Cross-vehicle load member for small overlap impact management

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Solution Overview

Problem

In vehicles, especially electric vehicles, small front overlap impacts often result in inadequate lateral deflection of loads due to the lack of a robust load path, leading to increased intrusion into the passenger compartment and inefficient energy management.

Innovation Solution

A cross-vehicle load member is introduced, extending between frame rails and coupled to a cradle, providing a perpendicular load path that transfers Y-direction loads laterally, enhancing deflection and reducing intrusion by establishing an early and robust lateral deflection mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional frame structure is used without a cross-vehicle load member, then the vehicle structure is simpler and manufacturing is easier, but lateral deflection of loads is inadequate and passenger compartment intrusion increases during small overlap impacts

Engineering Contradiction:

Improvelateral deflection capabilityVSAvoidframe structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The frame structure is segmented by adding a discrete cross-vehicle load member that creates a dedicated load path, separating the lateral load transfer function from the longitudinal frame rails. This allows the load path to be optimized independently while maintaining the overall frame structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cross-vehicle load member is added in the lateral dimension (Y-direction) to create a three-dimensional load path network. This transforms the primarily longitudinal load path into a multi-directional system that can effectively transfer lateral impact loads across the vehicle width.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If the load member is coupled to the cradle at multiple attachment points, then manufacturing precision and motor mount system tolerance are improved, but the device complexity and number of attachment points increase

Engineering Contradiction:

Improvemotor mount system toleranceVSAvoidattachment points configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The load member features localized structural variations including channels at its ends for receiving cradle portions, and specific attachment surfaces for frame rail coupling. These local structural qualities enable precise positioning and multiple attachment points that improve manufacturing tolerance without requiring complex overall geometry.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11299206B2Vehicle structure for a cross-vehicle load path

Publication Date: 2022.04.12 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A load impact management system for an automotive vehicle includes a load member extending from a first vehicle frame rail to a second vehicle frame rail and perpendicular to each of the first and second vehicle frame rails and to a vehicle body axis. The load member is coupled to the first vehicle frame rail at two attachment points and coupled to the second vehicle frame rail at two attachment points. The load member defines a load path between a first side of the automotive vehicle to a second side of the automotive vehicle opposite the first side and the load member is forward of a passenger compartment of the vehicle.