Vehicle Front End Module Frame for Short-Overhang Crash Absorption
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Solution Overview
Problem
Micro-vehicles face insufficient shock absorption in frontal collisions due to short front overhangs, leading to increased passenger injury rates, while medium-sized vehicles struggle to form a crash box with a bent fender apron member, making it difficult to respond to frontal collisions effectively.
Innovation Solution
A front end module frame comprising a lower member, front bumper beam, and upper member, each with crash boxes and flange parts, connected to form load paths and absorb shock, integrated with a radiator support system using insulators and beads for enhanced energy dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the fender apron member is bent and connected to the front side member in medium/large vehicles, then the vehicle structure can accommodate larger components, but the space for forming crash boxes becomes limited and frontal collision response becomes difficult
Solution Approach 1:
The front end module frame is divided into three separate members: lower member, front bumper beam, and upper member. Each member can be independently designed and manufactured, with the upper member specifically configured to connect to the bent fender apron member while providing crash box formation capability.
Solution Approach 2:
The upper member extends in the width direction of the vehicle and connects to the bent fender apron member, utilizing the spatial arrangement in multiple dimensions to create crash box formation space despite the bent configuration of the fender apron member.
2Length of moving object
If micro-vehicles have a short front overhang design, then the vehicle size is reduced for personal mobility, but the shock absorbing space in collision becomes very insufficient
Solution Approach 1:
The front end module frame concentrates shock absorption functionality in specific local regions through the lower member and upper member configurations, creating efficient shock absorption zones within the limited front overhang space of micro-vehicles.
Solution Approach 2:
The front end module frame utilizes composite structural design combining multiple members (lower member, front bumper beam, upper member) with different structural characteristics to achieve effective shock absorption within the constrained space of micro-vehicles.
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 frame reduces energy transfer to passengers during frontal collisions by distributing shock through optimized load paths and energy absorption, improving safety and reducing injury risk.
Implementation Method 1
a rod-shaped lower shock absorbing part and a lower flange part at a rear end of the lower shock absorbing part
Implementation Method 2
including a radiator insulator for heat dissipation
Data Source
AI summary
A front end module frame of a vehicle, and the front end module frame including a lower member arranged at a front lower portion of the vehicle and extending in a vehicle width direction, wherein each of opposite ends thereof is connected to a front end of a front sub frame of the vehicle, a front bumper beam extending in the width direction, and connected to the lower member in a vehicle height direction, wherein each of opposite ends thereof is connected to a front end of a front side member of the vehicle, and an upper member arranged at a front upper portion of the vehicle and extending in the width direction, and connected to the front bumper beam in the height direction, wherein each of opposite ends thereof is bent toward the vehicle and connected to a fender apron member of the vehicle is introduced.