Vehicle Front Structure for Small Overlap Yaw Suppression
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Solution Overview
Problem
Eco-friendly motor vehicles face increased impact energy due to heavier energy sources, leading to enhanced vehicle body stiffness and manufacturing costs, and existing front pillar reinforcement systems are inadequate in preventing yaw motion and damage during small overlap crashes.
Innovation Solution
A vehicle front structure design featuring a pair of front side members, a front bumper beam, bumper beam extension portions, deflectors, and supports, with a frunk bar and front subframe, to increase lateral displacement and suppress yaw motion by distributing lateral forces effectively during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the vehicle uses heavier energy sources (batteries, fuel cells) to achieve eco-friendly operation, then the energy storage capacity is improved, but the vehicle weight increases leading to increased impact energy
Solution Approach 1:
The patent applies beforehand cushioning by designing a bumper beam extension portion that can deform and absorb impact energy before it reaches the front side member. The extension portion acts as a pre-positioned energy absorption mechanism that reduces the transmission of impact forces to the vehicle body during small overlap crashes, thereby mitigating the increased impact energy resulting from heavier vehicle weight.
2Strength
If the end portion of the bumper and the support are always in contact or have very small distance between them, then the structural stiffness is improved, but the vehicle becomes easily damaged in low-speed impact
Solution Approach 1:
The patent applies dynamics by designing the bumper beam extension portion with controlled deformability. The extension portion can dynamically adjust its rigidity based on impact conditions - maintaining structural stiffness during normal operation while allowing controlled deformation during low-speed impacts to prevent damage. This dynamic characteristic resolves the contradiction between maintaining structural strength and avoiding damage in low-speed scenarios.
3Force
If the support is positioned close to the front side member to provide support during crash, then the lateral force is improved, but the front side member is excessively bent during small overlap crash
Solution Approach 1:
The patent applies the intermediary principle by introducing the bumper beam extension portion as a mediator between the bumper and the front side member. This extension portion serves as an intermediate element that transfers and distributes impact forces, reducing the direct bending load on the front side member while still providing necessary lateral support during small overlap crashes.
4Reliability
If the vehicle body reinforcing structure is improved to handle increased impact energy, then the crashworthiness is improved, but the manufacturing cost and vehicle weight increase
Solution Approach 1:
The patent applies segmentation by dividing the front bumper structure into separate functional components: the main bumper beam, the deformable extension portion, and the support structure. This segmented design allows each component to be optimized independently for its specific function - the extension portion for energy absorption and the support for structural reinforcement - achieving improved crashworthiness without requiring uniform strengthening of the entire vehicle body, thereby controlling manufacturing costs.
Data Source
AI summary
In an embodiment, a vehicle front structure includes a front side member, a front bumper beam located in front of the front side member, a bumper beam extension portion extending from an end of the front bumper beam, a deflector mounted on the bumper beam extension portion, and a support located behind the deflector, wherein the support is attached to an outboard surface of the front side member.