Vehicle Front Structure for Small-Overlap Crash Box Load Transfer
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Solution Overview
Problem
In existing vehicle front structures, the crash box cannot be used as a reaction force surface during a small-overlap collision due to bending deformation, leading to potential damage and ineffective load transmission.
Innovation Solution
A vehicle front structure design that includes a bumper reinforcement with a protruding part having an inclined portion to transmit collision loads to the crash box, allowing it to function as a reaction force surface by inhibiting local damage and ensuring stable load transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the crash box is used as a reaction force surface during small-overlap collision, then lateral force generation is improved, but the crash box undergoes bending deformation and cannot function properly
Solution Approach 1:
The protruding part with the first inclined portion acts as an intermediary between the bumper reinforcement and the crash box. It transmits the collision load to the side surface of the crash box in a controlled manner, enabling the crash box to function as a reaction force surface without undergoing damaging bending deformation.
2Device complexity
If the protruding part has a vertical end surface, then load transmission is simple, but local damage to the crash box occurs
Solution Approach 1:
The end surface of the protruding part is changed from a vertical orientation to an inclined orientation (first inclined portion). This parameter change in the geometry of the protruding part allows the collision load to be transmitted to the side surface of the crash box in a more distributed manner, reducing local damage while maintaining structural simplicity.
3Loss of energy
If the crash box undergoes bending deformation to absorb collision load, then collision energy absorption is improved, but the crash box cannot be used as a reaction force surface
Solution Approach 1:
The collision load transmission path is segmented into two distinct functions: the protruding part with the first inclined portion handles load transmission to prevent crash box deformation, while the crash box handles lateral force generation. This segmentation allows both energy absorption and lateral force generation to occur simultaneously without interference.
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 design reduces crash box damage and enables efficient load transmission, enabling the crash box to generate a lateral force during a small-overlap collision, thereby enhancing collision energy management.
Implementation Method 1
the first inclined portion of the protruding part hits the side surface on the outer side in the vehicle width direction of the crash box. That is, the collision load transmitted from the bumper reinforcement is input through the first inclined portion
Implementation Method 2
the collision load that is further input causes the end portion on the outer side in the vehicle width direction of the bumper reinforcement to undergo bending deformation, so that the collision load is transmitted through the protruding part to the crash box
Data Source
AI summary
A vehicle front structure includes: a framework part; a crash box; a bumper reinforcement; a protruding part that protrudes from an end portion of the bumper reinforcement toward a vehicle rear side. An end portion of the protruding part includes a first inclined portion. The end portion of the bumper reinforcement extends along the vehicle width direction so as to project toward the outer side in the vehicle width direction beyond an end portion of the crash box. As seen in a plan view, the first inclined portion slopes outward from an inner side of the end portion of the protruding part in the vehicle width direction toward the vehicle rear side.