Front Module Rib Structure for Small-Overlap Crash Load Transfer
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Solution Overview
Problem
Existing vehicle front structures face challenges in reducing the progression of bending deformation of the bumper reinforcement during a small overlap crash, particularly due to the impact of load transfer members, which can lead to cracking and distortion in the framework components.
Innovation Solution
A vehicle front structure design incorporating a single-piece cast front module with a bumper reinforcement, extension member, and a grid-patterned ribbed front side member, where a load transfer member is disposed in a grid of ribs, and a cross member is connected to transfer impact loads, with reinforcing pieces or high-density rib collections to absorb and distribute impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the front module is increased to prevent cracking and distortion during cooling, then manufacturing reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The front module is divided into multiple framework components (front side members, cross members, bumper reinforcement) that are cast separately and then assembled. This segmentation allows each component to have optimized thickness without causing overall distortion, while maintaining manufacturing reliability.
Solution Approach 2:
Reinforcing ribs are added to specific locations of framework components rather than uniformly increasing thickness throughout. This local reinforcement prevents cracking and distortion at critical areas during cooling while maintaining overall manufacturing feasibility.
2Strength
If a rib is provided on the front side member to reinforce the framework component, then structural strength improves, but the rib may break due to impact from the load transfer member, reducing reliability
Solution Approach 1:
The rib structure is segmented into multiple smaller ribs arranged in a grid pattern rather than a single large rib. This segmentation prevents stress concentration at any one location, reducing the likelihood of complete failure while maintaining overall structural strength.
Solution Approach 2:
The reinforcement structure transitions from a single-dimensional rib to a two-dimensional grid pattern of multiple ribs. This dimensional change distributes impact forces across multiple elements, preventing single-point failure and improving reliability.
3Loss of energy
If the bumper reinforcement is allowed to buckle toward the rear to absorb impact energy, then crash energy absorption improves, but bending deformation progresses further, compromising structural integrity
Solution Approach 1:
The load transfer member acts as an intermediary between the bumper reinforcement and the front side member. It transfers impact loads through the grid-patterned ribs to the front side member, controlling the buckling progression and maintaining structural integrity while still absorbing crash energy.
Solution Approach 2:
The front module uses composite construction with multiple framework components (front side members, cross members, bumper reinforcement) made from different materials or with different structural properties. This composite structure allows controlled deformation in some areas while maintaining integrity in others, optimizing both energy absorption and structural stability.
Data Source
AI summary
A bumper reinforcement is disposed forward of a front module. The front module includes a front side member. An outer end of the bumper reinforcement in a vehicle width direction is disposed outward of the front side member in the vehicle width direction. The front side member is in the shape of a rectangular groove that is open outward in the vehicle width direction. A horizontal rib and vertical ribs are formed in the rectangular groove of the front side member. A reinforcing piece (load transfer member) is disposed in the grid of the horizontal and vertical ribs.