DESC:FIELD
The present disclosure generally relates to a frame structure of a vehicle, and in particular to a cradle frame of an electric vehicle for use in connecting parts to a vehicle body.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Typically, the core of an electric vehicle's functionality lies in its battery pack, that provides the essential power to drive the vehicle. The battery pack is strategically positioned on the frame of the electric vehicle. However, as the concern for safety takes precedence, particularly in collision scenarios, the intricacies of the battery pack's arrangement and protection come to the forefront.
In instances of direct head-on collisions, the initial impact is orchestrated by the front portion or cradle frame of the vehicle. This structural arrangement is configured to absorb and distribute the impact's energy, aimed at safeguarding the occupants within.
However, the conventional configuration of the front structure, despite its protective intentions, exhibits significant deformation under the force of impact, resulting in transfer of impact towards the battery pack assembly. The transfer of impact results in potential damage to the structural integrity of the battery pack assembly and, disruption to the intricate electrical connections that facilitate the electric vehicle (EV's) operational capacity.
Thus, there is felt a need for a cradle frame for electric vehicle (EV’s), that alleviates the aforementioned drawbacks.

OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a cradle frame for an electric vehicle.
Another object of the present disclosure is to provide a cradle frame for an electric vehicle that withstands the impact force.
Still another object of the present disclosure is to provide a cradle frame for an electric vehicle that reduces the amount of deformation of longitudinal members.
Yet another object of the present disclosure is to provide a cradle frame for an electric vehicle that enhances the battery pack protection from the impact force.
Still another object of the present disclosure is to provide a cradle frame for an electric vehicle that strengthen front portion of the vehicle.
Yet another object of the present disclosure is to provide a cradle frame for an electric vehicle that absorbs maximum amount of impact energy.
Still another object of the present disclosure is to provide a cradle frame for an electric vehicle that minimizes the impact force on battery mounting bolts.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a cradle frame for an electric vehicle (EV). The cradle frame comprises a first operative longitudinal member defined by a first end portion and a second end portion; a second operative longitudinal member defined by a third end portion and a fourth end portion; at least one transverse member spanning an operative portion of the first operative longitudinal member and the second operative longitudinal member; a first connecting member connected between an operative portion of the first end and the third end, defining a fifth end and a sixth end; a second connecting member connected between an operative portion of the second end and the fourth end; the first end, the third end, the first connecting member defining a front portion of the cradle frame; the second end, the fourth end, and the second connecting member defining a rear portion of the cradle frame. The cradle frame is characterized in that: the distance between the second end and the fourth end is less than the distance between the first end and the third end; the first end portion and the third end portion are twisted at an angle ranging between 100°-150° with respect to a central axis of the respective longitudinal members; the fifth end and the sixth end are nose-shaped and operatively projecting upward with respect to a plane containing the longitudinal members; and bolts are secured to the second end and the fourth end portion for mounting of the battery frame of the vehicle.
In an embodiment, the first end, the third end, and the first connecting member are configured to define a C-shaped structure.
In an embodiment, the second connecting member has spaced apart central mounts. The mounts and fixtures on the fifth end and the sixth end configured to mount an operative body portion of the vehicle.
In an embodiment, the first longitudinal member and the second longitudinal member are configured with a plurality of apertured grooves. The apertured grooves extend along the width of the first longitudinal member and the second longitudinal member.
In an embodiment, the plurality of apertured grooves is configured to facilitate at least two points bending and twisting of the longitudinal members along a predefined direction.
In an embodiment, the length of the first longitudinal member and the second longitudinal member is greater than the length of each of the transverse member, the connecting member and the second connecting member.
In an embodiment, the first end portion is twisted at an angle of 140° with respect to the central axis and the third end portion is twisted at an angle of 130° with respect to the central axis of the respective longitudinal members. Thus, the twisting of the different longitudinal members at different angle facilitates the absorption of comparatively high amount of impact energy and increase the time duration in transferring the impact from the operative front portion towards the operative rear portion near to the battery pack assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A cradle frame for an electric vehicle (EV), of the present disclosure will now be described with the help of the accompanying drawing in which:
Figure 1 illustrates a perspective isometric view of a cradle frame for an electric vehicle in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a perspective side view of a cradle frame for an electric vehicle of Figure 1 in accordance with an embodiment of the present disclosure.
Figure 3 illustrates a perspective enlarged side view of a rear portion of a cradle frame in accordance with an embodiment of the present disclosure.
Figure 4 illustrates a perspective view of the cradle frame with the vehicle body and battery frame in accordance with an embodiment of the present disclosure.
Figure 5A illustrates a perspective view of a longitudinal member of the cradle frame with a plurality of apertured grooves in accordance with an embodiment of the present disclosure.
Figure 5B illustrates a graphical illustration of force transmission along the length of the longitudinal member vs time in accordance with an embodiment of the present disclosure.
Figure 6 illustrates a different zone of transfer of impact force along the longitudinal member of the cradle frame in accordance with an embodiment of the present disclosure.
Figure 7 illustrates the twisting of longitudinal member under an impact load at varying angle in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
1000 Cradle frame
10 first longitudinal member
10A first end portion of first longitudinal member
10B second end portion of first longitudinal member
20 second longitudinal member
20A third end portion of second longitudinal member
20B fourth end portion of second longitudinal member
30 transverse member
40 first connecting member
40A fifth end of first connecting member
40B sixth end of first connecting member
50 Second connecting member
60 central axis of the longitudinal members
70 bolt
80 battery frame
90 central mount
110 Body of the vehicle
120 bracket
P1 first apertured grooves
P1 second apertured grooves
P3 third apertured grooves
P4 impact transfer near bolts
F front portion of cradle frame
R rear portion of cradle frame
Z1 first zone along the longitudinal member
Z2 second zone along the longitudinal member
Z3 third zone along the longitudinal member
Z4 fourth zone along the longitudinal member
Z5 fifth zone along the longitudinal member
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
Typically, during the instances of direct head-on collisions, the initial impact is orchestrated by the front portion or cradle frame of the vehicle. This structural arrangement is configured to absorb and distribute the impact's energy, aimed at safeguarding the occupants within. However, the conventional configuration of the front structure, despite its protective intentions, exhibits significant deformation under the force of impact, resulting in transfer of impact towards the battery pack assembly. The transfer of impact results in potential damage to the structural integrity of the battery pack assembly and, disruption to the intricate electrical connections that facilitate the electric vehicles (EV's) operational capacity.
Therefore, the present disclosure envisages a cradle frame (1000) for an electric vehicle. The different embodiments of the present disclosure is explained with reference to the Figure 1 through Figure 7.
In accordance with the present disclosure, the cradle frame (1000) comprises a first longitudinal member (10), a second longitudinal member (20), at least one transverse cross member (120), a first connecting member (10) and a second connecting member (50) and are operatively connected to define the cradle frame (1000). The first longitudinal member (10) is defined by a first end portion (10A) and a second end portion (10B). The second longitudinal member (20) is defined by a third end portion (20A) and a fourth end portion (20B). The transverse member (30) spanning an operative portion of the first longitudinal member (10) and the second longitudinal member (20). Figure 1 illustrates a perspective isometric view of a cradle frame (1000) for an electric vehicle and Figure 2 illustrates a perspective side view of a cradle frame (1000) for an electric vehicle of Figure 1 in accordance with an embodiment of the present disclosure.
Further the first connecting member (10) is connected between an operative portion of the first end and the third end portion (20A), thus defining a fifth end portion (40A) and a sixth end portion (40B). The second connecting member (50) is connected between an operative portion of the second end and the fourth end.
In an embodiment, the first end portion (10A), the third end portion (20A), the first connecting member (10) define a front portion of the cradle frame (1000), whereas the second end portion, the fourth end portion, and the second connecting member (50) define a rear portion of the cradle frame (1000).
In an embodiment, the first end portion (10A), the third end portion (20A), and the first connecting member (40) are configured to define a C-shaped structure.
In an embodiment, the first end portion (10A) and the third end portion (20A) are twisted at angle ranging between 100°- 150° with respect to a central axis (60) of the respective longitudinal members (10, 20).
In another embodiment, the first end portion (10A) is twisted at an angle of 140° with respect to the central axis (60) and the third end portion (20A) is twisted at angle at an angle of 130° with respect to the central axis (60) of the respective longitudinal members (10, 20). Advantageously, the twisting of the different longitudinal members (10, 20) at different angle facilitates the absorption of high amount of impact energy and increase the time duration in transferring the impact from the operative front portion towards the operative rear portion near to the battery pack assembly.
In an embodiment, the second connecting member (50) has spaced apart central mounts (80). The mounts (80) and fixtures on the fifth end portion (40A) and the sixth end portion (40B) are configured to mount an operative body portion of the vehicle thereon.
Further, the transverse cross member (120) is configured to be mounted in between the first connecting member (10) and the second connecting member (50) and is further configured to intermediately mount the first longitudinal member (10) and the second longitudinal member (20). Advantageously, the transverse cross member (120) facilitates transfer of impact force between the longitudinal members (10, 20) during the front or head on collision and thereby reduces the amount of deformation of the longitudinal members (10, 20). Figure 3 illustrates a perspective enlarged side view of a rear portion of a cradle frame (1000) and Figure 4 illustrates a perspective view of the cradle frame (1000) with the vehicle body and battery frame (80) in accordance with an embodiment of the present disclosure.
In an embodiment, the first longitudinal member (10), the second longitudinal member (20), the transverse cross member (120), the first connecting member (10) and the second connecting member (50) are selected from a hollow geometrical configuration.
In an embodiment, the first longitudinal member (10), the second longitudinal member (20), the transverse cross member (120), the first connecting member (10) and the second connecting member (50) are selected from a group consisting of grade of carbon steel, grade of alloy steel or any combination thereof to provide sufficient impact strength and rigidity to cradle frame (1000).
Further, the distance between the second end portion (10B) and the fourth end portion (20B) is less than the distance between the first end portion (10A) and the third end portion (20A). A plurality of bolts (70) is secured to the second end and the fourth end portion (20B) for mounting of the battery frame (80) of the vehicle.
In an embodiment, the fifth end portion (40A) and the sixth end portion (40B) are nose-shaped and operatively projecting upward with respect to a plane containing the longitudinal members (10, 20).
In a preferred embodiment, the first longitudinal member (10), the second longitudinal member (20), is configured with a plurality of apertured grooves (150). The apertured grooves (150) extend along the width of the first longitudinal member (10) and the second longitudinal member (20). The apertured groove divides the longitudinal members in first zone (Z1), second zone (Z2), third zone (Z3), fourth zone (Z4), and fifth zone (Z5). These aperture grooves (150) are configured to act as bending and twisting initiator for the cradle frame (1000). Advantageously, during impact or head on collision, the cradle frame (1000) bends and twist around the apertured grooves (150) and thus protects the transmission of impact or deformation to the battery mounting bolts (70) or the battery pack arrangement (130). Therefore, in the event of a crash, the impact is transmitted from the first zone (Z1) to the fifth zone (Z2), extending the duration of impact and effectively absorbing a significant amount of impact energy. Figure 5A illustrates a perspective view of a longitudinal member of the cradle frame (1000) with a plurality of apertured grooves in accordance with an embodiment of the present disclosure.
In an embodiment, the plurality of apertured grooves (150) configured to facilitate at least two points bending and twisting of the longitudinal members (10, 20) along a predefined direction.
In an embodiment, the length of the first longitudinal member (10) and the second longitudinal member (20) is greater than the length of each of the transverse member (30), the connecting member (10) and the second connecting member (50).
In an embodiment, the different components of the cradle frame (1000) are casted individually and welded together to form the frame.
In another embodiment, the cradle frame (1000) with integral components is casted or forged completely to form the frame.
In an embodiment, the front portion (2) of the cradle frame (1000) is configured with a pair of first fixing brackets (30) and a pair of second fixing brackets (40). The pair of first fixing brackets (30) and the pair of second fixing brackets (40) facilitates the mounting of different body parts of the vehicle.
In an embodiment, the first longitudinal member (10) and the second longitudinal member (20), are configured with a plurality of mounting brackets to mount and support different components thereon.
In an embodiment, a fixing bracket is provided on the front portion (2) of the frame for each of the longitudinal member.
In an embodiment, the first longitudinal member (10), the second longitudinal member (20), the transverse cross member (120), the first connecting member (10) and the second connecting member (50) are configured with a plurality of holes to receive fastening elements thereon.
The inclusion of a transverse cross member (120) onto the longitudinal members offers a notable advantage by streamlining the conveyance of impact force between these longitudinal components. This strategic arrangement contributes significantly to the optimal dissipation of impact energy, particularly in the context of front or side collisions.
Further, the longitudinal members (10, 20) of the cradle frame (1000) during the impact bends and twist which limits the deformation to travel longitudinally and thus results in protection of the structural integrity of the battery pack's mounting arrangement (130), as well as the battery mounting bolts (70).
Additionally, the front impact induces bending and torsional in the longitudinal members (10, 20) of the cradle frame (1000) which restricts the extent of longitudinal deformation, consequently ensuring the safeguarding of both the structural integrity of the battery pack's mounting arrangement (130) and the integrity of the battery mounting bolts (70). Figure 5B illustrates a graphical illustration of force transmission along the length of the longitudinal member vs time in accordance with an embodiment of the present disclosure.
Furthermore, the presence of the cross member (120) yields an additional benefit as it serves as a safeguard against excessive deformation of the longitudinal members. As a result, it protects the structural integrity of the battery pack's mounting arrangement (130), as well as the battery mounting bolts (70), and protect the battery from the damage that could potentially arise from the front collision.
In an exemplary embodiment, the cradle frame (1000) is subjected to a front crash impact. It has been observed that, during deformation, the different longitudinal members bend and twist along the plurality of apertured grooves and thus it increases the time travel for the impact to reach near to the periphery of the bolts (70), and thus it protects the battery frame (80) from any damage. Figure 6 illustrates different zones (Z1… Z5) of transfer of impact force along the longitudinal member of the cradle frame (1000). Figure 7 illustrates the twisting of longitudinal member under an impact load at varying angle in accordance with an embodiment of the present disclosure.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, a cradle frame for an electric vehicle, that;
• withstands the impact force;
• reduces the amount of deformation of longitudinal members and thus, it protects the battery from the impact;
• enhances the battery pack protection from the impact force;
• strengthens the front portion of the vehicle due to the presence of the cross member;
• absorbs maximum amount of impact energy;
• minimizes the impact force on battery mounting bolts; and
• provides a predefined path-way for the failure of the cradle frame due to the presence of the apertured grooves on the longitudinal members of the cradle frame and thus it absorbs comparatively large amount of impact energy during impact.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A cradle frame (1000) for an electric vehicle (EV), said cradle frame (1000) comprising:
• a first longitudinal member (10) defined by a first end portion (10A) and a second end portion (10B);
• a second longitudinal member (20) defined by a third end portion (20A) and a fourth end portion (20B);
• at least one transverse member (30) spanning an operative portion of said first longitudinal member (10) and said second longitudinal member (20);
• a first connecting member (10) connected between an operative portion of said first end portion (10A) and the third end portion (20A), defining a fifth end portion (40A) and a sixth end portion (40B); and
• a second connecting member (50) connected between an operative portion of said second end portion (10B) and said fourth end portion (20B);
said first end portion (10A), said third end portion (20A), and said first connecting member (10) defining a front portion of said cradle frame (1000), and
said second end portion (10B), said fourth end portion (20B), and said second connecting member (50) defining a rear portion of the cradle frame (1000),
characterised in that:
? the distance between said second end portion (10B) and said fourth end portion (20B) is less than the distance between said first end portion (10A) and said third end portion (20A);
? said first end portion (10A) and said third end portion (20A) are twisted at angle ranging between 100°- 150° with respect to a central axis (60) of the respective longitudinal members (10, 20);
? said fifth end portion (40A) and said sixth end portion (40B) are nose-shaped and operatively project upwards with respect to a plane containing said longitudinal members (10, 20); and
? bolts (70) are secured to said second end portion (10B) and said fourth end portion (20B) for mounting of the battery frame (80) of the vehicle.
2. The cradle frame (1000) as claimed in claim 1, wherein said first end portion (10A), said third end portion (20A), and said first connecting member (10) configured to define a C-shaped structure.
3. The cradle frame (1000) as claimed in claim 1, wherein said second connecting member (50) has spaced apart central mounts (80), said mounts (80) and fixtures on said fifth end portion (40A) and said sixth end portion (40B) configured to mount an operative body portion of the vehicle thereon.
4. The cradle frame (1000) as claimed in claim 1, wherein said first longitudinal member (10) and said second longitudinal member (20) are configured with a plurality of apertured grooves (150), said apertured grooves (150) extend along the width of said first longitudinal member (10) and said second longitudinal member (20).
5. The cradle frame (1000) as claimed in claim 4, wherein said plurality of apertured grooves (150) configured to facilitate at least two points bending and twisting of said longitudinal members (10, 20) along a predefined direction.
6. The cradle frame (1000) as claimed in claim 1, wherein the length of said first longitudinal member (10) and said second longitudinal member (20) is greater than the length of each of said transverse member (30), said first connecting member (10) and said second connecting member (50).
7. The cradle frame (1000) as claimed in claim 1, wherein said first end portion (10A) is twisted at an angle of 140° with respect to said central axis (60) and said third end portion (20A) is twisted at an angle of 130° with respect to said central axis (60) of the respective longitudinal members (10, 20).
Dated this 16th day of February, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI