Vehicle Front Body Structure for Full- and Small-Wrap Crash Loads
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Solution Overview
Problem
Existing vehicle body front structures struggle to effectively absorb collision loads during both full-wrap and small-wrap frontal collisions, leading to deformation of the power unit room, especially in electric vehicles where the power unit is downsized.
Innovation Solution
The vehicle body front structure incorporates a front side frame, a lower side frame, a first crash box, a second crash box, and an inclined plate. The inclined plate is fixed to the lower side frame behind the second crash box and is inclined upward and outward, allowing it to face the outer surface of the front side frame. This configuration disperses and absorbs collision loads, reducing deformation of the power unit room.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid power unit is mounted in the power unit room, then the power unit can be securely installed, but the power unit cannot absorb collision impact and may deform the vehicle interior during frontal collision
Solution Approach 1:
A cushioning member is introduced as an intermediary component between the power unit and the power unit room. This cushioning member absorbs collision impact through elastic deformation, preventing the rigid power unit from directly transmitting impact forces to the vehicle interior, thus protecting both the power unit and surrounding structures while maintaining secure installation
2Reliability
If the power unit room absorbs collision load, then the power unit is protected from impact, but the structure becomes more complex and may affect power unit accessibility
Solution Approach 1:
The power unit room structure is segmented into multiple functional components: a front wall, a cushioning member positioned between the power unit and front wall, and support structures. This segmentation allows each component to perform its specific function - the front wall provides structural support while the cushioning member handles impact absorption - thereby protecting the power unit without requiring complete structural redesign
Solution Approach 2:
A cushioning member is pre-installed between the power unit and the power unit room front wall. This cushioning member is designed to deform elastically upon collision impact, absorbing impact energy before it reaches the power unit. This beforehand cushioning arrangement protects the power unit without requiring complex active protection systems
3Use of energy by moving object
If the power unit is downsized in electric vehicles, then vehicle efficiency is improved, but the power unit room becomes more susceptible to deformation during collision
Solution Approach 1:
The power unit room structure is designed with local quality variations - the front wall and surrounding structures maintain high strength to provide structural integrity, while the cushioning member introduces localized compliance for impact absorption. This allows the overall structure to be optimized for both protection and energy efficiency without requiring complete reinforcement of the entire power unit room
Data Source
AI summary
A vehicle body front structure includes a front side frame, a lower side frame, a first crash box, a second crash box, and an inclined plate. The front side frame extends on a side of a power unit room in a front-rear direction of a vehicle body. The lower side frame extends in the front-rear direction of the vehicle body. The first crash box is provided at a front end of the front side frame. The second crash box is provided at a front end of the lower side frame. The inclined plate is fixed to the lower side frame immediately behind the second crash box. The inclined plate is inclined upward of the lower side frame and outward in a vehicle width direction in a state where at least a part of a plate surface of the inclined plate faces an outer surface of the front side frame.