Vehicle Frame Cushion Bracket Load Distribution
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Solution Overview
Problem
Existing vehicle frames face challenges in managing load and energy inputs during off-road travel, leading to potential deformation of the passenger area due to insufficient load and energy management, particularly around suspension and powertrain components.
Innovation Solution
A single-part cushion bracket that integrates mounting locations for various components like headlights, radiators, and dampers, tying the vehicle's left and right sides together while distributing load and energy inputs across the frame to control deformation and maintain passenger area dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate parts are used for mounting various components, then ease of manufacture and assembly are improved, but device complexity increases and load management performance deteriorates
Solution Approach 1:
The patent combines multiple separate mounting parts into a single integrated bracket structure that simultaneously mounts dampers, radiators, and headlight assemblies. This merging reduces the total number of parts, simplifies assembly procedures, and improves load management by creating a unified structural element that distributes forces across multiple mounting points.
Solution Approach 2:
The bracket is designed as a multi-functional component that performs multiple mounting functions within a single structure. It provides mounting locations for dampers, radiators, and headlight assemblies, allowing one component to serve several purposes and reducing overall device complexity while maintaining manufacturing ease.
2Strength
If a rigid frame structure is used to withstand load inputs, then strength and stability are improved, but adaptability to uneven terrain deteriorates due to potential deformation
Solution Approach 1:
The bracket incorporates localized flexible mounting points and cushioning elements at specific locations where it interfaces with suspension components, while maintaining overall structural rigidity. This allows the frame to be stiff where needed for strength while having compliant areas that adapt to terrain variations and absorb shock inputs.
Solution Approach 2:
The bracket includes built-in cushioning elements and compliant mounting features that are pre-positioned to absorb and dissipate shock loads before they propagate through the frame structure. This beforehand cushioning protects the rigid frame from excessive deformation when subjected to uneven terrain impacts.
3Reliability
If a single integrated bracket is used to tie frame sides together, then load and energy management are improved, but manufacturing precision requirements increase
Solution Approach 1:
While the bracket is integrated, it incorporates modular mounting sections and standardized interface features that can be manufactured and assembled with conventional precision tolerances. The segmentation of functional zones within the integrated structure allows each mounting area to be optimized independently, reducing overall manufacturing precision requirements while maintaining reliable load management.
Data Source
AI summary
A front frame assembly for mounting a front suspension and wheel assembly of a vehicle can include a pair of longitudinally extending frame members, a pair of upwardly extending frame members, and a transverse bracket frame member extending transversely from and connected to each of the upwardly extending frame members. The transverse bracket can include mount structures for connecting to various vehicle components, such as a pair of dampers, a radiator, hood cushions, and a headlight assembly. The transverse bracket can be locate in an upper portion of the vehicle engine compartment, and extending above a top most position of the radiator.