Front Structure Deformation Element for Trailer Impact Protection
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Solution Overview
Problem
Commercial vehicles face inadequate protection for drivers and sensitive components during collisions with preceding or stationary trailers due to the protruding lower edge of trailers, which conventional crash structures fail to adequately address.
Innovation Solution
A front-end structure for commercial vehicles featuring parallel longitudinal frame members with a deformation element, such as a crash strut, positioned to absorb impact forces and protect the cooling module and associated components by extending transversely and being arranged above the frame members, thereby reducing intrusion and providing comprehensive protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crash structures are used, then the structure is simple and easy to manufacture, but the protection against collision with trailers is inadequate
Solution Approach 1:
The front-end structure is divided into multiple functional segments: a lower crash structure for ground-level impacts and an upper deformation element specifically for trailer collisions. This segmentation allows each component to be optimized for its specific protective function, with the upper deformation element extending above the cooling module to prevent trailer intrusion while the lower structure handles conventional crash scenarios.
Solution Approach 2:
The deformation element extends in the vertical dimension above the cooling module, creating a three-dimensional protective barrier. This vertical extension adds a new dimension of protection that conventional horizontal-only crash structures cannot provide, specifically addressing the gap left by the cooling module's position relative to trailer lower edges.
2Use of energy by moving object
If the cooling module is positioned to optimize cooling, then cooling efficiency is improved, but vulnerability to trailer intrusion increases
Solution Approach 1:
The upper deformation element is positioned beforehand to cushion against trailer intrusion before the cooling module can be damaged. This pre-positioned protective barrier absorbs and redirects impact forces away from the cooling module, allowing the cooling module to maintain its optimal position for cooling efficiency without being directly exposed to trailer collision risks.
Solution Approach 2:
The deformation element acts as an intermediary between the trailer and the cooling module. It intercepts and absorbs impact forces from trailer collisions, preventing direct contact with the cooling module. This intermediary structure allows the cooling module to remain in its optimal position while being indirectly protected from harmful trailer intrusion.
3Reliability
If the deformation element is positioned to maximize protection, then crash protection is improved, but the structure becomes more complex
Solution Approach 1:
The upper deformation element serves multiple functions simultaneously: it prevents trailer intrusion into the cooling module, provides structural reinforcement to the front-end assembly, and contributes to overall crashworthiness. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in structural complexity while maximizing protective reliability.
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 described front-end structure effectively reduces damage to the cooling module and associated components during frontal collisions with trailers by absorbing impact forces through deformation, ensuring reliable protection and minimizing intrusion.
Implementation Method 1
The first deformation element (e.g., a hollow profile, made of steel or carbon fiber reinforced plastic (CFRP)) is designed to deform upon impact (e.g., a frontal collision), preferably in a predetermined manner, thereby dissipating impact forces.
Data Source
Figure 1a~1d
Figure 2a~2c
Figure 3a~3d
AI summary
The invention relates to a front-end structure (10) for a motor vehicle and to a motor vehicle with a corresponding front-end structure (10). The front-end structure (10) comprises two frame longitudinal members (11, 12), each with a front end (11a, 12a). Preferably, the front-end structure (10) includes a cooling module (13) which is mounted at the respective front ends (11a, 12a) of the frame longitudinal members (11, 12) and which extends transversely to the frame longitudinal members (11, 12). Furthermore, the front-end structure (10) comprises a crash structure (14), which preferably serves to protect the cooling module (13) in the event of an impact (e.g., a frontal collision). The crash structure (14) has a first deformation element (14a) which is deformable during the impact event by reducing impact forces and which extends above and transversely to the two frame longitudinal members (11, 12).It is preferred that the aforementioned first deformation element (14a) is arranged in front of the cooling module (13).