Vehicle Front Side Frame Gusset Inversion for Collision Load Resistance
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Solution Overview
Problem
The existing vehicle body front part structure is prone to gusset separation from the front side frame when collision loads are applied, as the gusset is fixed outwardly and horizontally, leading to ineffective load distribution and potential structural failure.
Innovation Solution
A vehicle body front part structure featuring a pair of front side frames with inner and outer members, where the gusset is inclined and vertically fixed to a width widening portion of the outer member, enhancing its attachment and preventing separation during collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the gusset is fixed outwardly and horizontally to the front side frame, then the structure is simple and easy to manufacture, but the gusset separates from the front side frame when collision loads are applied
Solution Approach 1:
Instead of fixing the gusset horizontally outward from the front side frame (conventional approach), the invention inverts the fixation orientation by extending the gusset rearward and fixing it to the rearward-facing surface of the front side frame. This inverted configuration allows the gusset to effectively resist collision loads that tend to separate it from the frame, while maintaining manufacturing simplicity through the same basic fixation methods.
2Device complexity
If the gusset extends outward in vehicle width direction, then the fixation is simple, but collision load transmitted to flange portions separates the gusset from the front side frame
Solution Approach 1:
The invention applies asymmetry by changing the gusset's extension direction from horizontal (vehicle width direction) to rearward (vehicle front-rear direction). The gusset now extends rearward at an angle relative to the front side frame, creating an asymmetric configuration that optimizes load distribution. This asymmetric arrangement allows the gusset to effectively counteract collision loads transmitted through the flange portions, preventing separation while maintaining structural simplicity.
3Strength
If the gusset is arranged further rearward than crash cans, then the crash cans can absorb collision load effectively, but the gusset cannot effectively resist separation force from collision load
Solution Approach 1:
The invention addresses the limitation by changing the dimensional orientation of the gusset extension. Instead of extending the gusset horizontally outward (vehicle width direction), it extends the gusset in the vehicle front-rear direction at a rearward angle. This dimensional change allows the gusset to effectively engage with the front side frame's rearward-facing surface, enabling it to resist separation forces from collision loads while maintaining its rearward position for effective crash can functionality.
Data Source
AI summary
Included are a pair of left and right front side frames extending in a vehicle front-rear direction, and each including an inner side frame on an inner side and an outer side frame on an outer side; and a gusset member arranged on a vehicle width direction outer side of a vehicle front-side end portion of each front side frame, and including an inclination portion which inclines such that, in its plan view, becomes closer to the front side frame toward a vehicle rear. A vehicle front-side end portion of the outer side frame includes a width widening portion which becomes wider outward in a vehicle width direction. The gusset member includes a fixation portion which is vertically fixed to the width widening portion.