Bent Front End Panel Assembly for EV Pedestrian Impact Protection
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Solution Overview
Problem
The transition from fuel-driven to electric vehicles necessitates new design possibilities for the front fascia of cars, which must integrate energy absorption upon impact, electronics, and lighting features while addressing pedestrian safety concerns, particularly in the untested area between 1000 mm and 930 mm WAD.
Innovation Solution
A front end panel assembly with a bended shape and a carrier structure forming a closed space, incorporating energy-absorbing components and foamed structures, and integrating lighting and electronic modules, made from thermoplastic materials with optional translucent portions, to enhance pedestrian safety and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the grille is replaced by a closed component for electric vehicles, then new design possibilities are opened up, but the need to integrate multiple functions (energy absorption, electronics, lighting) increases device complexity
Solution Approach 1:
The patent merges multiple functions into a single integrated front panel assembly. The closed component structure combines energy-absorbing elements, electronic component mounting areas, and lighting feature integrations into one unified assembly, reducing the number of separate parts while maintaining all required functions.
Solution Approach 2:
The front panel assembly is designed as a multi-functional universal component that simultaneously provides structural support, pedestrian impact protection, electronic component housing, and lighting integration. This universal design allows a single component to fulfill multiple roles that traditionally required separate parts.
2Object-affected harmful factors
If energy-absorbing components are integrated into the front panel assembly, then pedestrian safety is enhanced, but the structural complexity of the assembly increases
Solution Approach 1:
The energy-absorbing components are pre-integrated into the front panel assembly structure during manufacturing. This preliminary integration ensures that the protective function is built-in from the start, eliminating the need for additional separate protective components and reducing overall structural complexity.
Solution Approach 2:
The patent employs composite material structures that combine different materials with complementary properties. The front panel uses composite construction that provides both structural integrity and energy-absorbing characteristics, achieving pedestrian protection without requiring complex multi-layered or multi-component structures.
3Shape
If the front cover is designed in a bended shape to form a closed space, then aesthetic appeal and design distinctiveness are improved, but manufacturing complexity increases
Solution Approach 1:
The front cover incorporates controlled curved and bended shapes to achieve aesthetic appeal and design distinctiveness. The curvature is designed to flow naturally through the structure, creating visual interest while remaining compatible with standard manufacturing processes for molded plastic components.
Solution Approach 2:
The bended shape design utilizes parameter optimization in the molding process, such as adjusting wall thickness distribution, radius of curvature, and structural reinforcement locations. These parameter changes allow complex shapes to be manufactured efficiently using conventional injection molding or similar processes, minimizing manufacturing complexity.
Data Source
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AI summary
The invention relates to a front end panel assembly for an electric vehicle, the assembly comprising a front cover having side edges, the front cover extending in a bended shape such that a first angle (α) is enclosed between a first portion and a second portion of the front cover; and a carrier structure comprising a base and a peripheral wall extending from the base, wherein the carrier structure comprises a first part and a second part that enclose a second angle (β); wherein the upstanding wall connects to the front cover at or near at least part of the side edges of the front cover, such that a space is formed and enclosed between the front cover and the carrier structure, wherein the first portion of the front cover covers the first part of the carrier structure, and the second portion of the front cover covers the second part of the carrier structure. The invention also relates to a vehicle provided with such a front end panel assembly.