Front Rail Deformation Zones for Impact Force Control
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Solution Overview
Problem
Existing shock-absorbing devices for motor vehicles require different designs based on vehicle mass, leading to inefficiencies and increased costs due to the need for multiple designs to manage varying impact forces effectively.
Innovation Solution
A tubular front stretcher with specific deformation zones and cutouts, allowing for adjustable deformation force levels through stamping and punching processes, enabling economic adjustment of deformation force during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different absorption devices are designed for different vehicle masses, then the deformation force can be matched to specific vehicle requirements, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent applies local quality by introducing cutouts at specific locations on the beam cross-section to modify deformation characteristics. Instead of redesigning the entire beam for different vehicle masses, only specific regions (where cutouts are added) are modified to change the deformation force level. This allows a single base design to serve multiple vehicle mass categories by selectively adding cutouts.
Solution Approach 2:
The patent changes geometric parameters of the beam cross-section by adding cutouts of varying sizes, positions, and quantities. These parameter changes directly affect the deformation force characteristics without requiring complete redesigns. The cutout parameters (dimensions, locations, numbers) can be adjusted to match different vehicle mass requirements, enabling one design to accommodate multiple applications.
2Reliability
If multiple design variants are created for different vehicle masses, then appropriate deformation force levels are achieved, but the manufacturing cost and economic efficiency decrease
Solution Approach 1:
The patent creates a universal beam design that can serve multiple vehicle mass categories through the addition of cutouts. A single base beam design incorporates features that allow it to be adapted for different deformation force requirements by adding cutouts in various configurations. This multi-functional approach eliminates the need for completely separate designs for different vehicle types, reducing manufacturing complexity and cost.
Solution Approach 2:
The patent segments the beam cross-section by introducing cutouts that divide the material distribution. This segmentation allows the deformation characteristics to be adjusted without changing the overall beam structure. The cutouts create distinct zones that control how the beam deforms under impact, enabling cost-effective adaptation to different vehicle mass requirements while maintaining a unified manufacturing process.
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
Enables economic adjustment of deformation force levels in shock-absorbing devices, reducing the need for multiple designs and improving cost-effectiveness while maintaining effective impact absorption.
Implementation Method 1
Document FR-A-2 375 500 discloses a shock absorbing device, placed on the front part of a motor vehicle, making it possible to absorb, by plastic deformation, the energy of an impact with an obstacle.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a front longitudinal member (10) of a motor vehicle comprising at least one first deformable zone (105) arranged so as to be deformed with a first degree of force upon impact, and at least one second deformable zone (110). Said second deformable zone (110) comprises at least one first cut-out space (115) with dimensions (d1, d2) such that the second deformable zone (110) deforms upon impact with a second degree of force which is weaker than the first degree of force.