Hybrid Motor Vehicle Front-End Module Supporting Structure
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Solution Overview
Problem
The existing front end module supporting structures in motor vehicles, made entirely of strong materials like steel, result in significant weight, high fuel consumption, and elevated CO2 emissions while failing to optimize vehicle operation and safety standards.
Innovation Solution
A hybrid material comprising a metallic insert covered with plastics is used for the upper crossmember, combined with lightweight plastics for the lower crossmembers and lateral uprights, along with metallic support wings, to form a more efficient and safer supporting structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the supporting structure is made entirely from steel, then the strength and stiffness comply with safety standards, but the weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining plastic and metal components in the supporting structure. Specifically, the upper crossmember includes a metal insert (steel tube) embedded in a plastic housing, creating a hybrid component that leverages the strength of metal and the weight-saving properties of plastic. This composite approach allows the structure to meet safety strength requirements while significantly reducing overall weight compared to an all-steel construction.
2Stability of the object's composition
If the supporting structure is made entirely from steel, then the stiffness meets safety requirements, but the fuel consumption increases
Solution Approach 1:
The hybrid composite structure reduces vehicle weight by replacing portions of steel with plastic components, directly lowering the energy required for vehicle operation and thus reducing fuel consumption. The metal inserts are strategically placed only where structural reinforcement is necessary to maintain stiffness.
3Reliability
If the supporting structure is made entirely from steel, then the safety standards are met, but the CO2 emissions increase
Solution Approach 1:
By implementing a composite structure with plastic and metal components, the patent reduces the vehicle's overall weight, which directly decreases CO2 emissions during operation. The safety requirement is maintained through the strategic placement of metal inserts in critical load-bearing areas, ensuring the structure meets safety standards while minimizing environmental impact.
4Weight of moving object
If hybrid materials are used for the upper crossmember, then the weight is reduced by 30-40%, but the manufacturing complexity increases
Solution Approach 1:
The patent employs the nesting principle by placing a metal insert (steel tube) inside a plastic housing, creating a nested composite structure. The metal insert is embedded within the plastic component during the molding process, integrating two materials into a single unified part. This nesting approach simplifies assembly operations while achieving significant weight reduction.
Solution Approach 2:
The hybrid composite construction using plastic and metal materials reduces the weight of the upper crossmember by 30-40% compared to an all-metal design. The composite approach allows optimization of each material's properties for its specific function while reducing overall mass.
Data Source
AI summary
A supporting structure for a motor vehicle front end module is disclosed. The supporting structure includes a lower crossmember, a first lateral upright, a second lateral upright, an upper crossmember, and a support wing fixed to one end of the upper crossmember with connection means. The first lateral upright, the second lateral upright, and the upper crossmember define a frame that is formed of a hybrid material comprising a plastics material and a metallic material.