Off-Center Impact Reinforcement Structure for Vehicle Frames

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Solution Overview

Problem

Conventional vehicle structures fail to effectively absorb and redirect impact energy during off-center impact tests, leading to inadequate protection and potential damage to the vehicle and its occupants.

Innovation Solution

The vehicle frame is enhanced with an off-center impact reinforcement structure that includes a push arm, energy absorbing structure, and suspension components, which absorb and redirect impact forces by imparting impact energy to the energy absorbing structure, thereby distributing the force laterally and reducing the load on critical components like the dash-wall and A-pillar.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional vehicle structures are used, then the structure is simpler, but impact energy is not effectively absorbed and redirected

Engineering Contradiction:

Improveimpact energy absorptionVSAvoidvehicle frame structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The vehicle frame is divided into multiple functional components: the push arm for impact redirection, the energy absorbing structure for energy dissipation, and the support structure for structural integrity. Each segment performs a specific function in the impact management system, allowing the overall structure to handle impact forces more effectively while maintaining clarity in design and manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The push arm acts as an intermediary element between the impact source and the energy absorbing structure. It receives impact forces from off-center collisions and redirects them toward the energy absorbing structure, which then dissipates the energy. This intermediary mechanism enables efficient energy transfer and absorption without requiring the entire vehicle frame to be complex.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If additional structural elements are added to absorb impact energy, then impact protection is improved, but the vehicle weight increases

Engineering Contradiction:

Improveimpact protectionVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The energy absorbing structure is strategically positioned at the specific location where off-center impacts occur, rather than uniformly distributing reinforcement throughout the entire vehicle frame. The push arm is located precisely to intercept and redirect impact forces. This localized approach provides maximum impact protection while minimizing unnecessary weight in areas that do not require reinforcement.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The energy absorbing structure utilizes composite construction combining a hollow beam with a bulkhead structure, creating a lightweight yet high-strength component. This composite design provides superior impact energy absorption and redirection capabilities while maintaining lower weight compared to solid alternative structures, achieving the desired reliability without excessive mass.

Inventive Principle:

Principle #40Composite materials

3Force

If the energy absorbing structure is positioned closer to the front suspension, then impact force distribution is improved, but the gap between components is reduced

Engineering Contradiction:

Improveimpact force distributionVSAvoidgap between push arm and suspension

Core Design Contradiction:

ForceVSLength of stationary object

Solution Approach 1:

The push arm and energy absorbing structure are pre-positioned with a specific gap during manufacturing, allowing them to move into optimal alignment during impact events. The design anticipates the impact scenario and positions components accordingly, so that when impact occurs, the push arm and energy absorbing structure automatically achieve the optimal force distribution configuration without requiring excessive adjustment or complex mechanisms.

Inventive Principle:

Principle #10Preliminary action

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

This configuration effectively absorbs and redirects impact energy, reducing the risk of damage to the vehicle and enhancing occupant safety by moving the vehicle laterally away from the impact zone, thereby distributing the force and reducing the load on critical components.

Implementation Method 1

the energy absorbing structure is spaced apart from the front suspension structure in a non-impacted state such that in response to an off-center impact event against the front surface of the push arm, the push arm imparts impact force to the energy absorbing structure pushing the energy absorbing structure into contact with the front suspension structure

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS10526015B2Vehicle structure

Publication Date: 2020.01.07 NISSAN MOTOR CO LTD

AI summary

A push arm is coupled to a vehicle frame proximate an intersection of a first side member and a first cross-member. A rear surface of the push arm is located adjacent to a front suspension structure with a gap defined therebetween. The push arm extends forward and laterally outward such that a front surface of the push arm is located outboard of and spaced apart from a front end of the first side member. An energy absorbing structure is positioned within the gap and is attached to the rear surface of the push arm and is spaced apart from the front suspension structure in a non-impacted state. The energy absorbing structure is configured such that in response to an off-center impact event, impact force to the energy absorbing structure pushes the energy absorbing structure into contact with the front suspension structure.