Double-Shear Auxiliary Frame Mounting for Crash Load Distribution

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Solution Overview

Problem

Existing vehicle designs face challenges in ensuring occupant safety and protecting sensitive components during crashes while optimizing structural space and weight.

Innovation Solution

A connection apparatus for a double-shearing connection of an auxiliary frame to a body and support structure, allowing forces to be distributed via two load paths, thereby increasing rigidity and reducing the need for crumple zones, which enables more efficient use of structural space and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a robust and rigid frame is used to ensure occupant safety and protect sensitive components during crashes, then safety and crash performance are improved, but vehicle weight increases and structural space decreases

Engineering Contradiction:

Improveoccupant safetyVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The connection apparatus divides the force transmission path into multiple segments: the auxiliary frame connects to both the body and the support structure of the motor vehicle component, creating separate load paths. This segmentation allows forces to be distributed to multiple structural elements rather than concentrated in a single heavy frame section, reducing the overall weight required for safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection apparatus acts as an intermediary structure between the auxiliary frame and the body/support structure. It includes a support element with a first interface connecting to the support structure and a second interface connecting to the auxiliary frame, plus an auxiliary frame screw connecting the auxiliary frame to the body. This intermediary distributes loads through multiple paths, allowing weight reduction while maintaining safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a robust and rigid frame is used to ensure occupant safety and protect sensitive components during crashes, then crash performance is improved, but available structural space for components and passengers decreases

Engineering Contradiction:

Improvecrash performanceVSAvoidstructural space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

By segmenting the force transmission into multiple paths through the connection apparatus, the patent reduces the need for large monolithic structural elements. The support element and auxiliary frame screw create separate load paths that allow more efficient use of space, as forces are distributed rather than requiring concentrated heavy structural sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection apparatus serves as a space-efficient intermediary that provides robust crash performance without occupying excessive structural space. The support element with its two interfaces and the auxiliary frame screw create a compact connection system that distributes forces effectively while minimizing space requirements compared to traditional single-path rigid frame designs.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If connection elements are oversized to handle crash forces, then safety is improved, but vehicle weight increases

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The connection apparatus segments the load-bearing function across multiple elements: the support element connecting to the support structure and the auxiliary frame screw connecting to the body. This segmentation allows each connection element to be optimized for its specific load path rather than requiring all elements to be oversized for maximum crash forces, reducing total connection weight while maintaining strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection apparatus uses partial action by distributing crash forces across multiple connection points and paths. Rather than requiring one excessively strong connection element, the system uses multiple elements (support element, auxiliary frame screw) sharing the load, allowing each element to be sized appropriately for its portion of the total force, thus reducing overall weight.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12534134B2Connection apparatus, and arrangement for a vehicle for double-shearing connection of a drive train component to a body and to a support structure, and an associated motor vehicle and method

Publication Date: 2026.01.27 AUDI AG

AI summary

A connection apparatus and an arrangement for a motor vehicle may be provided for a double-shearing connection of a drive train component to a body and to a support structure. A support element of the connection apparatus may have a first interface to connect the support element to the support structure of a motor vehicle component. The support element may have a second interface to connect the support element to an auxiliary frame of the drive train component. An auxiliary frame screw of the connection apparatus may be constructed to connect the auxiliary frame at the lower side to the second interface of the support element and at the upper side to the body.