Automotive Front Side Frame Bend Portion Impact Load Dispersion
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Solution Overview
Problem
The existing front body structures of automotive vehicles face challenges in effectively absorbing impact loads, leading to potential rearward movement of the front side frame and risk of breakage at curve portions, especially when impact load absorption is insufficient.
Innovation Solution
A front body structure that includes a suspension tower, a front side frame with a bend portion that contacts the suspension damper during impact, an apron reinforcement, and additional reinforcement members to disperse impact loads to the front hinge pillar and side sill, preventing rearward movement and reducing load on curve portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the front side frame relies solely on bend portions to absorb impact load, then the structure remains simple, but the impact load absorption is insufficient and the front side frame may move back
Solution Approach 1:
The impact load absorption function is segmented across multiple components: the front side frame's bend portions, the suspension damper, the apron reinforcement, and the side sill. Each component handles a portion of the load through different mechanisms (bending, compression, structural support), collectively achieving sufficient absorption while maintaining reasonable structural simplicity.
Solution Approach 2:
The suspension damper acts as an intermediary element between the front side frame and the apron reinforcement. When the bend portion contacts the damper, it transfers and dissipates impact energy through the damper's shock-absorbing mechanism, preventing direct transmission of full impact load to the rear structure.
2Reliability
If the bend portion is positioned to contact the damper during impact, then impact load is dispersed to the front hinge pillar and side sill, but the structure becomes more complex
Solution Approach 1:
The suspension damper serves multiple functions: it provides normal suspension operation during vehicle operation and acts as an impact load transfer medium during frontal collisions. The apron reinforcement similarly provides structural support during normal operation and additional impact resistance during collisions, eliminating the need for separate dedicated impact components.
Solution Approach 2:
The bend portion is designed with specific geometric characteristics that allow it to dynamically transition from a rigid structural element to a flexible bending element during impact. The curvature radius and positioning are optimized to enable controlled bending and contact with the damper only under impact conditions, maintaining structural integrity during normal operation.
3Adaptability or versatility
If a curve portion is provided at the rear portion of the front side frame, then the structure can extend below the dash panel, but the curve portion is prone to breakage when impact load absorption is insufficient
Solution Approach 1:
The bend portion is positioned upstream (toward the front) of the curve portion to preemptively absorb and dissipate impact energy before it reaches the vulnerable curve portion. This preliminary action of the bend portion contacting the damper prevents excessive loads from being transmitted to the curve portion, protecting it from breakage.
Solution Approach 2:
The controlled bending of the front side frame at the bend portion, which might appear as structural deformation, is actually beneficial as it activates the impact absorption mechanism. This deliberate deformation allows energy dissipation through plastic deformation and contact forces, protecting other critical components including the curve portion from more harmful failure modes.
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 proposed structure effectively disperses impact loads to prevent rearward movement of the front side frame and reduces the risk of breakage at curve portions, ensuring improved safety and structural integrity during frontal impacts.
Implementation Method 1
when an impact load acts on the front side frame from ahead
Implementation Method 2
the bend portion which is operative to bend outward when an impact load acts on the front side frame from ahead
Implementation Method 3
part of the impact load acting on the front side frame is transmitted to the front hinge pillar via the damper
Data Source
AI summary
A front side frame includes a bend portion which is operative to bend outward when an impact load acts on the front side frame from ahead. The bend portion is provided in a specified location such that the bend portion in a bending state substantially contacts a damper of the suspension from a vehicle front side. Accordingly, a rear end of the front side frame can be prevented properly from moving back when the impact load acts on the front side frame from ahead.