Front End Support with Multi-Level Crash Structure
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Solution Overview
Problem
Modern passenger cars with a relatively flat front design are at risk of underrunning in collisions with taller vehicles, leading to increased occupant injury and stress due to the non-activation of the crash structure.
Innovation Solution
A front end support system with a cross support element, lateral strut elements, and energy absorption elements that create additional load paths to absorb collision forces, including a main longitudinal beam level and a secondary load level above it, which activates the crash structure and reduces the risk of underrunning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the front structure is designed to be relatively flat to achieve a sporty look, then the aesthetic appearance is improved, but the risk of underrunning in collisions with tall vehicles increases
Solution Approach 1:
The patent introduces an additional vertical dimension to the crash structure by providing energy absorption elements at two different longitudinal beam levels (first and second longitudinal beam levels). This multi-level arrangement creates a three-dimensional crash management system that prevents underrunning while maintaining the flat front aesthetic, as the energy absorption occurs across multiple vertical planes rather than a single level.
Solution Approach 2:
The crash structure is segmented into multiple independent energy absorption elements distributed across different longitudinal beam levels. Each energy absorption element can independently deform and absorb energy, creating a distributed crash management system that enhances safety without requiring a taller overall front structure.
2Strength
If energy absorption elements are added above the first longitudinal beam level, then the energy absorption capacity is improved, but the structural complexity increases
Solution Approach 1:
The front strut elements serve multiple functions: they provide structural support for the front end assembly and simultaneously act as mounting structures for the energy absorption elements at both longitudinal beam levels. This multi-functionality reduces the need for additional dedicated components, thereby limiting the increase in structural complexity while still achieving enhanced energy absorption capacity.
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 system effectively absorbs collision forces, reducing the risk of underrunning and enhancing accident safety by providing an additional load path and energy absorption capacity, while maintaining a lightweight design.
Implementation Method 1
energy absorption elements, which can be deformed in an energy-absorbing manner
Data Source
Figure 1~2
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AI summary
The invention relates to a front end support for a passenger car, comprising at least one transverse support member (18), at least two lateral strut members (20) connected to each other by way of the transverse support member (18) and extending in the vehicle vertical direction downwards away from the transverse support member (18), by way of which the front end support (10) can be supported at a main longitudinal support plane (28) of the passenger car, and comprising at least one additional load plane (36) above the main longitudinal support plane (28) and below the transverse support member (18).