Vehicle Subframe Lateral Extensions for Small Overlap Impact Absorption
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Solution Overview
Problem
Existing vehicle subframes are inadequate in absorbing impacts that occur outside the width of the longitudinal members, leading to insufficient protection for the occupant compartment during small overlap impact tests.
Innovation Solution
The proposed subframe design includes longitudinal members with lateral extensions that extend outward from the longitudinal centerline of the vehicle, covering more than 165 millimeters into opposite outer quarters of the vehicle width. These lateral extensions are contoured to avoid turn radii of steerable tires and are coupled to the longitudinal members to absorb impact forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing vehicle subframes with limited lateral extensions are used, then the structure is simpler and easier to manufacture, but the impact absorption capability outside the longitudinal members is insufficient
Solution Approach 1:
The subframe is divided into longitudinal members and separate lateral extensions that can be coupled together. This segmentation allows the lateral extensions to be optimized for impact absorption while keeping the longitudinal members for structural support, resolving the contradiction between impact absorption capability and structural simplicity
Solution Approach 2:
The subframe design extends laterally beyond the longitudinal members into the outer quarters of the vehicle width. This dimensional expansion in the lateral direction provides additional impact absorption zones without significantly complicating the overall structure, as the extensions are integrated along the longitudinal axis
2Strength
If lateral extensions extend further outward to cover more outer quarters, then impact absorption improves, but the risk of contact with steerable tires increases
Solution Approach 1:
The lateral extensions feature contoured outer edges with varying geometry along their length. The contours are specifically designed to avoid turn radii of steerable tires in certain zones while maintaining extended coverage in impact-prone areas, allowing local optimization of both impact absorption and tire clearance
Solution Approach 2:
The outer edges of the lateral extensions incorporate curved contours rather than straight lines. These curvatures are designed to clear the turn radii of steerable tires, allowing the extensions to reach further outward for improved impact absorption without interfering with tire movement during steering operations
3Reliability
If the subframe structure is expanded to cover more outer quarters, then protection of occupant compartment improves, but the manufacturing process becomes more complex
Solution Approach 1:
The subframe is segmented into longitudinal members and lateral extensions that can be manufactured separately and then coupled together. This allows each component to be optimized for its specific function while simplifying manufacturing and assembly processes compared to a fully integrated complex structure
Solution Approach 2:
The lateral extensions serve multiple functions: they extend the subframe coverage into outer quarters for improved impact absorption, they are contoured to clear tire turn radii, and they can be coupled to longitudinal members using standard joining methods. This multi-functionality reduces the need for additional specialized components
Data Source
AI summary
Vehicle subframes and methods of producing the same are disclosed. An example apparatus includes a subframe of a vehicle including longitudinal members, and lateral extensions extending from the longitudinal members, the lateral extensions extending outward from a longitudinal centerline of the vehicle, outer edges of the lateral extensions including contours to avoid turn radii of steerable tires of the vehicle.