Collision-Fracture Suspension Support for Power Assembly Drop

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Solution Overview

Problem

Existing automobile collision structures cause severe deformation of the passenger compartment during collisions, leading to insufficient survival space and serious injuries to occupants due to poor collision force transmission and energy absorption.

Innovation Solution

A suspension support system with a collision fracture design, including a suspension front arm and rear arm, each with fracture inducing portions, that breaks during a collision to allow the power assembly to descend in the Z-direction, reducing impact on the dash panel and ensuring survival space, and is made with inner cavities and reinforcement ribs for structural integrity and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the suspension support is designed as a rigid structure to maintain structural strength, then the structural strength is improved, but the passenger compartment deforms severely during collision causing insufficient survival space

Engineering Contradiction:

Improvestructural strengthVSAvoidpassenger compartment deformation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The suspension support is divided into multiple segments including the suspension front arm, suspension rear arm, and power assembly mounting portion. These segments are connected through fracture inducing portions that allow controlled separation during collision, enabling the structure to absorb impact energy while preventing force transmission to the passenger compartment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The suspension support acts as an intermediary component between the power assembly and the sub-frame. During collision, it absorbs and dissipates impact energy through controlled fracture, serving as a mediator that protects the passenger compartment from severe deformation caused by power assembly movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the suspension support is designed to be rigid to maintain structural integrity, then the structural integrity is improved, but the power assembly squeezes the front dash panel causing serious occupant injury

Engineering Contradiction:

Improvestructural integrityVSAvoidfront dash panel squeeze

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

Fracture inducing portions are pre-designed at specific locations on the suspension front arm and rear arm. These predetermined fracture zones ensure that during collision, the suspension support breaks at controlled locations before the power assembly can move forward and squeeze the front dash panel, preventing serious occupant injury.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The potential harmful effect of suspension support fracture during collision is converted into a beneficial protective mechanism. By designing controlled fracture paths, the structure intentionally breaks to absorb impact energy and prevent more severe damage to the passenger compartment and occupants.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If the suspension front arm and rear arm are made with solid structure to ensure strength, then the strength is improved, but the weight increases

Engineering Contradiction:

Improvearm strengthVSAvoidsuspension support weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The suspension front arm and rear arm incorporate hollow internal structures with porous or cavity-filled designs. This reduces the overall weight of the suspension support while maintaining sufficient strength for normal operation. The hollow structures also contribute to energy absorption during collision.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The suspension support utilizes composite material structures combining different materials or material configurations to achieve optimal strength-to-weight ratio. The composite design allows the arms to be lighter while still providing the necessary structural integrity for normal vehicle operation.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12448046B2Suspension support for improving collision performance, power assembly structure, and automobile

Publication Date: 2025.10.21 ZHEJIANG GEELY HLDG GRP CO LTD

AI summary

A suspension support for improving collision performance, a power assembly structure, and an automobile. The suspension support includes a first sub-frame mounting portion, a suspension front arm and a power assembly mounting portion. The suspension front arm is connected between the first sub-frame mounting portion and the power assembly mounting portion. The first sub-frame mounting portion is connected to a sub-frame. The power assembly mounting portion is connected to a power assembly. The suspension support is configured to break at the suspension front arm under the squeeze of the power assembly. The suspension support is designed into a collision fracture structure, such that the suspension support may break in a collision, avoiding the power assembly impacting with a front dash panel, and solving the problem of serious collision injuries of the occupants due to the power assembly squeezing on a passenger compartment and causing serious deformation.