S-Shaped Front Pillar with Stepwise Flange Connection

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Solution Overview

Problem

Conventional front pillar structures for vehicles are heavy and costly due to multiple mounting and reinforcing members, and lack impact absorption capabilities, leading to potential deformation during frontal impacts.

Innovation Solution

A front pillar structure featuring a vertically extending lower pillar with an S-shaped cross-section, obliquely extending upper pillar, and a connection member with stepwise flanges, incorporating reinforcing ribs and a unitary extension portion that integrates with the fender, allowing for uniform impact energy distribution and reduced weight and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple mounting members and reinforcing members are mounted on the front pillar, then the strength and stiffness of the front pillar is improved, but the weight and manufacturing cost of the front pillar structure increases

Engineering Contradiction:

Improvestrength and stiffness of front pillarVSAvoidweight of front pillar structure

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent merges multiple separate components (mounting members, reinforcing members, and the front pillar itself) into a single integrated front pillar structure. The front pillar is designed with built-in mounting portions and reinforcing ribs that are formed as one piece, eliminating the need for separate mounting members and reducing overall weight while maintaining structural strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The front pillar is constructed using composite material structures with varying wall thicknesses and integrated reinforcing ribs. The S-shaped cross-section design incorporates different material densities or thickness configurations to optimize the strength-to-weight ratio, providing necessary strength without excessive weight.

Inventive Principle:

Principle #40Composite materials

2Strength

If multiple mounting members and reinforcing members are mounted on the front pillar, then the strength and stiffness of the front pillar is improved, but the manufacturing cost of the front pillar structure increases

Engineering Contradiction:

Improvestrength and stiffness of front pillarVSAvoidmanufacturing cost of front pillar structure

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

By combining multiple components into a single integrated front pillar structure with built-in mounting portions and reinforcing ribs, the number of manufacturing steps and assembly operations is significantly reduced. This integration simplifies the manufacturing process and lowers production costs while maintaining the necessary structural strength.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If no additional impact absorption structure is provided, then the device complexity is reduced, but the front pillar is easily deformed due to impact load

Engineering Contradiction:

Improvestructure complexityVSAvoiddeformation resistance of front pillar

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The front pillar incorporates an impact absorption structure with varying wall thicknesses and integrated reinforcing ribs formed as one piece. This composite structural design provides impact absorption capabilities and deformation resistance without requiring separate additional components, thereby maintaining structural simplicity while improving stability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The front pillar features an S-shaped cross-section design with curved surfaces that are optimized for impact absorption. The curved geometry distributes impact forces more effectively throughout the structure, preventing deformation while maintaining a relatively simple overall design.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Weight of moving object

If a unitary extension portion is integrated with the fender, then the weight and manufacturing cost are reduced, but the impact energy distribution capability must be optimized

Engineering Contradiction:

Improveweight of front pillar structureVSAvoidimpact energy distribution capability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The extension portion is designed with an S-shaped cross-section that includes curved surfaces optimized for impact energy distribution. The curved geometry allows for uniform distribution of impact forces throughout the integrated structure, maintaining strength capabilities while achieving weight reduction through integration.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11260913B2Front pillar structure for vehicle

Publication Date: 2022.03.01 HYUNDAI MOTOR CO LTD

AI summary

A front pillar structure for a vehicle includes a front pillar including a front pillar lower extending vertically and a front pillar upper extending obliquely from the front pillar lower. A connection member is coupled to a bottom end of the front pillar lower and connects a front side member and a side sill. The front pillar lower has an S-shaped cross section and the connection member has stepwise flanges coupled to the bottom end of the front pillar lower.