Automotive Front Member Shell Assembly for Lightweight Crash Absorption
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Solution Overview
Problem
Current front member assemblies in vehicles are complex, heavy, and costly to produce, while also being structurally weak due to multiple assembly points, which can lead to safety issues and increased greenhouse gas emissions.
Innovation Solution
A redesigned front member assembly comprising an upper shell and a lower shell, each with right and left portions linked by transverse portions, forming hollow volumes that absorb crash energy and resist intrusion, thereby simplifying production and reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate parts are used to form the front member assembly, then the structural robustness is improved, but the device complexity and production costs increase
Solution Approach 1:
The patent merges multiple separate front member parts into a single integrated front member assembly comprising an upper shell and a lower shell. This integration reduces the number of assembly points and simplifies production while maintaining structural robustness through the coordinated design of the shell portions and transverse connections.
Solution Approach 2:
The front member is segmented into functional portions (upper shell with right and left portions, lower shell with right and left portions, and transverse portions) that are linked together. This segmentation allows each portion to be optimized for specific crash management functions while forming an integrated structure.
2Strength
If traditional front member design is used, then the structural strength is maintained, but the vehicle weight increases
Solution Approach 1:
The front member employs shell structures (upper and lower shells) that provide structural strength while minimizing weight. The shell design with right and left portions linked by transverse portions creates a lightweight yet robust framework for crash energy absorption and transmission.
Solution Approach 2:
The front member assembly integrates different material properties in the upper and lower shells to achieve optimal strength-to-weight ratio, allowing effective crash management with reduced weight compared to traditional solid constructions.
3Stability of the object's composition
If multiple assembly points are used, then the structural integrity is improved, but the production time and costs increase
Solution Approach 1:
By integrating the front member into a unified assembly with upper and lower shells linked by transverse portions, the number of assembly points is reduced. This merging maintains structural integrity through the coordinated design of shell portions while significantly improving production efficiency.
Solution Approach 2:
The integrated front member assembly performs multiple functions (crash energy absorption, transmission, and structural support) through its unified structure, eliminating the need for multiple separate components and assembly operations, thereby improving productivity without compromising integrity.
4Reliability
If heavy front member assembly is used, then the crash protection is improved, but the greenhouse gas emissions increase
Solution Approach 1:
The shell-based front member design provides effective occupant protection through its structural configuration while minimizing weight, thereby reducing vehicle fuel consumption and greenhouse gas emissions compared to traditional heavy front member assemblies.
Solution Approach 2:
The invention changes the design parameters of the front member by using an integrated shell structure with optimized portions and linkages, achieving the same protective function with reduced weight, which directly lowers greenhouse gas emissions during vehicle operation.
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 redesigned front member assembly achieves high crash management efficiency with reduced weight, complexity, and production costs, while enhancing structural robustness and reducing environmental impact.
Implementation Method 1
The front members pick up the crash energy transmitted by the bumper beam through the front crash boxes and act to absorb part of said energy
Implementation Method 2
transmit the energy to the rest of the vehicle structure
Data Source
AI summary
Front member assembly (1) for an automotive vehicle including an upper shell (11) and a lower shell (12), wherein the upper and lower shells (11, 12) each include a right, left and transverse portion and wherein the upper and lower shells are assembled together by attaching them at least along upper and lower contours (1121, 1122, 1221, 1222, 1131, 1132, 1231, 1232) of the right and left portions.