# US 8,540,259 B1 · Construction method to control front engine compartment deformation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,540,259 B1 - Document ID: US8540259B1 - Status: Granted - Kind: B1 - Application number: 13/445,145 - Filed: 2012-04-12 - Published: 2013-10-17 - Granted: 2013-09-24 - Earliest claimed: 2012-04-12 - Assignees: Toyota Motor Engineering & Manufacturing North America, Inc. - Applicants: Jonathan Richard Young; Taichi Yamashita; Jesse Thomas Buehler; Gerritt Benjamin Meyers - Inventors: Jonathan Richard Young; Taichi Yamashita; Jesse Thomas Buehler; Gerritt Benjamin Meyers - Web page: https://patentgrep.com/patent/US8540259B1 ## CPC - B62D 21/155: {Sub-frames or underguards} - Y10T 29/49622: Vehicular structural member making - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A frame structure absorbs energy from frontal impacts and extends under a front portion of the body frame. The frame structure includes a rear sub-frame located below and in front of a pair of side frame under-members, and an inverter protection brace extending between the front sub-frame and the rear sub-frame. Loading from the inverter protection brace travels through the rear sub-frame to A-point bolt connections located on the pair of front frame side members. The rear sub-frame moves rearward and deforms at the A-point bolt connections. The load through the A-point bolt connections changes the deformation mode of the frame front side members between the A-point bolt connections and B-point bolt connections. At least one of the pair of side frame under-members buckles rearward of the B-point bolt connection located on the pair of side frame under-members for energy absorption during the frontal impact. ## Claims ### Claim 1 A frame structure for a land vehicle having wheels to engage a surface over which the vehicle moves, an electric motor enabling the vehicle to be moved along the surface, the frame structure providing support for a vehicle body, where at least a portion of the frame structure changes shape in response to impact of the frame structure with another body, the frame structure adapted to absorb energy from frontal impacts, the frame structure extending under a front portion of the vehicle body, the frame structure comprising: a front sub-frame and a rear sub-frame located below and in front of a pair of side frame under-members; and an inverter protection brace extending between the front sub-frame and the rear sub-frame for transferring energy from the front sub-frame to the rear sub-frame during a frontal impact. ### Claim 2 (depends on 1) The frame structure of claim 1 further comprising: a gusset at a front end of the inverter protection brace for connecting the front sub-frame to load a beam section without overloading attaching bolts. ### Claim 3 (depends on 1) The frame structure of claim 1 further comprising: a bolted connection at a rear end of the inverter protection brace to the rear sub-frame. ### Claim 4 (depends on 1) The frame structure of claim 1 further comprising: A-point bolt connections of the rear sub-frame to a pair of front frame side members located above the rear sub-frame; and B-point bolt connections of the rear sub-frame to the pair of side frame under-members, wherein loading from the inverter protection brace travels through the rear sub-frame to the A-point bolt connections located on the pair of front frame side members, the rear sub-frame moves rearward and deforms at the A-point bolt connections, at least one of the pair of side frame under-members buckles rearward of the B-point bolt connections for energy absorption during the frontal impact. ### Claim 5 (depends on 4) The frame structure of claim 4, wherein a portion of the inverter protection brace load through the A-point bolt connections contributes to deformation timing and shape of the front frame side members between the A-point bolt connections and the B-point bolt connections. ### Claim 6 (depends on 4) The frame structure of claim 4 further comprising: a gusset at a front end of the inverter protection brace for connecting the front sub-frame to load a beam section without overloading attaching bolts, wherein the gusset rotates below the front sub-frame to delay loading of the inverter protection brace and to delay bending of the front frame side members to improve energy absorption of the front frame side members during frontal impacts. ### Claim 7 (depends on 1) The frame structure of claim 1, wherein the inverter protection brace deforms adjacent a bolted connection at a rear end to form a safety cage around an inverter during the frontal impact. ### Claim 8 (depends on 1) The frame structure of claim 1 further comprising: a gusset at a front end of the inverter protection brace connecting to the front sub-frame to load a beam section without overloading attaching bolts, the gusset connected to the front sub-frame at a location outboard from a centerline of the vehicle; and a bolted connection at a rear end of the inverter protection brace attaching to the rear sub-frame, the bolted connection connected to the rear sub-frame at a location outboard of the centerline of the vehicle and inboard of the gusset location. ### Claim 9 (depends on 1) The frame structure of claim 1 further comprising: the inverter protection brace having an elongate angled shape angling inboard with respect to a centerline of the vehicle adjacent a rear end. ### Claim 10 (depends on 1) The of claim 1 further comprising: the inverter protection brace having a generally concave arcuate shape from front to rear. ### Claim 11 A method of assembling structural members for absorbing energy from frontal impacts of a frame structure for a land vehicle having wheels to engage a surface over which the vehicle moves, an electric motor enabling the vehicle to be moved along the surface, the frame structure providing support for a vehicle body, where the frame structure changes shape in response to impact of the frame structure with another body, the frame structure extending under a front portion of the vehicle body, the method comprising: locating a front sub-frame and a rear sub-frame below and in front of a pair of side frame under-members; and connecting an inverter protection brace extending between the front sub-frame and the rear sub-frame for transferring energy during a frontal impact. ### Claim 12 (depends on 11) The method of claim 11 further comprising: connecting a gusset at a front end of the inverter protection brace to the front sub-frame to load a beam section without overloading attachment bolts. ### Claim 13 (depends on 11) The method of claim 11 further comprising: bolting the inverter protection brace at a rear end to the rear sub-frame. ### Claim 14 (depends on 11) The method of claim 11 further comprising: connecting the rear sub-frame to a pair of front frame side members located above the rear sub-frame at A-point bolt connections; and connecting the rear sub-frame to the pair of side frame under-members at B-point bolt connections, wherein loading from the inverter protection brace travels through the rear sub-frame to the A-point bolt connections located on the pair of front frame side members, the rear sub-frame moves rearward and deforms at the A-point bolt connections, at least one of the pair of side frame under-members buckles rearward of the B-point bolt connections for energy absorption during the frontal impact. ### Claim 15 (depends on 14) The method of claim 14 further comprising: loading a portion of the inverter protection brace through the A-point bolt connections to contribute to deformation timing and shape of the front frame side members between the A-point bolt connections and the B-point bolt connections. ### Claim 16 (depends on 14) The method of claim 14 further comprising: connecting a gusset at a front end of the inverter protection brace to the front sub-frame to load a beam section without overloading attachment bolts; and rotating the gusset below the front sub-frame to delay loading of the inverter protection brace and delay bending of the front frame side members to improve energy absorption of the front frame side members during frontal impacts. ### Claim 17 (depends on 11) The method of claim 11 further comprising: deforming the inverter protection brace adjacent a bolted connection at a rear end to form a safety cage around an inverter during the frontal impact. ### Claim 18 (depends on 11) The method of claim 11 further comprising: connecting the inverter protection brace to the front sub-frame with a gusset at a front end to load a beam section without overloading attaching bolts, the gusset connected to the front sub-frame at a location outboard from a centerline of the vehicle; and connecting the inverter protection brace to the rear sub-frame with a bolted connection at a rear end, the bolted connection connected to the rear sub-frame at a location outboard of the centerline of the vehicle and inboard of the gusset location. ### Claim 19 (depends on 11) The method of claim 11 further comprising: providing the inverter protection brace with an elongate angled shape; and angling the inverter protection brace inboard with respect to a centerline of the vehicle adjacent a rear end. ### Claim 20 (depends on 11) The method of claim 11 further comprising: providing the inverter protection brace with a generally concave arcuate shape from front to rear. ### Claim 21 A frame structure adapted to absorb energy from frontal impacts, the frame structure extending under a front portion of a vehicle body, the frame structure comprising: a front sub-frame and a rear sub-frame located below and in front of a pair of side frame under-members; and an inverter protection brace extending between the front sub-frame and the rear sub-frame for transferring energy from the front sub-frame to the rear sub-frame during a frontal impact. ### Claim 22 (depends on 21) The frame structure of claim 21 further comprising: a gusset at a front end of the inverter protection brace connecting to the front sub-frame to load a beam section without overloading attaching bolts; and a bolted connection at a rear end of the inverter protection brace to the rear sub-frame. ### Claim 23 (depends on 21) The frame structure of claim 21 further comprising: A-point bolt connections of the rear sub-frame to a pair of front frame side members located above the rear sub-frame; and B-point bolt connections of the rear sub-frame to the pair of side frame under-members, wherein loading from the inverter protection brace travels through the rear sub-frame to the A-point bolt connections located on the pair of front frame side members, the rear sub-frame moves rearward and deforms at the A-point bolt connections, at least one of the pair of side frame under-members buckles rearward of the B-point bolt connections for energy absorption during the frontal impact. ### Claim 24 (depends on 23) The frame structure of claim 23, wherein a portion of the inverter protection brace load through the A-point bolt connections contributes to deformation timing and shape of the front frame side members between the A-point bolt connections and the B-point bolt connections. ### Claim 25 (depends on 23) The frame structure of claim 23 further comprising: a gusset at a front end of the inverter protection brace connecting to the front sub-frame to load a beam section without overloading attaching bolts, wherein the gusset rotates below the front sub-frame to delay loading of the inverter protection brace and delay bending of the front frame side members to improve energy absorption of the front frame side members during frontal impacts. ### Claim 26 (depends on 21) The frame structure of claim 21, wherein the inverter protection brace deforms adjacent a bolted connection at a rear end to form a safety cage around an inverter during the frontal impact.