Lower Dash Crossmember Layout for Oblique Collision Load Paths

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Solution Overview

Problem

Existing vehicle structures are prone to deformation of the lower dash panel towards the compartment during minor wrap or oblique collisions due to moment-induced stress, necessitating a structural improvement.

Innovation Solution

A vehicle substructure comprising a floor tunnel, side sill, floor panel, front pillar, and lower dash crossmember, which are interconnected to disperse collision loads and prevent deformation by transmitting them linearly to the floor frame and front pillar.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the floor reinforcement is arranged vertically between the floor panel and dash crossmember, then the collision load can be transmitted to the floor reinforcement, but the lower dash panel deforms toward the compartment due to moment-induced stress

Engineering Contradiction:
Improvecollision load transmissionVSAvoidlower dash panel deformation
Core Design Contradiction:
StrengthVSStability of the object's composition

Solution Approach 1:

The floor reinforcement is segmented by introducing a floor reinforcement upper member and floor reinforcement lower member as separate components. The upper member is arranged above the dash crossmember while the lower member is arranged below it, creating a segmented reinforcement system that prevents moment-induced deformation of the lower dash panel while maintaining collision load transmission capability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The reinforcement structure is extended from a single vertical arrangement to a three-dimensional configuration by adding both upper and lower members relative to the dash crossmember. This multi-level arrangement in the vertical dimension creates a more effective load path that resists both collision forces and moment-induced deformation.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Force

If the dash crossmember is coupled to the side sill, then the structure can handle collision loads, but the lower dash panel is subject to moment causing deformation toward the compartment

Engineering Contradiction:
Improvecollision load handlingVSAvoidmoment-induced deformation
Core Design Contradiction:
ForceVSObject-affected harmful factors

Solution Approach 1:

The reinforcement system is divided into upper and lower segments positioned on opposite sides of the dash crossmember. This segmentation allows the structure to handle collision loads through the coupled dash crossmember while the distributed reinforcement arrangement prevents concentration of moment forces that would cause deformation of the lower dash panel.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The floor reinforcement upper member positioned above the dash crossmember acts as a counterbalancing element to the floor reinforcement lower member below it. This creates a balanced reinforcement system that counteracts moment-induced stresses, preventing the lower dash panel from deforming toward the compartment while maintaining the load-bearing capability of the dash crossmember coupling.

Inventive Principle:
Principle #8Anti-weight (Counterweight)

Data Source

PatentUS12473035B2Vehicle substructure preventing dash panel from deformation toward compartment
Publication Date: 2025.11.18 HONDA MOTOR CO LTD
  • US12473035B2 patent drawing
  • US12473035B2 patent drawing
  • US12473035B2 patent drawing

AI summary

A vehicle substructure includes: a floor panel placed in a tense state between a floor tunnel and a side sill; a front pillar extending in a vehicle up-down direction from a front end of the side sill. The vehicle substructure further includes: a lower dash panel arranged at a front portion of the floor panel; and a lower dash crossmember extending in a vehicle width direction at a lower end of the lower dash panel. The lower dash crossmember has an inner end in the vehicle width direction thereof coupled to the floor tunnel and an outer end in the vehicle width direction thereof coupled to the front pillar.