Toyota Motor Engineering & Manufacturing North America, Inc.

Toyota Technical Center, U.s.a., Inc.

Jesse Thomas Buehler

Jonathan Richard Young

Taichi Yamashita

Gerritt Benjamin Meyers

Naipaul Deo Ramoutar

Ben Penner

Takao Sato

A frame structure is adapted to absorb 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 at least one ramp connected to the pair of side frame under-members for directing rearward sliding movement of the rear sub-frame and attached structures downwardly beneath a battery assembly. A catching surface engages a steering gear to improve energy absorption during frontal impacts. A reinforcement bracket attached to the pair of side frame under-members defines a pocket for temporarily catching the rear sub-frame providing an energy absorption path before releasing the rear sub-frame to slide past. A tether is connected between the pair of side frame under-members and the rear sub-frame for holding the rear sub-frame against the ramp to increase energy absorption.

Sub-frame intrusion control by ramping during frontal impact for electric vehicle battery protection

A battery attachment bracket and method of assembly for protecting a battery of a motor vehicle from damage during a rear impact. The battery attachment bracket connects the battery to support structure of the motor vehicle in an area subject to deformation during a rear impact. The battery attachment bracket is formed by a body member extending from a battery-engaging surface to a vehicle-support-engaging surface. The vehicle-support-engaging surface has a bolt-receiving aperture, and a notch cut-out adjacent to the bolt-receiving aperture located in a vehicle-front direction with respect to the bolt-receiving aperture to define a narrowed portion of the battery attachment bracket. A gusset having an angled surface is located on a vehicle-front-facing surface of the battery attachment bracket. The gusset resists deformation of the battery attachment bracket and promotes separation of the battery attachment bracket from the support structure of the motor vehicle adjacent the bolt-receiving aperture.

Vehicle construction method to prevent battery damage in rear impact using optimized bracket separation

A vehicle frame includes an inverter protection brace extending between front and rear sub-frames located below and in front of side under frame members. A gusset of the brace strongly connects to the front sub-frame to load a beam section without overloading attaching bolts. The brace has a bolted connection attaches to the rear sub-frame. The brace deforms forward of the bolted connection creating a safety cage around an inverter during frontal impacts. A reinforcement bracket attaches to the side frame under members to define a pocket for temporarily catching the rear sub-frame. Ramps connect to the reinforcement bracket allowing sliding of the rear sub-frame rearward, and direct movement downwardly beneath a battery assembly. A catching surface defined on the ramp engages at least one rear sub-frame attached structure. A tether connects between the pair of side frame under-members and the rear sub-frame for improving the interaction of the rear sub-frame against the ramps.

Electric vehicle construction methods for frontal impact

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.

Construction method to control front engine compartment deformation

An occupant restraint mechanism is disposed between a rigid member and an instrument panel of an automotive vehicle. The occupant restraint mechanism includes first and second brackets each extending between proximal ends fixedly secured to the rigid member and distal ends coupled to the instrument panel. One of the first and second brackets has at least one notch formed therein. The notch has a predetermined size to allow a predetermined amount of deformation of the first and second brackets during contact of an occupant with the instrument panel during a sudden deceleration of the vehicle.

Growing community of inventors

Ypsilanti, MI, United States of America

Jesse Thomas Buehler