Vehicle Front Side Member Push-Off Structure for Off-Center Impact Management
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Solution Overview
Problem
Existing vehicle front end structures are inadequate in absorbing, redirecting, and deflecting forces during off-center impact events, as they do not effectively distribute and dissipate the impact forces across the vehicle's frame and engine compartment.
Innovation Solution
A push-off structure is attached to the outboard side of the front side member, extending downward to the engine cradle, forming a honey-comb-like or labyrinth-like internal assembly that absorbs and redirects impact forces, thereby distributing them across the vehicle's frame and engine compartment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional front end structures are used, then the structure is simple, but the ability to absorb and redirect impact forces during off-center impacts is insufficient
Solution Approach 1:
The front side member is divided into multiple functional segments: an upper portion that maintains structural integrity, a lower portion that provides impact absorption, and a push-off structure that redirects forces. This segmentation allows each portion to specialize in specific impact management functions, improving overall reliability without requiring complete structural redesign.
Solution Approach 2:
The push-off structure extends downward from the front side member to engage with the ground or lower structures, creating a three-dimensional force redistribution pathway. This vertical dimension addition allows impact forces to be redirected through multiple spatial paths, enhancing impact absorption capability while maintaining a relatively simple overall structure.
2Strength
If the push-off structure extends downward to engage lower structures, then impact force distribution improves, but the structural complexity increases
Solution Approach 1:
The push-off structure is integrated with the existing front side member and engine cradle assembly, merging multiple functions into a unified structure. The push-off structure shares attachment points and structural pathways with the engine cradle, allowing force distribution across the entire front end assembly without requiring separate complex subsystems.
Solution Approach 2:
The front side member serves multiple functions: it provides structural support for the engine cradle, acts as a mounting structure for the push-off structure, and directly participates in impact force absorption and redirection. This multi-functionality reduces the need for additional specialized components, maintaining structural simplicity while improving strength.
Data Source
AI summary
A vehicle frame structure has a front side member that extends forward from a dashwall. An engine cradle is attached to the front side member with a lateral side portion of the engine cradle being located beneath and spaced apart from a lower surface of the front side member. An engine installed to the engine cradle with a portion of the engine extending upward from the engine cradle adjacent to an inboard surface of the front side member, A push-off structure is attached to an outboard surface of the front side member adjacent to a front end surface of the front side member. A portion of the push-off structure extends outboard from the outboard surface. Another portion of the push-off structure extends downward below the lower surface of the front side member toward the lateral portion of the engine cradle and the engine.