Vehicle Frunk Reinforcement Structure with Truss Bracket
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Solution Overview
Problem
Conventional vehicle frunk structures lack sufficient support rigidity and resistance to rotational distortion, particularly in electric vehicles where the engine compartment is repurposed as cargo space, leading to potential deformation and failure in load-bearing scenarios.
Innovation Solution
A structure comprising a frunk bar, motor mounts, and a subframe aligned in the height direction, coupled to front side members via a longitudinal bolting structure and a truss-shaped bracket to enhance load resistance and rotational stability, with additional through-pipes for improved coupling rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple thin bracket mounting manner is used to connect the transverse member, then the device complexity is reduced, but the resistance to rotational distortion deteriorates
Solution Approach 1:
The connection structure is divided into multiple functional components: a bracket with first and second connection portions, a fastener, and a reinforcement plate. Each component performs a specific function - the bracket provides geometric resistance to rotation, the fastener secures the connection, and the reinforcement plate distributes loads. This segmentation allows optimization of each component for its specific purpose while maintaining overall simplicity.
Solution Approach 2:
The bracket is designed with a specific geometric configuration that extends in multiple dimensions. The first connection portion connects to the transverse member while the second connection portion connects to the side member, creating a three-dimensional connection structure that resists rotational distortion through its spatial geometry rather than requiring complex multi-component assemblies.
2Ease of manufacture
If the transverse member is connected using a simple mounting manner, then the ease of manufacture is improved, but the load path capability in collision events deteriorates
Solution Approach 1:
The connection system is segmented into distinct components (bracket, fastener, reinforcement plate) that can be manufactured separately using standard processes and then assembled. This maintains ease of manufacture while the specific geometry of each component ensures proper load path transmission during collision events.
Solution Approach 2:
The bracket acts as an intermediary component between the transverse member and the side member. It mediates the transmission of collision loads by providing a geometrically optimized connection that distributes forces appropriately, ensuring the transverse member functions as an effective load path without requiring complex integrated manufacturing.
3Device complexity
If both ends of the transverse member are simply coupled to side members, then the device complexity is reduced, but the elastic deformation increases with distance from fixed end
Solution Approach 1:
The connection is segmented into multiple functional elements working together: the bracket provides geometric stiffness, the fastener ensures rigid attachment, and the reinforcement plate distributes stresses. This segmentation allows control of elastic deformation through the combined action of these simple components rather than requiring a complex monolithic structure.
Solution Approach 2:
The connection structure utilizes a composite approach combining different material properties and structural forms - the bracket geometry provides structural stiffness, the fastener provides rigid mechanical attachment, and the reinforcement plate provides stress distribution. This composite strategy controls elastic deformation effectively while maintaining manufacturing simplicity.
Data Source
AI summary
A structure for reinforcing and supporting a vehicle frunk includes front side members installed in a front-to-back direction of a vehicle body at both sides of a front floor panel of a vehicle, a frunk bar extending in a width direction of the vehicle between the front side members and connected to the front side members, a bracket formed at a position corresponding to connection between the frunk bar and a respective one of the front side members, to couple the frunk bar to the respective one of the front side members, at least two motor mounts formed beneath the frunk bar in a height direction of the frunk bar, and a subframe positioned beneath the motor mounts in a height direction of the motor mounts and connected to the front side members to extend in the width direction of the vehicle.