Integrated Cross-Member Crash System for Weight Reduction
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Solution Overview
Problem
Current crash management systems for vehicles face challenges in providing adequate protection for both vehicle structures and pedestrians in frontal and rear impacts, especially with the need for improved energy absorption, reduced weight, and efficient packaging in smaller, more energy-efficient cars, while meeting new safety standards and styling requirements.
Innovation Solution
A crash management system featuring integrated cross-members and crash absorbing components, optimized for improved strength and stiffness-to-weight ratio, with a wider and higher geometry, allowing for efficient energy dissipation and airflow, and reduced component complexity, using aluminum alloys and specific deformation techniques during manufacturing to enhance force transfer and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mechanically assembled crash boxes and cross-members are used, then the system provides basic crash protection, but the strength and stiffness to weight ratio is lower and packaging efficiency is reduced
Solution Approach 1:
The patent integrates the cross-member and crash boxes into a single monolithic component formed from one continuous piece of material. This merging eliminates the need for separate crash boxes and cross-member components, creating an integrated structure that improves the strength and stiffness to weight ratio while reducing overall system weight through eliminated redundant materials and connections.
Solution Approach 2:
The integrated cross-member structure utilizes composite material construction with varying wall thicknesses and material distributions optimized for different structural requirements. The monolithic design allows for strategic material placement that enhances strength and stiffness characteristics while minimizing weight, achieving a superior strength and stiffness to weight ratio compared to traditional assembled systems.
2Device complexity
If multiple separate components are used for crash management, then assembly flexibility is provided, but device complexity and assembly operations increase
Solution Approach 1:
By combining multiple separate components (crash boxes and cross-members) into a single integrated component, the patent reduces device complexity from multiple parts to one monolithic structure. This integration eliminates the need for complex assembly operations involving multiple components, fasteners, and joints, thereby simplifying both the device structure and manufacturing process.
3Area of stationary object
If a larger crash system is used to increase crash area for better energy dissipation, then crash protection improves, but packaging space in the vehicle is reduced
Solution Approach 1:
The integrated cross-member structure extends in multiple dimensions with strategic variations in height, width, and wall thickness to maximize the effective crash area. By utilizing three-dimensional space efficiently and creating a multi-dimensional structure that expands the crash interaction surface without proportionally increasing overall volume, the system achieves better energy dissipation while maintaining packaging efficiency.
Solution Approach 2:
The monolithic structure incorporates local variations in geometry, wall thickness, and material distribution tailored to specific crash zones. This local quality optimization allows the crash system to have enlarged cross-sectional areas where needed for energy dissipation while maintaining a compact overall footprint that preserves vehicle packaging space.
4Device complexity
If integrated cross-member with crash boxes is used, then component reduction and assembly simplification are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The integration of cross-member and crash boxes into one monolithic component reduces the total number of parts from multiple separate components to a single unified structure. This component reduction simplifies the bill of materials and eliminates assembly steps, though it requires precise forming processes to achieve the complex integrated geometry in one manufacturing operation.
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 system provides enhanced crash protection across various impact speeds and scenarios, reduces vehicle weight and bulk, improves airflow, and integrates seamlessly with other vehicle components, meeting stringent safety standards while optimizing production and operational costs.
Implementation Method 1
crash absorbing components (4, 5) integrated in one same and single part... efficient energy dissipation
Implementation Method 2
using aluminum alloys and specific deformation techniques during manufacturing to enhance force transfer
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
Crash management system for a vehicle including at least one first cross-member (2) and two crash absorbing components (4, 5), where the system further comprises a second cross-member (3) integrated with said first cross-member. The invention also relates to a method for making such a system.