Integrated Front Side Body Structure for Lightweight Crash Load Dispersion
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Solution Overview
Problem
Existing vehicle front side bodies are heavy due to numerous parts, which complicates manufacturing and weakens structural robustness, necessitating a design that reduces weight while maintaining robustness.
Innovation Solution
Integrally molding the front side member, shock absorber housing, and A-pillar with horizontal and vertical ribs to create spaces and deform upon impact, allowing for efficient load dispersion and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the front side body is formed by assembling 50 or more parts, then the structural robustness is improved, but the vehicle weight increases and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate body parts (front side member, shock absorber housing, A-pillar, and reinforcement ribs) into a single integrally molded component. This consolidation eliminates the need for 50 or more separate parts while maintaining structural robustness through built-in reinforcement ribs that provide necessary strength without requiring additional welded or fastened components, thereby reducing vehicle weight.
Solution Approach 2:
Within the integrally molded structure, the patent incorporates segmented reinforcement features (horizontal ribs, vertical ribs, and diagonal ribs) that are formed as integrated parts of the molding process. These segmented reinforcement elements distribute structural strength throughout the component, providing robustness equivalent to multiple separate parts while maintaining the benefits of integral construction.
2Strength
If the front side body is formed by assembling 50 or more parts, then the structural robustness is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple assembly operations into a single injection molding process. The front side member, shock absorber housing, A-pillar, and reinforcement ribs are all formed in one integral molding operation, eliminating the need for complex assembly procedures involving 50 or more parts. This significantly reduces manufacturing complexity while maintaining structural robustness through the integrated design.
Solution Approach 2:
The integrally molded component serves multiple functions simultaneously: it provides structural support, houses the shock absorber, forms the A-pillar, and includes built-in reinforcement ribs for enhanced strength. This multi-functionality is achieved through a single molded part rather than requiring separate components for each function, thereby reducing device complexity.
3Weight of moving object
If weight reduction of the front side body is realized, then the vehicle weight is reduced, but the structural robustness may be weakened
Solution Approach 1:
The patent applies local quality enhancement by incorporating reinforcement ribs (horizontal, vertical, and diagonal) at specific locations within the integrally molded front side body. These ribs are strategically positioned to provide localized strength enhancement in areas requiring robustness while maintaining overall weight reduction. The ribs create a cellular structure that provides high strength-to-weight ratio without requiring the vehicle weight to increase.
Data Source
AI summary
A body of a vehicle may comprise a front side member comprising a crash box at a front end of the front side member, wherein the front side member is configured to extend in a longitudinal direction of the vehicle, a shock absorber housing disposed between the front end and a rear end of the front side member and connected to the front side member, and a pillar connected to the rear end of the front side member, wherein the front side member, the shock absorber housing, and the pillar are molded integrally with each other, and first horizontal ribs and first vertical ribs are formed to cross each other at the front end to create spaces, wherein the first horizontal ribs are parallel to the longitudinal direction of the vehicle, and wherein the first vertical ribs are vertical to the longitudinal direction of the vehicle.