Front End Module Crash Structure for Small Overlap Protection

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Solution Overview

Problem

Current front vehicle parts of motor vehicles do not adequately address the challenge of improving crash behavior, particularly in small overlap crashes, where the front wheel is vulnerable to damage and steering capability is compromised.

Innovation Solution

A front end module with a crossmember connected to the motor vehicle frame, an upper frame element supporting the engine hood, a receiving region for the radiator grill, and a crash structure connected to fastening elements that absorb impact energy through plastic deformation, replacing the intercooler to cover the front wheel and enhance energy absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an intercooler is installed in front of the wheel arch for cooling charge air, then the turbocharger cooling function is improved, but the crash structure cannot adequately protect the front wheel and absorb impact energy in small overlap crashes

Engineering Contradiction:

Improvecharge air coolingVSAvoidcrash behavior

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The front end module is divided into distinct functional regions: a receiving region for the radiator grill between the crossmember and upper frame element, and a separate region in front of the wheel arch for the crash structure. This segmentation allows the intercooler to be positioned in the radiator grill region while the crash structure occupies the wheel arch region, enabling both cooling and crash protection functions to coexist without interference.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crash structure acts as an intermediary element that absorbs impact energy during small overlap crashes, protecting the front wheel and steering mechanism. It is connected to the fastening elements on the crossmember or upper frame element, serving as a mediator between the external impact force and the vehicle's structural components, thereby improving crash behavior while maintaining space for the intercooler.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the front wheel is exposed in the wheel arch for steering capability, then the steering mechanism is accessible, but the front wheel becomes vulnerable to damage in small overlap crashes

Engineering Contradiction:

Improvesteering capabilityVSAvoidwheel vulnerability

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The crash structure is positioned in front of the wheel arch to provide beforehand cushioning protection. It is designed to deform plastically during small overlap crashes, absorbing impact energy before it can reach the front wheel and steering mechanism. This prior cushioning protects the vulnerable wheel while maintaining steering capability during normal operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a crash structure is added to cover the front wheel for energy absorption, then crash behavior is improved, but the space for the intercooler is reduced

Engineering Contradiction:

Improvecrash behaviorVSAvoidintercooler space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The crash structure is positioned in front of the wheel arch, utilizing the spatial dimension in front of the wheel rather than competing for the same space as the intercooler. This dimensional placement allows the intercooler to be installed in the radiator grill region while the crash structure occupies the wheel arch region, resolving the space conflict between these two components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution enables a motor vehicle to maintain satisfactory crash behavior and steering capability in small overlap crashes by effectively absorbing impact energy and protecting the front wheel, allowing for targeted force transmission and positioning of components.

Implementation Method 1

A crash structure (28) connected to the fastening elements for absorbing impact energy by way of plastic deformation

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10315595B2Front end module

Publication Date: 2019.06.11 DR ING H C F PORSCHE AG

AI summary

A front end module for covering a front of a front vehicle part of a motor vehicle includes a crossmember that is connectable to longitudinal carriers of a motor vehicle frame so as to absorb loads of a bumper. An upper frame element is connected to the crossmember for supporting an engine hood. A receiving region for receiving a radiator grill is disposed between the crossmember and the upper frame element. Fastening elements disposed on the crossmember and/or the upper frame element are configured to fasten an intercooler for cooling charge air of a turbocharger, with respect to the driving direction, in front of a wheel arch that receives a front wheel. A crash structure is connected to the fastening elements for absorbing impact energy by way of plastic deformation and covers a majority of the front wheel in an installed state of the front end module.