tool pass-through part, which directly faces the front installation drive pipe (2061), for an external installation tool to pass through is arranged on the corresponding front longitudinal beam (201) of the sub-frame.

### Claim 6 (depends on 4)

The chassis collision structure of the new energy vehicle according to claim 4, wherein a front mounting support (207) which extends towards an inside of the longitudinal beam (201) of the sub-frame is fixedly connected to the longitudinal beam (201) of the sub-frame on one side; the longitudinal beam installation position (20902) at a position of the longitudinal beam (201) of the sub-frame on the side is arranged on the front mounting support (207); and the powertrain rear mounting installation part (2010) is provided with a plurality of rear cross beam installation positions (z) which are distributed on the rear cross beam (203) of the sub-frame regularly.

### Claim 7 (depends on 3)

The chassis collision structure of the new energy vehicle according to claim 3, wherein stabilization bar installation positions (2014), large bushing installation positions of swing arms (2015), and small bushing installation positions (2017) of swing arms which are opposite to each other are arranged on the longitudinal beams (201) of the sub-frame on the two sides; steering gear installation positions (2013) are arranged on the rear cross beam (203) of the sub-frame; and installation positions (2011) of front battery pack bottom fender are arranged on one side of the rear cross beam (203) of the sub-frame, which is back on to the front cross beam (202) of the sub-frame.

### Claim 8 (depends on 7)

The chassis collision structure of the new energy vehicle according to claim 7, wherein the large bushing installation positions (2015) of swing arms are colinear with the stabilization bar installation positions (2014) along a length direction of the longitudinal beams (201) of the sub-frame, and the stabilization bar installation positions (2014) are located on a top of the longitudinal beams (201) of the sub-frame; the large bushing installation positions (2015) of swing arms are provided with first large bushing installation points (20151) and second large bushing installation points (20152) which are arranged at intervals along the length direction of the longitudinal beams (201) of the sub-frame; the first large bushing installation points (20151) are close to the stabilization bar installation positions (2014) and run through a bottom of the longitudinal beams (201) of the sub-frame; and the second large bushing installation points (20152) run through the longitudinal beams (201) of the sub-frame from top to bottom.

### Claim 9 (depends on 3)

The chassis collision structure of the new energy vehicle according to claim 3, wherein a plurality of collapsing deformation intervals which are arranged along a length direction of the longitudinal beams (201) of the sub-frame are arranged on the longitudinal beams (201) of the sub-frame; each collapsing deformation interval is provided with a front interval (b) located on a front end of each of the longitudinal beams (201) of the sub-frame, a middle interval (c) close to a middle of each of the longitudinal beams (201) of the sub-frame, and a rear interval (d) located on a rear end of each of the longitudinal beams (201) of the sub-frame, and a collapsing rib (2020) is arranged on the longitudinal beam (201) of the sub-frame at the middle interval (c); and a strip deformation guide port (2021) is formed on the longitudinal beam (201) of the sub-frame at the rear interval (d).

### Claim 10 (depends on 3)

The chassis collision structure of the new energy vehicle according to claim 3, wherein a front cross beam inclined plane (20203) which inclines towards an outside of the cross beam (202) of the sub-frame is formed on an upper part of one side of the front cross beam (202) of the sub-frame, which directly faces the rear cross beam (203) of the sub-frame; a curb stone entry part (20303) which extends outwards is arranged on one side of the rear cross beam (203) of the sub-frame, which directly faces the front cross beam (202) of the sub-frame, and an up-dip upper inclined plane (20304) of the rear cross beam and a down-dip lower inclined plane (20305) of the rear cross beam are constructed at a top and a bottom of the rear cross beam (203) of the sub-frame and the curb stone entry part (20303) which are connected, respectively; a planar lifting contact part (20307) is arranged at a bottom of the rear cross beam (203) of the sub-frame; and a front battery pack fender connecting part (20306) which extends outwards is arranged on one side, which is back on to the front cross beam (202) of the sub-frame, of the rear cross beam (203) of the sub-frame.

### Claim 11 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the front battery pack bottom fender (3) is in a triangular shape; and a front sub-frame connecting part (55) is arranged at a position of a vertex angle which is close to the front battery pack bottom fender (3); and the connecting parts which are connected with the battery pack (8) are arranged along an edge of the front battery pack bottom fender (3), which directly faces the front sub-frame connecting part (55).

### Claim 12 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the top fender (602) comprises a straight middle connecting panel (6021), and an upper left panel (6022) and an upper right panel (6023) which are fixedly connected to two ends of the middle connecting panel (6021); the connecting holes are distributed in the upper left panel (6022) and the upper right panel (6023), and one end of the upper left panel (6022) and one end of the upper right panel (6023) are in bifurcated forms; and a planar lifting contact part (6016) is formed on the bottom fender (601), with respect to the middle connecting panel (6021).

### Claim 13 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the bottom fender body is provided with a first edge (605) which is linear and is located on one side of the rear battery pack connecting parts (7), and a second edge (606) which is located on one side of each of the rear sub-frame connecting parts and extends to be connected with two ends of the first edge (605); the second edge (606) is in an arc shape; the bottom fender (601) at the second edge (606) extends outwards with respect to the top fender (602); a flange (6013) is constructed on an overhang edge of the bottom fender (601); a plurality of drain holes (6015) are formed in the bottom fender (601); the flange (6013) located in the middle of the second edge (606) is provided with an up-dip bulged part (6014); and a bulged dimension of the bulged part (6014) is reduced gradually from the middle to the two sides.

### Claim 14 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein the rear sub-frame assembly (5) comprises a rear sub-frame main body, and two positioning supports which are arranged close to left ends and right ends of the rear sub-frame main body respectively; body connecting parts and rear battery pack bottom fender connecting parts are constructed on the rear sub-frame main body; stabilization bar installation parts, upper control arm installation parts, and lower control arm installation parts are arranged on the rear sub-frame main body; and positioning parts (66) which are matched with an external positioning element to locate the rear sub-frame main body are constructed on the two positioning supports.

### Claim 15 (depends on 14)

The chassis collision structure of the new energy vehicle according to claim 14, wherein the rear sub-frame main body has a bilaterally symmetrical structure, and comprises a rear sub-frame body located in the middle of the rear sub-frame main body, and rear sub-frame cross beams (503) and stabilization bar installation supports (502) which are arranged on two opposite sides of the rear sub-frame body respectively; the rear sub-frame main body further comprises lower supports (5010) which are connected between the rear sub-frame cross beams (503) on two sides and the rear sub-frame body respectively; and the positioning supports at two ends are fixedly connected to the stabilization bar installation support (502) on the corresponding end.

### Claim 16 (depends on 15)

The chassis collision structure of the new energy vehicle according to claim 15, wherein the rear sub-frame body is provided with a rear sub-frame front panel (504) and a rear sub-frame rear panel (506) which are in fixed overlap joint; the rear sub-frame cross beams (503) on the two sides are in fixed overlap joint with the rear sub-frame front panel (504); and the lower supports (5010) on the two sides are fixedly connected between the rear sub-frame front panel (504) and the rear sub-frame cross beam (503) on the corresponding sides.

### Claim 17 (depends on 16)

The chassis collision structure of the new energy vehicle according to claim 16, wherein an internal reinforcement panel (5012) is fixedly connected between the rear sub-frame front panel (504) and the rear sub-frame rear panel (506), and a rear installation position support panel (5013) is fixedly connected to the rear sub-frame rear panel (506); the plurality of body connecting parts and the plurality of rear battery pack bottom fender connecting parts are bilaterally symmetrical on the rear sub-frame main body; and all of the stabilization bar installation parts, the upper control arm installation parts, and the lower control arm installation parts have two groups that are bilaterally symmetrical with respect to the rear sub-frame main body.

### Claim 18 (depends on 2)

The chassis collision structure of the new energy vehicle according to claim 2, wherein a plurality of collapsing parts are arranged at intervals on each energy-absorbing box (102) along a length direction of each energy-absorbing box; and each collapsing part consists of bulges formed on an upper end face and a lower end face of each energy-absorbing box (102), and pits formed on a left end face and a right end face of each energy-absorbing box (102) with respect to the position of the bulges; or each collapsing part is a collapsing hole.

### Claim 19 (depends on 1)

The chassis collision structure of the new energy vehicle according to claim 1, wherein a bottom surface of the front sub-frame assembly (2) and the front battery pack bottom fender (3) which are connected show a gradually-lowered stair-step shape along the direction from the head to the tail of the vehicle; and a bottom surface of the rear battery pack bottom fender (6) shows a down-dip shape form along the direction from the tail to the head of the vehicle.