Dual-Part Sub-Frame with Single-Piece Lower Sheet for Offset Collision Management
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Solution Overview
Problem
Existing sub-frame arrangements in vehicles are ineffective in managing small offset collisions, as they reduce the force absorption capacity and can lead to uncontrolled deformation and intrusion of the engine into the passenger compartment, while also being costly to produce.
Innovation Solution
A dual part sub-frame arrangement with a single-piece lower sheet section extending the entire length, featuring rear portions that deform to absorb collision forces and maintain engagement with the vehicle body, preventing complete detachment and ensuring controlled deformation, thereby enhancing safety and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If releasing mechanisms are arranged to absorb collision force and give way to release the sub-frame, then deformation performance is enhanced, but uncontrolled deformation and path occur especially after complete decoupling from the vehicle body
Solution Approach 1:
The sub-frame is divided into a front section and a rear section that can be selectively released. The front section is equipped with releasing mechanisms that give way during collision, while the rear section maintains engagement through retained fastening means. This segmentation allows controlled deformation of the front section while preventing uncontrolled complete decoupling.
Solution Approach 2:
The fastening system transitions from a static fully-attached state to a dynamic partially-released state. The releasing mechanisms are designed to dynamically respond to collision forces by giving way in a controlled manner, while the retained rear fastening means dynamically maintain engagement to guide the deformation path.
2Duration of action of moving object
If sub-frame arrangements are adapted to cope with front collisions by releasing the sub-frame, then deformation distance is prolonged, but the amount of force that the vehicle structure absorbs during small offset collision is reduced
Solution Approach 1:
Different parts of the sub-frame have different engagement qualities during collision. The front section is designed with releasing mechanisms that allow deformation and energy absorption, while the rear section maintains firm engagement to preserve force transmission paths to the vehicle body structure, ensuring both deformation distance and force absorption capacity.
3Ease of manufacture
If a dual part sub-frame with single-piece lower sheet section is used, then production cost is decreased and material consumption is minimized, but structural complexity increases
Solution Approach 1:
The lower sheet section is merged into a single-piece construction that extends the entire length of the sub-frame, combining what would traditionally be multiple separate components. This merging reduces the number of parts, simplifies assembly, decreases production cost, and minimizes material consumption while maintaining structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sub-frame arrangement effectively absorbs collision forces during both front and small offset collisions, maintaining structural integrity and preventing engine intrusion, while being cost-effective to produce and maintain.
Implementation Method 1
the lower sheet section is further formed with two rear portions each extending backwards in the travel direction of said vehicle and adapted to deform during a collision
Data Source
AI summary
A sub-frame arrangement (1) in a vehicle and method thereof wherein the sub-frame arrangement comprises a sub-frame (2), a first body member, and rear attachment means for attaching said sub-frame to the first body member. The sub-frame is a dual part sub-frame comprising a lower sheet section (2b) formed in a single piece wherein said lower sheet section extends the entire length of said sub-frame. The lower sheet section is further formed with two rear portions (21) each extending backwards in the travel direction of said vehicle and the rear portions are adapted to host the rear attachment means.