Funnel-Shaped Deformation Element for Vehicle Front Structure

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Solution Overview

Problem

Existing structural elements in the front area of motor vehicles face limitations in lightweight construction potential and encounter issues with thermal expansion and corrosion when combining metallic and CFRP structures, as well as inadequate energy absorption in crashes.

Innovation Solution

A structural element with a deformation element fastened between the engine mount and bulkhead, forming a closed, funnel-shaped structure using fiber-reinforced plastic and a fiber composite material with a foam core, allowing for controlled deformation and enhanced energy absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metallic materials are used for structural elements, then strength and rigidity are ensured, but lightweight construction potential is limited and thermal expansion and corrosion problems arise

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs composite materials consisting of CFRP (carbon fiber reinforced plastic) and aluminum alloy in the structural element. The CFRP portions provide high strength-to-weight ratio while the aluminum alloy portions provide ductility and energy absorption. This composite approach resolves the contradiction by achieving both lightweight construction and sufficient strength simultaneously.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If metallic and CFRP structures are combined, then lightweight construction is achieved, but thermal expansion and corrosion problems occur

Engineering Contradiction:

ImproveweightVSAvoidreliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent introduces an intermediary transition zone between the CFRP and aluminum alloy portions, where the material composition gradually changes. This transition zone accommodates thermal expansion differences and prevents direct contact between dissimilar materials, thereby eliminating corrosion issues while maintaining lightweight construction benefits.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent varies the material composition parameters along the length of the structural element, creating a gradient from pure CFRP to pure aluminum alloy. This parameter change approach allows smooth transition of thermal and mechanical properties, preventing stress concentrations and corrosion at material interfaces.

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If a pure CFRP shell construction is used, then lightweight construction potential is maximized, but energy absorption in crashes is insufficient

Engineering Contradiction:

ImproveweightVSAvoidenergy absorption

Core Design Contradiction:

Weight of moving objectVSLoss of energy

Solution Approach 1:

The patent applies different material qualities to different portions of the structural element. The CFRP portions are used where lightweight construction is prioritized, while aluminum alloy portions are strategically placed in regions requiring high energy absorption during crashes. This local differentiation resolves the contradiction by optimizing each region for its specific function.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If the deformation element design is changed to adapt to different crash weights, then adaptability is improved, but device complexity increases

Engineering Contradiction:

ImproveadaptabilityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent enables adaptability by changing geometric parameters of the deformation element (such as wall thickness, cross-sectional dimensions, and deformation groove patterns) rather than redesigning the entire structure. This parameter adjustment approach allows the same basic design to serve multiple vehicle variants with different crash weight requirements, maintaining simplicity while achieving versatility.

Inventive Principle:

Principle #35Parameter changes

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 offers increased lightweight construction potential and improved crash energy absorption, with adaptable deformation behavior and easy repairability, while maintaining structural rigidity and introducing crash loads effectively into the bulkhead.

Implementation Method 1

the deformation element and the front clamp are fastened to the motor mount

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

the deformation element consists of a fiber-reinforced plastic

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 3

the end wall consists of a fiber composite material with a foam core

Methodology Applied

Scientific EffectFoam: Foam

Data Source

PatentEP2983930B1Structural element in the front region of a motor vehicle

Publication Date: 2018.10.24 BAYERISCHE MOTOREN WERKE AG

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AI summary

The present invention relates to a structural element in the front region of a motor vehicle, which structural element is arranged between an engine subframe (8) and a bulkhead (6) of the motor vehicle, and which structural element has a deformation element (1) which is fastened via a front fixing (4) to the engine subframe (8) and a rear fixing (5) to the bulkhead (6), wherein the front fixing (4) is connected via an upper shell (2) and a lower shell (3) to the bulkhead (6) in such a way that the two shells (2, 3) form a closed, funnel-shaped structure with one another.