Dash Crossmember Reinforcement for Small Overlap Crash Safety
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Solution Overview
Problem
Current vehicle body designs face challenges in achieving excellent anti-collision safety performance, particularly in small overlap crash tests where deformation of critical components can occur, compromising safety standards.
Innovation Solution
The vehicle body design incorporates a dash crossmember with an uneven inner wall and a reinforcement plate with a bent shape that conforms to the dash crossmember, securely coupling the dash crossmember and front pillar via the reinforcement plate, enhancing rigidity and preventing deformation during crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement plate is used to couple the dash crossmember and front pillar, then the coupling strength is improved, but the rigidity at the joint between the dash crossmember and reinforcement plate is insufficient, allowing deformation during crash loads
Solution Approach 1:
The inner wall of the dash crossmember is designed with an uneven shape including bends, and the reinforcement plate is formed with a bent shape that conforms to this uneven inner wall. This curvature matching creates a form-fit joint that significantly increases rigidity at the connection point, preventing deformation of the dash crossmember toward the cabin during crash loads while maintaining strong coupling between components
Solution Approach 2:
The uneven shape with bends is applied locally at the joint region of the dash crossmember where it connects to the reinforcement plate, rather than throughout the entire structure. This localized geometric feature concentrates rigidity enhancement precisely where needed at the joint interface, addressing the specific weakness without adding unnecessary complexity elsewhere in the structure
Data Source
AI summary
A vehicle body may include a dash crossmember, a rocker extending rearwards from an end of the dash crossmember, a front pillar extends upwards from the rocker along the side portion of the cabin and a reinforcement plate including a first end joined to the dash crossmember and a second end joined to the front pillar. An inner wall of the dash crossmember may have an uneven shape that defines at least one bend extending in the right-left direction. The first end of the reinforcement plate may at least partly have a bent shape that conforms with the uneven shape of the dash crossmember.