Front Lower Load Path Node Assembly With Fewer Welds
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Solution Overview
Problem
Current vehicle front structures face challenges in efficiently distributing impact energy during crashes, particularly due to complex assembly processes that increase weight, manufacturing costs, and potential weaknesses in load path connections.
Innovation Solution
A simplified assembly process for a structural node comprising a crash extender and crash box with optimized connectors, reducing the number of fastening points and welds, while enhancing mechanical strength and cooperation between load paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex assembly processes with multiple fastening points and welds are used to connect load paths, then structural strength and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple connection functions into a single integrated structural node that simultaneously connects the lower load path, middle load path, and transverse cross-member. This merging of connection points reduces the total number of fastening points and welds from multiple separate connections to a unified assembly process, thereby reducing device complexity while maintaining structural strength.
Solution Approach 2:
The structural node is designed as a multi-functional component that performs multiple connection tasks simultaneously - connecting crash extenders to the lower load path, attaching the transverse cross-member, and providing attachment points for the middle load path. This universal connector eliminates the need for separate specialized connectors for each connection, reducing overall assembly complexity.
2Reliability
If multiple fastening points and welds are used to ensure robust connections between load paths, then reliability during impact is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple fastening operations and welding steps into a single integrated assembly process. The structural node is designed to accommodate all connections (crash extender attachments, cross-member mounting, and middle load path connections) in one assembly sequence, reducing the total manufacturing time while ensuring reliable connections through the unified design.
Solution Approach 2:
The structural node is pre-configured with integrated connection features and pre-positioned fastening points that align all components for immediate assembly. This preliminary design preparation eliminates the need for multiple sequential adjustment and alignment steps during manufacturing, reducing assembly time while maintaining connection reliability.
3Strength
If traditional assembly processes with numerous fasteners and welds are used, then structural integrity is improved, but vehicle weight increases
Solution Approach 1:
The patent consolidates multiple separate fasteners and welds into a reduced set of fastening points within the integrated structural node. By merging connection functions, the total number and mass of fastening components is reduced, thereby decreasing vehicle weight while maintaining structural integrity through the optimized unified design.
4Use of energy by moving object
If complex multi-component nodes are used to distribute impact forces, then energy distribution effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple component manufacturing processes into a single integrated structural node design. This consolidation reduces the total number of parts that need to be manufactured, inventoried, and assembled, thereby reducing manufacturing cost while maintaining the multi-path energy distribution capability through the integrated design.
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The invention relates to a structural components node (9) comprising a crash box connector (14) and a crash extender connector (13) each having a top plate extending in a substantially horizontal plane and allowing to secure directly together the crash extender (7) and the crash box (8). Advantageously, said structural components node (9) can further optionally comprise connections with a hanger (10) and a front transverse member (11). By applying the invention, it is possible to reduce the amount of welding operations needed to assemble said structural components node (9) and to provide a robust structural components node (9) ensuring a high structural strength to the assembly and an efficient cooperation between the lower and middle load paths and between the left and right side of the vehicle in case of a front impact. Finally, the invention relates to a process of assembling such a structural components node (9).