Front End Module Plastic Cross Member Connection
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Solution Overview
Problem
Existing front-end modules for motor vehicles face issues with the insufficient mechanical hold of injection-molded components on the cross member, leading to potential detachment under higher loads due to the shrinking of plastic onto the tube.
Innovation Solution
The solution involves an indirect connection of injection-molded components to the cross member, generating a moment of inertia that counteracts loads through a torsional stress in the connecting element, combined with a network of longitudinal and transverse ribs forming a highly rigid connection, and a non-round cross-sectional profile for enhanced stability and anti-rotation, along with material bonding and form-fitting elements for improved hold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection-molded components are connected to the cross member through shrinking of plastic onto the tube, then the connection is simple to manufacture, but the mechanical hold is insufficient under higher loads
Solution Approach 1:
The connection system is segmented into multiple independent plastic components (first and second plastic components) that are separately molded onto the cross member at different locations. This segmentation allows each component to independently contribute to the overall mechanical hold, preventing single-point failure and distributing mechanical loads across multiple attachment points.
Solution Approach 2:
The patent transitions from simple radial shrinking connection to a three-dimensional connection system that includes axial spacing, radial attachment, and longitudinal distribution along the cross member. The first and second plastic components are positioned at different axial locations, creating a spatial distribution that resists both radial detachment forces and axial rotational moments.
2Strength
If the plastic component is fixed in the bending area, then the hold is particularly strong against axial and radial movement, but the component cannot be moved at all under any load
Solution Approach 1:
Different regions of the cross member are assigned different functional qualities: the bending area provides strong anchorage that prevents axial and radial movement, while the straight sections allow for controlled rotational movement and assembly adjustments. This local differentiation of mechanical properties optimizes both stability and adaptability.
Solution Approach 2:
The connection system is designed to be dynamically responsive to load conditions. Under normal operation, the plastic components in bending areas provide rigid anchorage. Under extreme loads, the system allows for controlled deformation and movement to prevent catastrophic failure, transitioning from a completely rigid to a semi-flexible connection.
3Stability of the object's composition
If a non-round cross-sectional profile is used, then the plastic component is fixed in a rotationally fixed manner, but the manufacturing complexity increases
Solution Approach 1:
The cross member employs a non-round, asymmetric cross-sectional profile that creates geometric interlocking with the plastic components. This asymmetric shape prevents rotational movement of the plastic components relative to the cross member, providing inherent rotational stability without requiring additional locking mechanisms or complex assembly procedures.
4Stability of the object's composition
If the plastic components are spaced axially from the ends of the cross member, then the connection is more stable, but the space for other components is reduced
Solution Approach 1:
The patent utilizes the longitudinal dimension of the cross member to distribute plastic components at different axial positions rather than concentrating them at the ends. This axial distribution in the longitudinal dimension provides stability through spacing while maintaining efficient use of the cross-sectional dimension for other components like lighting units and crash boxes.
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
This configuration significantly enhances the mechanical hold of plastic components on the cross member, even under high forces, providing a secure and rigid connection with reduced material usage and space requirements, while allowing for multifunctional integration with additional features like lighting units and crash boxes.
Implementation Method 1
the hold of the two uprights on the tube, which results from the shrinking of the plastic onto the tube
Implementation Method 2
which causes torsional stress in the connecting element of the connection and thus counteracts the load
Data Source
AI summary
The invention relates to a front end module (1) for a motor vehicle, comprising a tubular transverse support (2) and injection molded components made of plastic, said components being injection molded onto the transverse support (2). The aim of the invention is to achieve an improved hold of the injection molded components on the transverse support (2) in a simple manner. According to the invention, this is achieved in that at least two of the injection molded components (7, 8) are connected to each other separately from the transverse support (2).