Vehicle Front Fender Apron Coupling for Small Overlap Crash Load
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Solution Overview
Problem
Current vehicle coupling structures fail to effectively transmit and spread impact loads during small overlap crashes, leading to excessive deformation of occupant seats and increased injury to occupants due to poor coupling between the front fender apron and side outer members.
Innovation Solution
A coupling structure where the extended end portion of the front fender apron member is joined as a unit to the side inner member of the front side member, enhancing coupling stiffness through spot or laser welding, ensuring impact loads are transmitted and spread to the front side member, thereby preventing excessive deformation of the occupant seat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the front fender apron member is flange-coupled to the side outer member, then easy separation is achieved at the coupled cross-section during small overlap crash, but transmission and spreading of crash stiffness or impact load becomes poor
Solution Approach 1:
The front fender apron member is divided into multiple sections, with the lower front extended end portion formed as a separate unit that can be independently coupled to the side inner member. This segmentation allows the lower front section to maintain strong coupling for load transmission while the upper sections can separate more easily during crash
Solution Approach 2:
The side inner member acts as an intermediary component between the front fender apron member and the side outer member. The lower front extended end portion of the front fender apron is coupled to this intermediary, which then transmits the load to the side outer member, creating a load path that improves crash stiffness transmission
2Strength
If the front fender apron member is plug welded to a section of the side outer member, then connection is achieved, but the plug welding is easily separated at the time of crash
Solution Approach 1:
Instead of directly welding the front fender apron to the side outer member, the side inner member serves as an intermediary component. The lower front extended end portion is coupled to the side inner member, which then connects to the side outer member, distributing the crash forces and preventing direct separation at weld points
Solution Approach 2:
The lower front extended end portion of the front fender apron is inserted into a space between the side outer front member and side outer rear member, creating a nested configuration. This nested structure provides mechanical interlocking that prevents easy separation during crash while maintaining connection strength
3Strength
If the impact load is transmitted to the cowl side member and front pillar, then the entire impact load is absorbed, but the occupant seat is excessively deformed, increasing injury of the occupants
Solution Approach 1:
The coupling structure is designed with localized reinforcement at the lower front extended end portion, which has different properties than the rest of the front fender apron. This local quality enhancement allows the structure to transmit loads through specific paths that protect the occupant seat area while maintaining overall impact absorption capability
Solution Approach 2:
The lower front extended end portion is pre-formed as an integrated unit with the front fender apron, creating a predetermined load transmission path before crash occurs. This preliminary structural configuration ensures that during crash, forces are directed through the side inner member and side outer member, preventing excessive deformation of the occupant seat
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 proposed structure securely transmits and spreads impact loads to the front side member, reducing occupant seat deformation and enhancing protection during small overlap crashes.
Implementation Method 1
The joining is made by spot welding or laser welding.
Implementation Method 2
The joining is made by spot welding or laser welding.
Data Source
AI summary
A structure for coupling vehicle members is disclosed, wherein in a coupling structure for coupling a front side member having a side inner member and a side outer member to a front fender apron member together, the front fender apron member is coupled to the side outer member together with a fender apron inner panel, the side outer member has a side outer front member and a side outer rear member, and the front fender apron member has a rear side of a bottom end joined the side outer rear member of the front side member, and a lower front extended end portion formed as one unit and joined a side inner member inserted between the side outer front member and the side outer rear member of the front side member.