Integral Front-End Module Impact Distribution
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Solution Overview
Problem
Conventional front-end modules in vehicles fail to effectively absorb impact in frontal collisions due to breakage of the back beam or collision boxes, leading to increased risk of injury from transmitted impact, especially in next-generation vehicles with compact designs.
Innovation Solution
An integral type front-end module with a quadrangular frame, multiple load paths, and a back beam system that distributes impact through multiple paths, including a horizontal back beam, first and second vertical back beams, and ribs, made of fiber-reinforced plastic to reduce weight and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single back beam is used to transmit impact to collision boxes, then the structure is simple, but the impact concentration causes breakage and reduces reliability
Solution Approach 1:
The single back beam is segmented into multiple back beams (first back beam, second back beam, third back beam) that are distributed across the front-end module. This segmentation divides the impact load into multiple separate load paths, preventing concentration of stress on a single component and thereby reducing breakage risk while maintaining structural reliability.
Solution Approach 2:
The back beams are arranged in different spatial dimensions and orientations (horizontal, vertical, and diagonal arrangements) to create a three-dimensional load distribution network. This dimensional expansion allows impact forces to be dispersed across multiple spatial paths rather than concentrated along a single linear path.
2Reliability
If multiple load paths are introduced to distribute impact, then breakage is prevented, but the structural complexity increases
Solution Approach 1:
Multiple back beams are merged with the frame structure through integral connections, forming a unified load-bearing system. The first, second, and third back beams are combined with vertical members and horizontal members of the frame, creating an integrated structure that distributes loads through multiple paths while maintaining structural coherence and avoiding the complexity of separate, loosely-connected components.
Solution Approach 2:
The back beams and frame structure utilize composite material construction, combining different materials with complementary properties to achieve both strength and weight optimization. This allows the creation of a complex multi-path load distribution system without proportionally increasing the overall weight or manufacturing complexity.
3Object-affected harmful factors
If conventional back beam and collision box structure is used, then manufacturing is simple, but impact absorption is insufficient leading to injury risk
Solution Approach 1:
The impact absorption function is segmented across multiple components (first back beam, second back beam, third back beam, collision boxes) rather than relying on a single component. This segmentation creates redundant load paths that prevent catastrophic failure and reduce impact transmission to occupants, while each individual component remains relatively simple in design for ease of manufacturing.
Solution Approach 2:
The multiple back beams are positioned and configured in advance to create predetermined load paths that actively distribute impact forces before they can concentrate and cause damage. This prior arrangement of structural elements provides built-in cushioning and protection against impact transmission to the vehicle cabin and occupants.
Data Source
AI summary
An integral type front-end module is provided. The integral type front-end module includes a frame having an upper member, a lower member, and a pair of vertical members that connect the upper and lower members. The integral type front-end module also includes a horizontal back beam that connects the vertical members, a first vertical back beam that connects middle portions of the upper member and the lower member, and a pair of second vertical back beams, each disposed between one of the vertical members and the first vertical back beams. In particular, the horizontal back beam, the first vertical back beam, and the second vertical back beams are formed integrally.