Vehicle Front Structure for Small-Overlap Collision Energy Dissipation
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Solution Overview
Problem
Current motor vehicle front structures face challenges in managing low overlap frontal impacts, leading to potential wheel intrusion into the passenger compartment and inadequate energy dissipation, with existing solutions either being costly or ineffective in energy absorption.
Innovation Solution
The proposed front structure includes extended shock absorbers with open cross-section envelopes and energy dissipating elements mounted on the spar, which increase the overlap surface with obstacles during impacts, enhancing energy dissipation and reducing stresses on the passenger compartment by promoting deformation of the spar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the front structure is significantly reinforced to prevent wheel intrusion during low overlap frontal impacts, then the safety and reliability improve, but the weight and manufacturing cost increase
Solution Approach 1:
The front structure is divided into multiple functional zones: the deformable side member for initial energy absorption, the energy dissipating element for controlled deformation, and the reinforced transverse beam for structural integrity. This segmentation allows each component to be optimized for its specific function rather than uniformly reinforcing the entire structure.
Solution Approach 2:
The patent changes the geometric parameters of the energy dissipating element, specifically configuring it with an inclined wall at a specific angle and positioning it at a determined distance from the side member. These parameter optimizations enable effective energy dissipation through deformation without requiring excessive material or weight.
2Reliability
If a deflector is added to transmit forces obliquely to the side member to prevent wheel intrusion, then the reliability improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The energy dissipating element is integrated directly with the side member structure, with the inclined wall forming a continuous load path. This merging eliminates the need for separate deflectors or additional mounting components, reducing assembly complexity while maintaining the force transmission function.
Solution Approach 2:
The energy dissipating element serves multiple functions simultaneously: it acts as a force transmission path, an energy absorption zone, and a structural connector between the side member and transverse beam. This multi-functionality reduces the number of separate components needed.
3Reliability
If the deflector is made with sufficient resistance to transmit forces without crushing, then the force transmission reliability improves, but the energy dissipation capability deteriorates
Solution Approach 1:
The structure exhibits local quality variations: the side member is designed to be deformable for energy absorption, while the transverse beam and connecting plates are designed with sufficient rigidity for force transmission. The energy dissipating element itself has controlled deformation zones that localize energy absorption without compromising overall structural integrity.
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
This configuration effectively disperses and absorbs impact energy, reducing the risk of wheel intrusion and minimizing stresses on the passenger compartment during low overlap frontal collisions, while maintaining a cost-effective design.
Implementation Method 1
an energy dissipating element by deformation is associated with the at least one extended shock absorber
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a front structure (1) of a motor vehicle comprising a frame (2) including two side members (3), a crossbeam (4), and two shock absorbers (5), each fixed to the front end of a side member (3) in line with it by means of a plate (6) and to the crossbeam (4). At least one shock absorber (5) is extended laterally in the transverse direction by a casing (10) with an open cross-section extending from one side opposite the other shock absorber, the opening of which is closed by assembly to the shock absorber. The front structure also includes a deformation energy-dissipating element (20) associated with the at least one extended shock absorber (5), this element (20) being mounted on an outer lateral face (30) of the side member (3) to which the extended shock absorber is fixed, in alignment with the casing of the latter in the longitudinal direction.