FORM – 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
A MODULAR ENERGY-ABSORBING IMPACT PROTECTION FRAME FOR A
HEAVY-DUTY ELECTRIC VEHICLE
Applicant(s):
VE COMMERCIAL VEHICLES LTD
102, INDUSTRIAL AREA 1, PITHAMPUR- 454775, DIST. DHAR, MP, INDIA
Inventors:
(1) Neha Rai,
(2) Sharvang Uchgaonkar
(3) Yogendra Aniya
The following specification particularly describes the invention and the manner in which it
is to be performed.
2
A MODULAR ENERGY-ABSORBING IMPACT PROTECTION FRAME
FOR A HEAVY-DUTY ELECTRIC VEHICLE
FIELD OF THE DISCLOSURE
[0001] This invention generally relates to a field of vehicle safety and structural
protection systems for heavy-duty vehicles, and in particular, to a modular energy-5
absorbing impact protection frame for a heavy-duty electric vehicle and method
thereof.
BACKGROUND
[0002] The subject matter discussed in the background section should not be
assumed to be prior art merely as a result of its mention in the background section.10
Similarly, a problem mentioned in the background section or associated with the
subject matter of the background section should not be assumed to have been
previously recognized in the prior art. The subject matter in the background section
merely represents different approaches, which in and of themselves may also
correspond to implementations of the claimed technology.15
[0003] Heavy-duty electric vehicles, such as electric buses and commercial electric
transport vehicles, increasingly incorporate high-energy traction battery systems
that are mounted near an end region of the vehicle due to packaging constraints,
weight distribution requirements, and low-floor or flat-floor layout considerations.
Placement of such battery systems in proximity to vehicle end regions exposes the20
battery modules, battery enclosures, and associated mounting structures to elevated
risk during high-energy collision events, particularly when impact forces are applied
at specific heights relative to the vehicle structure.
[0004] In existing heavy-duty electric vehicle architectures, end-mounted impact
protection arrangements are primarily designed to satisfy minimum structural25
strength or regulatory requirements and are typically implemented as rigid or semi-
rigid assemblies. Such arrangements generally lack dedicated energy-management
capability and do not exhibit predictable or controlled deformation behavior during
severe impact events.
3
[0005] As a result, impact loads encountered during frontal or rear collision events
may be transmitted rapidly and directly into the vehicle chassis and adjacent
structural interfaces. Direct transmission of collision forces can lead to localized
overloading of the chassis structure and increased risk of damage to critical vehicle
systems, including traction battery modules, battery enclosures, power electronics,5
and related support structures.
[0006] Additionally, conventional impact protection designs offer limited
adaptability to vehicle-specific packaging constraints, including variations in
ground clearance, approach or departure angle requirements, and spatial limitations
associated with battery placement and electric drivetrain components. In many10
cases, such rigid designs cannot be readily tailored to different vehicle
configurations without extensive redesign.
[0007] Conventional end-mounted impact protection arrangements further lack
modularity, thereby limiting post-collision serviceability. Following an impact
event, damage to localized regions of a rigid impact structure often necessitates15
removal or replacement of an entire assembly, increasing repair time, vehicle
downtime, and overall maintenance cost.
[0008] Accordingly, there exists a need for an impact protection solution for heavy-
duty electric vehicles that is capable of absorbing and managing collision energy in
a controlled and staged manner, while reducing peak force transmission to the20
vehicle chassis and protected systems. There is also a need for such a solution to
provide defined load paths, modular construction, and compatibility with the spatial,
structural, and operational constraints associated with modern electric vehicle
architectures.
[0009] Another the patent application, “CN102431593A,” titled “Electric vehicle25
chassis,” describes the technical field of electric vehicles and relates to a
multifunctional vehicle chassis and in particular to a high-strength chassis applied
to an electric vehicle. The electric vehicle chassis comprises a vehicle frame and a
driving device, wherein the driving device comprises a driving motor, a motor
controller, a transmission, a half axle and a driving front axle. The electric vehicle30
chassis is characterized in that the vehicle frame is formed by welding rectangular
4
pipes of different specifications; a loading type overall rectangular pipe vehicle
frame is welded by left and right single pipe longitudinal beams and a middle
supporting beam through a front vehicle frame absorbing anti-collision beam, a
front baffle and a middle vehicle frame cross beam and a rear vehicle frame cross
beam; the vehicle frame comprises a front vehicle frame, a middle vehicle frame5
and a rear vehicle frame; an absorbing beam is welded on the middle vehicle frame;
a strengthening rib is welded between the middle vehicle frame and the rear vehicle
frame; and a triangular strengthening rib is welded on the rear vehicle frame. With
the adoption of the electric vehicle chassis, gravity is better distributed to each point
of the vehicle frame in a vehicle loaded condition, the uniform vehicle frame force10
is ensured, various stresses generated under a special condition can be quickly
absorbed at the same time, and the vehicle frame life is prolonged.
[0010] Another patent application, "WO2022031991A1," titled " Integrated energy
absorbing castings," describes An integrated energy absorbing system of a vehicle
with a front integrated energy absorbing casting and a back integrated energy15
absorbing casting. Each front and back casting is a single unified casting that makes
up the integrated energy absorbing system. Ribbed sections such as "I" sections and
"C" sections make up the castings and are formed from a variety of different
techniques and/or formings such as cutout, waveform profile, tapering, flaring
and/or rib spacing. Additional sections such as closed section castings may also be20
integrated in the integrated energy absorbing system.
[0011] In conventional end-region impact protection arrangements for heavy-duty
electric vehicles, accommodation of packaging constraints associated with low-
floor layouts and end-mounted traction battery systems is largely independent of
optimized energy-management and defined load-path control. Such arrangements25
typically rely on rigid or semi-rigid structural members, including straight beams,
plates, or welded frames, that are dimensioned primarily based on regulatory
strength requirements rather than tailored deformation behavior. As a result, when
high-energy collision loads are applied at specific impact heights relative to the
vehicle structure, conventional impact protection arrangements exhibit unfavorable30
load transmission characteristics, including rapid force transfer, localized
5
overstress, and limited energy dissipation prior to chassis engagement. These
traditional configurations provide limited capability to progressively absorb and
redistribute impact forces across multiple structural members, particularly within
constrained packaging envelopes at the vehicle end region. Attempts to compensate
through increased member thickness or added reinforcements further exacerbate5
weight, packaging, and serviceability challenges, while offering minimal
improvement in controlled deformation behavior. Consequently, conventional end-
mounted impact protection strategies are associated with increased risk of damage
to traction battery systems, reduced predictability of structural response under
severe impacts, and limited suitability for modern heavy-duty electric vehicle10
architectures requiring compact, modular, and energy-absorbing structural
solutions.
OBJECTIVES OF THE INVENTION
[0012] The objective of the present invention is to provide a modular energy-
absorbing impact protection frame for a heavy-duty electric vehicle, particularly for15
installation at an end region of the vehicle, capable of managing and dissipating
high-energy collision loads before such loads are transmitted to a vehicle chassis
and protected vehicle systems.
[0013] The objective of the present invention is to overcome limitations of
conventional rigid or semi-rigid end-mounted impact protection arrangements by20
providing a modular energy-absorbing impact protection frame that exhibits staged
and controlled deformation behavior, thereby enabling predictable and progressive
absorption of collision energy.
[0014] The objective of the present invention is to reduce peak impact forces
transmitted to traction battery systems, battery enclosures, and associated mounting25
structures by employing a plurality of vertically spaced tubular impact members
configured to engage an impacting vehicle at multiple structural planes.
[0015] The objective of the present invention is to provide a modular energy-
absorbing impact protection frame having a structural configuration in which
tubular impact members are configured to deform first under impact loading,30
6
followed by controlled load transfer through vertically oriented support uprights and
diagonally oriented plurality of diagonally oriented bracing members.
[0016] The objective of the present invention is to define guided and distributed
load paths within the modular energy-absorbing impact protection frame through a
cross-braced support architecture, thereby minimizing localized stress5
concentrations and improving load sharing during offset or asymmetric impact
events.
[0017] The objective of the present invention is to externalize energy absorption
away from critical vehicle components by absorbing and managing collision energy
within the modular energy-absorbing impact protection frame prior to transfer of10
loads to the vehicle chassis or traction battery mounting interfaces.
[0018] The objective of the present invention is to enhance durability and structural
reliability of end-region vehicle structures by limiting uncontrolled deformation of
the vehicle chassis and reducing the likelihood of damage to adjacent safety-critical
systems.15
[0019] The objective of the present invention is to provide a modular energy-
absorbing impact protection frame having a mechanically fastened construction that
enables selective replacement of deformed tubular impact members, support
uprights, or plurality of diagonally oriented bracing members following a collision
event.20
[0020] The objective of the present invention is to enable tuning of energy-
absorption characteristics of the modular energy-absorbing impact protection frame
by varying tube geometry, material properties, or bracket configuration without
altering the overall structural architecture.
[0021] The objective of the present invention is to provide a robust, scalable, and25
adaptable modular energy-absorbing impact protection frame that can be readily
integrated into existing heavy-duty electric vehicle platforms without substantial
redesign, increased packaging complexity, or significant increase in manufacturing
cost.
SUMMARY30
7
[0022] The present invention relates to a modular energy-absorbing impact
protection frame for a heavy-duty electric vehicle.
[0023] According to an aspect, a modular energy-absorbing impact protection
frame for a heavy-duty electric vehicle is disclosed. The modular energy-absorbing
impact protection frame comprises a plurality of horizontally extending tubular5
impact members arranged in vertically spaced relation at an end region of the
vehicle. The modular energy-absorbing impact protection frame further comprises
a load-managing support subsystem including a plurality of vertically oriented
support uprights spaced laterally along a width of the modular energy-absorbing
impact protection frame. The modular energy-absorbing impact protection frame10
further comprises a plurality of diagonally oriented plurality of diagonally oriented
bracing members interconnecting adjacent support uprights in a cross-braced
configuration. The modular energy-absorbing impact protection frame further
comprises a chassis interface subsystem including mounting brackets configured to
secure the support uprights to existing structural members of a vehicle chassis.15
Further, the tubular impact members are configured to undergo controlled plastic
deformation under axial and/or bending loads exceeding a predefined threshold to
dissipate collision energy. Further, the support uprights and the plurality of
diagonally oriented bracing members define guided load paths that redistribute
impact forces across multiple support uprights prior to transfer to the vehicle20
chassis. Further, the modular energy-absorbing impact protection frame attenuates
and manages collision energy before it is transmitted to protected vehicle systems.
[0024] According to another aspect, a method for providing modular energy-
absorbing impact protection frame for a heavy-duty electric vehicle is disclosed.
The method comprises steps of arranging a plurality of horizontally extending25
tubular impact members in vertically spaced relation at an end region of the vehicle.
The method further comprises steps of roviding a load-managing support subsystem
including a plurality of vertically oriented support uprights spaced laterally along a
width of the modular energy-absorbing impact protection frame. The method
comprises steps of interconnecting, via a plurality of diagonally oriented plurality30
of diagonally oriented bracing members, adjacent support uprights in a cross-braced
8
configuration. The method comprises steps of securing, via a chassis interface
subsystem including mounting brackets, the support uprights to existing structural
members of a vehicle chassis. Further, the tubular impact members are configured
to undergo controlled plastic deformation under axial and/or bending loads
exceeding a predefined threshold to dissipate collision energy. Further, the support5
uprights and the plurality of diagonally oriented bracing members define guided
load paths that redistribute impact forces across multiple support uprights prior to
transfer to the vehicle chassis. Further, the modular energy-absorbing impact
protection frame attenuates and manages collision energy before it is transmitted to
protected vehicle systems.10
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings illustrate various embodiments of systems,
methods, and embodiments of various other aspects of the disclosure. Any person
with ordinary skills in the art will appreciate that the illustrated element boundaries
(e.g., boxes, groups of boxes, or other shapes) in the figures represent one example15
of the boundaries. It may be that in some examples one element may be designed as
multiple elements or that multiple elements may be designed as one element. In
some examples, an element shown as an internal component of one element may be
implemented as an external component in another, and vice versa. Furthermore,
elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions20
are described with reference to the following drawings. The components in the
figures are not necessarily to scale, emphasis instead being placed upon illustrating
principles.
[0026] FIG. 1 illustrates a perspective view of a modular energy-absorbing impact
protection frame for a heavy-duty electric vehicle, according to an embodiment of25
the present disclosure;
[0027] FIG. 2 illustrates a perspective view of a portion of a heavy-duty electric
vehicle installed with the modular energy-absorbing impact protection frame,
according to an embodiment of the present disclosure; and
9
[0028] FIG. 3 illustrates a flowchart showing a method for providing modular
energy-absorbing impact protection frame for a heavy-duty electric vehicle,
according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0029] Some embodiments of this disclosure, illustrating all its features, will now5
be discussed in detail. The words “comprising,” “having,” “containing,” and
“including,” and other forms thereof, are intended to be equivalent in meaning and
be open ended in that an item or items following any one of these words is not meant
to be an exhaustive listing of such item or items or meant to be limited to only the
listed item or items. It must also be noted that as used herein and in the appended10
claims, the singular forms “a,” “an,” and “the” include plural references unless the
context clearly dictates otherwise.
[0030] Although any systems and methods similar or equivalent to those described
herein can be used in the practice or testing of embodiments of the present
disclosure, the preferred, systems and methods are now described. Embodiments of15
the present disclosure will be described more fully hereinafter with reference to the
accompanying drawings in which like numerals represent like elements throughout
the several figures, and in which example embodiments are shown. Embodiments
of the claims may, however, be embodied in many different forms and should not
be construed as limited to the embodiments set forth herein. The examples set forth20
herein are non-limiting examples and are merely examples among other possible
examples.
[0031] The present invention discloses various embodiments of a modular energy-
absorbing impact protection frame for a heavy-duty electric vehicle is disclosed.
The modular energy-absorbing impact protection frame comprises a plurality of25
horizontally extending tubular impact members arranged in vertically spaced
relation at an end region of the vehicle. The modular energy-absorbing impact
protection frame further comprises a load-managing support subsystem including a
plurality of vertically oriented support uprights spaced laterally along a width of the
modular energy-absorbing impact protection frame. The modular energy-absorbing30
impact protection frame further comprises a plurality of diagonally oriented
10
plurality of diagonally oriented bracing members interconnecting adjacent support
uprights in a cross-braced configuration. The modular energy-absorbing impact
protection frame further comprises a chassis interface subsystem including
mounting brackets configured to secure the support uprights to existing structural
members of a vehicle chassis. Further, the tubular impact members are configured5
to undergo controlled plastic deformation under axial and/or bending loads
exceeding a predefined threshold to dissipate collision energy. Further, the support
uprights and the plurality of diagonally oriented bracing members define guided
load paths that redistribute impact forces across multiple support uprights prior to
transfer to the vehicle chassis. Further, the modular energy-absorbing impact10
protection frame attenuates and manages collision energy before it is transmitted to
protected vehicle systems.
[0032] FIG. 1 illustrates a perspective view of a modular energy-absorbing impact
protection frame (100) for a heavy-duty electric vehicle, according to an
embodiment of the present disclosure. FIG. 2 illustrates a perspective view of a15
portion of a heavy-duty electric vehicle installed with the modular energy-absorbing
impact protection frame (100), according to an embodiment of the present
disclosure.
[0033] In some embodiments, the modular energy-absorbing impact protection
frame (100) is configured to be mounted at an end region of a heavy-duty electric20
vehicle. The modular energy-absorbing impact protection frame (100) is configured
to manage and dissipate collision energy arising from frontal or rear impact events.
The modular energy-absorbing impact protection frame (100) operates
independently of the vehicle chassis while remaining structurally integrated
therewith. The modular energy-absorbing impact protection frame (100) is25
configured to absorb impact energy before such energy is transmitted to protected
vehicle systems. The modular energy-absorbing impact protection frame (100) is
particularly suited for vehicles incorporating end-mounted traction battery systems.
The modular energy-absorbing impact protection frame (100) enhances vehicle
safety and structural reliability.30
11
[0034] The modular energy-absorbing impact protection frame (100) comprises a
plurality of horizontally extending tubular impact members (102) arranged in
vertically spaced relation. The plurality of horizontally extending tubular impact
members (102) is positioned to engage an impacting object at different vertical
heights. In some embodiments, the plurality of horizontally extending tubular5
impact members (102) includes an upper tubular impact member and a lower tubular
impact member arranged one above the other. The vertical spacing between the
upper tubular impact member and the lower tubular impact member is selected
based on expected impact height profiles. The vertically spaced arrangement
enables multi-level impact engagement. The plurality of horizontally extending10
tubular impact members (102) initiates energy absorption early during an impact
event.
[0035] Each tubular impact member is formed from metallic tubing selected to
undergo controlled and progressive plastic deformation when subjected to axial and
bending loads exceeding a predefined threshold. The material selection enables15
predictable deformation behavior under collision loading. The tubular impact
members are configured to deform prior to load transfer to downstream structural
components. Progressive deformation of the tubular impact members dissipates
kinetic energy over a defined stroke length. The tubular impact members provide
repeatable energy-absorption characteristics. The tubular impact members thereby20
reduce peak impact forces transmitted through the structure.
[0036] The modular energy-absorbing impact protection frame (100) further
comprises a load-managing support subsystem (104) including a plurality of
vertically oriented support uprights spaced laterally along a width of the modular
energy-absorbing impact protection frame (100). Each support upright extends from25
a lower mounting interface toward an upper region supporting the tubular impact
members. The support uprights provide vertical load-carrying capability and
structural stability. The support uprights define primary load paths for transferring
managed impact forces. The lateral spacing of the support uprights distributes loads
across the width of the modular energy-absorbing impact protection frame (100).30
12
The support uprights cooperate with the tubular impact members to control
deformation sequencing.
[0037] A plurality of diagonally oriented bracing members (106) interconnecting
adjacent support uprights in a cross-braced configuration. The plurality of
diagonally oriented bracing members (106) provide lateral stiffness to the modular5
energy-absorbing impact protection frame (100). The cross-braced configuration
defines guided load paths under impact loading. In offset or asymmetric impact
events, the plurality of diagonally oriented bracing members (106) redistribute loads
across multiple support uprights. The plurality of diagonally oriented bracing
members (106) control deformation modes of the support uprights. The plurality of10
diagonally oriented bracing members (106) reduce localized overstress and
structural instability. The cross-braced architecture improves load sharing and
impact predictability.
[0038] The modular energy-absorbing impact protection frame (100) further
comprises a chassis interface subsystem (108) including mounting brackets15
configured to secure the support uprights to existing structural members of a vehicle
chassis. The mounting brackets provide a defined interface between the modular
energy-absorbing impact protection frame (100) and the vehicle chassis. The
mounting brackets are configured to transfer managed loads into the vehicle chassis
after energy absorption. The mounting brackets are secured using mechanical20
fasteners. The mechanical fasteners enable disassembly without cutting or welding.
The chassis interface subsystem (108) supports modular integration with different
vehicle platforms.
[0039] In some embodiments, bolted interfaces are provided between the tubular
impact members, the support uprights, and the mounting brackets. The bolted25
interfaces enable selective replacement of deformed components following a
collision event. The bolted interfaces allow removal of the tubular impact members
without disturbing the entire modular energy-absorbing impact protection frame
(100). The bolted interfaces support modular assembly and disassembly. The
modular construction reduces repair time and vehicle downtime. The bolted30
interfaces improve serviceability and lifecycle cost efficiency.
13
[0040] In operation, collision energy is initially absorbed by controlled deformation
of the tubular impact members. Following deformation of the tubular impact
members, residual loads are transferred through the support uprights and
redistributed by the plurality of diagonally oriented bracing members (106). The
guided load paths reduce peak force transmission to the vehicle chassis. The5
modular energy-absorbing impact protection frame (100) externalizes energy
absorption away from traction battery mounting interfaces. The staged deformation
sequence improves impact response predictability. The modular energy-absorbing
impact protection frame (100) limits intrusion into protected vehicle zones.
[0041] In some embodiments, energy-absorption characteristics of the modular10
energy-absorbing impact protection frame (100) are tunable by varying tube
dimensions, material properties, or mounting bracket geometry. Such tuning may
be performed without altering the overall structural architecture of the modular
energy-absorbing impact protection frame (100). The modular energy-absorbing
impact protection frame (100) is adaptable to different vehicle mass classes and15
regulatory requirements. The architecture supports scalability across vehicle
platforms. The modular energy-absorbing impact protection frame (100) provides
controlled, repeatable, and manufacturable impact protection. The design enhances
safety while maintaining packaging efficiency.
[0042] FIG. 3 illustrates a flowchart showing a method (300) for providing modular20
energy-absorbing impact protection frame (100) for a heavy-duty electric vehicle,
according to an embodiment of the present disclosure.
[0043] At operation 302, the plurality of horizontally extending tubular impact
members (102) is arranged in vertically spaced relation at an end region of the
vehicle. The plurality of horizontally extending tubular impact members (102) is25
positioned to engage an impacting object at different vertical heights. In some
embodiments, the plurality of horizontally extending tubular impact members (102)
includes an upper tubular impact member and a lower tubular impact member
arranged one above the other. The vertical spacing between the upper tubular impact
member and the lower tubular impact member is selected based on expected impact30
height profiles. The vertically spaced arrangement enables multi-level impact
14
engagement. The plurality of horizontally extending tubular impact members (102)
initiates energy absorption early during an impact event.
[0044] Each tubular impact member is formed from metallic tubing selected to
undergo controlled and progressive plastic deformation when subjected to axial and
bending loads exceeding a predefined threshold. The material selection enables5
predictable deformation behavior under collision loading. The tubular impact
members are configured to deform prior to load transfer to downstream structural
components. Progressive deformation of the tubular impact members dissipates
kinetic energy over a defined stroke length. The tubular impact members provide
repeatable energy-absorption characteristics. The tubular impact members thereby10
reduce peak impact forces transmitted through the structure.
[0045] At operation 304, the load-managing support subsystem (104) is provided.
The load-managing support subsystem (104) includes the plurality of vertically
oriented support uprights spaced laterally along a width of the modular energy-
absorbing impact protection frame (100). The support uprights provide vertical15
load-carrying capability and structural stability. The support uprights define primary
load paths for transferring managed impact forces. The lateral spacing of the support
uprights distributes loads across the width of the modular energy-absorbing impact
protection frame (100). The support uprights cooperate with the tubular impact
members to control deformation sequencing.20
[0046] At operation 306, the plurality of diagonally oriented bracing members (106)
is interconnected adjacent support uprights in a cross-braced configuration. The
plurality of diagonally oriented bracing members (106) provide lateral stiffness to
the modular energy-absorbing impact protection frame (100). The cross-braced
configuration defines guided load paths under impact loading. In offset or25
asymmetric impact events, the plurality of diagonally oriented bracing members
(106) redistribute loads across multiple support uprights. The plurality of diagonally
oriented bracing members (106) control deformation modes of the support uprights.
The plurality of diagonally oriented bracing members (106) reduce localized
overstress and structural instability. The cross-braced architecture improves load30
sharing and impact predictability.
15
[0047] At operation 308, the chassis interface subsystem (108) including mounting
brackets is configured to secure the support uprights to existing structural members
of a vehicle chassis. Further, the tubular impact members are configured to undergo
controlled plastic deformation under axial and/or bending loads exceeding a
predefined threshold to dissipate collision energy. Further, the support uprights and5
the bracing members define guided load paths that redistribute impact forces across
multiple support uprights prior to transfer to the vehicle chassis. Further, the
modular energy-absorbing impact protection frame (100) attenuates and manages
collision energy before it is transmitted to protected vehicle systems.
[0048] The mounting brackets provide a defined interface between the modular10
energy-absorbing impact protection frame (100) and the vehicle chassis. The
mounting brackets are configured to transfer managed loads into the vehicle chassis
after energy absorption. The mounting brackets are secured using mechanical
fasteners. The mechanical fasteners enable disassembly without cutting or welding.
The chassis interface subsystem (108) supports modular integration with different15
vehicle platforms.
[0049] In some embodiments, bolted interfaces are provided between the tubular
impact members, the support uprights, and the mounting brackets. The bolted
interfaces enable selective replacement of deformed components following a
collision event. The bolted interfaces allow removal of the tubular impact members20
without disturbing the entire modular energy-absorbing impact protection frame
(100). The bolted interfaces support modular assembly and disassembly. The
modular construction reduces repair time and vehicle downtime. The bolted
interfaces improve serviceability and lifecycle cost efficiency.
[0050] In operation, collision energy is initially absorbed by controlled deformation25
of the tubular impact members. Following deformation of the tubular impact
members, residual loads are transferred through the support uprights and
redistributed by the plurality of diagonally oriented bracing members (106). The
guided load paths reduce peak force transmission to the vehicle chassis. The
modular energy-absorbing impact protection frame (100) externalizes energy30
absorption away from traction battery mounting interfaces. The staged deformation
16
sequence improves impact response predictability. The modular energy-absorbing
impact protection frame (100) limits intrusion into protected vehicle zones.
[0051] In some embodiments, energy-absorption characteristics of the modular
energy-absorbing impact protection frame (100) are tunable by varying tube
dimensions, material properties, or mounting bracket geometry. Such tuning may5
be performed without altering the overall structural architecture of the modular
energy-absorbing impact protection frame (100). The modular energy-absorbing
impact protection frame (100) is adaptable to different vehicle mass classes and
regulatory requirements. The architecture supports scalability across vehicle
platforms. The modular energy-absorbing impact protection frame (100) provides10
controlled, repeatable, and manufacturable impact protection. The design enhances
safety while maintaining packaging efficiency.
[0052] Various embodiments of the present invention provide significant
advantages through a modular energy-absorbing impact protection frame (100) for
a heavy-duty electric vehicle comprising a plurality of horizontally extending15
tubular impact members (102) arranged in vertically spaced relation, a load-
managing support subsystem (104) including a plurality of vertically oriented
support uprights, a plurality of diagonally oriented bracing members (106) arranged
in a cross-braced configuration, and a chassis interface subsystem (108) including
mounting brackets. The vertically spaced tubular impact members enable multi-20
level engagement with an impacting vehicle and initiate controlled energy
dissipation at different structural planes, unlike conventional end-mounted impact
structures relying on a single rigid impact beam. The staged deformation of the
tubular impact members, followed by guided load transfer through the support
uprights and redistribution via the bracing members, provides controlled and25
predictable energy absorption prior to load transmission to a vehicle chassis. The
cross-braced configuration of the bracing members defines managed load paths and
improves load sharing under offset or asymmetric impact conditions, thereby
reducing localized overstress. By externalizing energy absorption away from
traction battery systems and other protected vehicle components, the modular30
energy-absorbing impact protection frame (100) significantly limits peak force
17
transmission and intrusion risk. The mechanically fastened and modular
construction further enables selective replacement of deformable components and
tuning of energy-absorption characteristics, resulting in a robust, serviceable, and
scalable impact protection solution particularly suited for heavy-duty electric
vehicles such as electric buses while maintaining compatibility with existing vehicle5
architectures and packaging constraints.
[0053] It has thus been seen the modular energy-absorbing impact protection frame
(100) for a heavy-duty electric vehicle, as described. The modular energy-absorbing
impact protection frame (100) in any case could undergo numerous modifications
and variants, all of which are covered by the same innovative concept; moreover,10
all of the details can be replaced by technically equivalent elements. In practice, the
components used, as well as the numbers, shapes, and sizes of the components can
be whatever according to the technical requirements. The scope of protection of the
invention is therefore defined by the attached claims.

CLAIMS

1. A modular energy-absorbing impact protection frame (100) for a heavy-duty
electric vehicle, the modular energy-absorbing impact protection frame (100)
comprising:5
a plurality of horizontally extending tubular impact members (102)
arranged in vertically spaced relation at an end region of the vehicle;
a load-managing support subsystem (104) including a plurality of
vertically oriented support uprights spaced laterally along a width of the
modular energy-absorbing impact protection frame (100);10
a plurality of diagonally oriented plurality of diagonally oriented
bracing members (106) interconnecting adjacent support uprights in a cross-
braced configuration; and
a chassis interface subsystem (108) including mounting brackets
configured to secure the support uprights to existing structural members of a15
vehicle chassis,
wherein the tubular impact members are configured to undergo
controlled plastic deformation under axial and/or bending loads exceeding a
predefined threshold to dissipate collision energy,
wherein the support uprights and the plurality of diagonally oriented20
bracing members (106) define guided load paths that redistribute impact
forces across multiple support uprights prior to transfer to the vehicle chassis,
and
wherein the modular energy-absorbing impact protection frame (100)
attenuates and manages collision energy before it is transmitted to protected25
vehicle systems.
2. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein the plurality of horizontally extending tubular impact
members (102) includes an upper tubular impact member and a lower tubular30
impact member positioned one above the other with a predetermined vertical
spacing.
3. The modular energy-absorbing impact protection frame (100) as claimed in
claim 2, wherein the predetermined vertical spacing between the upper
tubular impact member and the lower tubular impact member is selected to5
enable sequential or simultaneous engagement with different structural
regions of an impacting vehicle.
4. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein each tubular impact member is formed from metallic tubing
selected to undergo progressive plastic deformation to achieve controlled and10
repeatable energy absorption during a collision event.
5. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein the diagonally oriented plurality of diagonally oriented
bracing members (106) provide lateral stiffness and control deformation
modes under offset or asymmetric impact loading.15
6. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein each support upright extends from a lower mounting
interface associated with the chassis interface subsystem (108) to an upper
region supporting the tubular impact members, thereby forming a continuous
vertical load path.20
7. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein the mounting brackets of the chassis interface subsystem
(108) are secured to the vehicle chassis using mechanical fasteners to permit
removal and replacement of selectively deformable components following a
collision.25
8. The modular energy-absorbing impact protection frame (100) as claimed in
claim 7, wherein bolted interfaces are provided between the tubular impact
members, the support uprights, and the mounting brackets to enable modular
assembly and disassembly without removal of the entire modular energy-
absorbing impact protection frame (100).30
9. The modular energy-absorbing impact protection frame (100) as claimed in
claim 1, wherein energy-absorption characteristics of the modular energy-
absorbing impact protection frame (100) are tunable by varying tube
dimensions, material properties, or mounting bracket geometry while
maintaining an overall structural architecture of the modular energy-5
absorbing impact protection frame (100).
10. A method (300) for providing a modular energy-absorbing impact protection
frame (100) for a heavy-duty electric vehicle, the method (300) comprising:
arranging a plurality of horizontally extending tubular impact
members (102) in vertically spaced relation at an end region of the vehicle;10
providing a load-managing support subsystem (104) including a
plurality of vertically oriented support uprights spaced laterally along a width
of the modular energy-absorbing impact protection frame (100);
interconnecting, via a plurality of diagonally oriented plurality of
diagonally oriented bracing members (106), adjacent support uprights in a15
cross-braced configuration; and
securing, via a chassis interface subsystem (108) including mounting
brackets, the support uprights to existing structural members of a vehicle
chassis,
wherein the tubular impact members are configured to undergo20
controlled plastic deformation under axial and/or bending loads exceeding a
predefined threshold to dissipate collision energy,
wherein the support uprights and the plurality of diagonally oriented
bracing members (106) define guided load paths that redistribute impact
forces across multiple support uprights prior to transfer to the vehicle chassis,25
and
wherein the modular energy-absorbing impact protection frame (100)
attenuates and manages collision energy before it is transmitted to protected
vehicle systems.