Vehicle Front-End Sheet-Metal Tension Strip for Crash Load Path
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Solution Overview
Problem
In vehicles experiencing frontal collisions with little lateral overlap, collision forces are not effectively dissipated through the bumper cross members and instead transmit through the upper wheel well and suspension strut dome, leading to potential intrusion into the A-pillar due to strong crash momentum.
Innovation Solution
A sheet-metal tension strip connects the suspension strut dome to the lower body longitudinal member, providing a load path to absorb and dissipate crash momentum, reducing intrusion into the A-pillar by opposing the crash force with tensile forces and reinforcing the structure with a double or triple sheet construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the suspension strut dome is reinforced to resist crash forces, then the A-pillar intrusion is reduced, but the manufacturing complexity and cost increase
Solution Approach 1:
The sheet-metal wheel well part is divided into multiple functional zones: a reinforcement zone with increased thickness at the critical crash load path, and a standard thickness zone in non-critical areas. This segmentation allows targeted reinforcement where needed while maintaining manufacturing efficiency and cost-effectiveness overall.
2Strength
If additional reinforcement elements are added to the suspension strut dome, then the crash force resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The sheet-metal wheel well part features local quality variation through zone-dependent thickness: a first zone with first thickness for reinforcement and a second zone with second thickness for standard coverage. This allows optimal strength-to-cost ratio by applying material only where structurally necessary.
3Strength
If the sheet-metal wheel well part is made thicker throughout, then the crash resistance is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The sheet-metal wheel well part is segmented into zones with different thicknesses: a reinforcement zone with increased thickness for crash load bearing, and standard zones with nominal thickness. This segmentation achieves crash resistance requirements while minimizing unnecessary material and weight.
4Stability of the object's composition
If the suspension strut dome is made more rigid, then the A-pillar intrusion is reduced, but the deformation energy absorption decreases
Solution Approach 1:
The sheet-metal wheel well part employs local quality differentiation: a reinforcement zone with higher rigidity for maintaining structural stability and preventing A-pillar intrusion, and zones with standard properties that can deform to absorb energy. This creates an optimized balance between stability and energy management.
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 sheet-metal tension strip effectively reduces A-pillar intrusion by transmitting crash forces to the lower body longitudinal member, where they are absorbed and dissipated, enhancing the vehicle's front-end structure's ability to manage collision forces without significant additional manufacturing costs.
Implementation Method 1
the sheet-metal tension strip provides a load path through which a tensile force opposing the crash force acts on the suspension strut dome
Implementation Method 2
the lower body longitudinal member, which absorbs it and dissipates it by means of deformation energy
Data Source
AI summary
A body front-end structure for a two-track vehicle, having an A-pillar from which an upper wheel well longitudinal member projects toward the front of the vehicle in the longitudinal direction of the vehicle, and from which a lower body longitudinal member that is offset toward the inside of the vehicle with respect to the upper wheel well longitudinal member projects toward the front of the vehicle in the longitudinal direction of the vehicle. In a head-on crash with small lateral overlap, a suspension strut dome is loaded with a crash force in the longitudinal direction of the vehicle. The body front-end structure has a sheet-metal tension strip that connects the suspension strut dome to the lower body longitudinal member in a force-transmitting manner. In the event of a head-on crash, the sheet-metal tension strip provides a load path through which a tensile force opposing the crash force acts on the suspension strut dome.