Integrated Instrument Cross-Member for Crash Force Absorption
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Solution Overview
Problem
Existing motor vehicle cross members are inefficient in force dissipation during crashes and require extensive assembly, lacking integrated support for functional components and adequate force absorption.
Innovation Solution
A thin-walled, one-piece instrument cross member with a varying wall thickness, incorporating a plate with instrument openings and a U-shaped crossbar for enhanced rigidity and force absorption, integrated with HVAC and cooling features to reduce assembly complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional separately designed components are attached to the cross member to support functional elements, then the accommodation of functional components is achieved, but the assembly complexity increases
Solution Approach 1:
The patent merges the cross member with integrated support structures into a single unified component. The T-shaped support elements are formed as one piece with the cross member, eliminating the need to attach separate components for mounting instruments and HVAC units, thus reducing assembly complexity while maintaining functional versatility
Solution Approach 2:
The cross member is designed as a multi-functional component that simultaneously serves as a structural element, a mounting platform for instruments, and an integrated HVAC unit holder. This universal design allows multiple functional components to be accommodated without requiring additional separate support structures
2Adaptability or versatility
If the cross member is designed to support multiple functional components, then the versatility is improved, but the structural strength for force absorption deteriorates
Solution Approach 1:
The cross member features varying wall thicknesses in different sections to optimize both strength and functionality. Thicker walls (3-5mm) are used in load-bearing areas for strength, while thinner walls (1-2mm) are used in non-critical areas to reduce weight and allow integration of functional components, thus achieving both versatility and force absorption capability
3Strength
If the wall thickness is increased to improve force absorption, then the strength is improved, but the weight increases
Solution Approach 1:
The cross member employs non-uniform wall thickness distribution, with thicker sections (3-5mm) positioned at critical load-bearing locations and thinner sections (1-2mm) in non-critical areas. This localized quality approach maximizes force absorption capability where needed while minimizing overall weight
Solution Approach 2:
The patent specifies using aluminum or aluminum alloys for the cross member, which provide high strength-to-weight ratio. This material choice enables the structure to achieve adequate force absorption capability with reduced wall thickness compared to traditional materials, thus reducing weight while maintaining strength
4Adaptability or versatility
If additional support elements are attached to accommodate functional components, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
The cross member and all support structures for instruments and HVAC units are manufactured as a single integrated component, eliminating the need for separate parts and assembly operations. This merging approach reduces manufacturing complexity and cost while maintaining the ability to accommodate multiple functional elements
Solution Approach 2:
The unified cross member design serves multiple functions simultaneously - structural support, instrument mounting, and HVAC unit integration - eliminating the need for multiple specialized components and reducing overall manufacturing cost
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
The solution effectively absorbs and dissipates forces during frontal impacts, reduces assembly effort, and integrates functional components without additional support elements, enhancing cost-effectiveness and crash performance while providing efficient heat dissipation.
Implementation Method 1
the instrument cross member assumes the function of force dissipation/force absorption in the event of a frontal impact
Implementation Method 2
The wall thickness can vary along the length of the instrument cross member, meaning that the wall thickness can be thicker in some areas of the instrument cross member, such as the cross member, for example, at 3.5 mm, and thinner in other areas, for example, at 1.5 mm
Implementation Method 3
A plate adjoins the cross member in the direction of the vehicle front or in the X direction or is arranged on the cross member. At least one instrument opening for receiving an instrument is formed in the plate
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Instrument crossmember (1) of a motor vehicle, comprising a cross member (2), wherein the cross member (2) extends transversely to the longitudinal direction of the motor vehicle from one A-pillar to an opposite A-pillar, wherein a plate (2, 4) adjoins the cross member (2) in the direction of the vehicle front (17), wherein at least one instrument opening (6) for receiving an instrument is formed in the plate (2, 4).