Vehicle Toe Board Closed Cross Section for Collision Energy Distribution
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Solution Overview
Problem
Existing vehicle-body front structures face challenges in maintaining rigidity while reducing weight, particularly when collision energy is transmitted from the vehicle front surface, and the provision of reinforcing beads increases weight.
Innovation Solution
A vehicle-body front structure comprising a toe board with overlapping upper and lower components forming a closed cross section, main frames extending in the vehicle front-rear direction, and front pillars, which absorbs collision energy and distributes it efficiently through a looped framework, eliminating the need for a torque box and reducing weight by integrating components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If reinforcing beads are provided on the dash panel to reduce vibrations and noise, then vibration resistance is improved, but weight increases
Solution Approach 1:
The dash panel is divided into an upper dash panel and a lower dash panel that are joined together. The first reinforcing bead is provided only on the upper dash panel, and the second reinforcing bead is provided only on the lower dash panel. This segmentation allows each panel to have its own reinforcement strategy, reducing the overall need for heavy reinforcement while maintaining vibration resistance.
Solution Approach 2:
The first reinforcing bead extends in the vehicle width direction on the upper dash panel, while the second reinforcing bead extends in the vehicle front-rear direction on the lower dash panel. This multi-directional reinforcement approach distributes structural support across different dimensions, achieving vibration resistance without concentrating weight in a single area.
2Strength
If a closed cross section structure is used to improve rigidity and prevent cabin deformation, then strength is improved, but device complexity increases
Solution Approach 1:
The upper dash panel and lower dash panel are joined together to form an integrated closed cross-section structure. The first reinforcing bead on the upper panel and the second reinforcing bead on the lower panel work together to create a unified rigid framework. This merging of components achieves the strength of a closed section structure without requiring a completely separate complex framework.
Solution Approach 2:
The dash panel structure serves multiple functions: it acts as a separator between the cabin and vehicle-body front part, provides rigidity through its closed cross-section form, reduces vibrations through reinforcing beads, and prevents cabin deformation during collisions. This multi-functionality reduces the need for additional separate components, thereby reducing overall device complexity.
3Object-affected harmful factors
If the toe board is separated from the vehicle-body front part to reduce collision energy transmission, then occupant safety is improved, but collision energy absorption capability worsens
Solution Approach 1:
The dash panel with its closed cross-section structure and reinforcing beads acts as an intermediary between the vehicle-body front part and the cabin. It selectively transmits certain types of forces (providing rigidity and vibration resistance) while isolating the cabin from harmful collision energies. This intermediary structure achieves both protection and energy management.
Solution Approach 2:
The dash panel structure has different properties in different areas: the closed cross-section provides rigidity where needed, the reinforcing beads provide vibration resistance in specific directions, and the overall structure provides collision protection. This localized optimization of structural properties allows the panel to absorb and manage collision energy effectively while protecting the cabin.
Data Source
AI summary
A vehicle-body front structure includes: a toe board including an upper toe board and a lower toe board joined to each other with a vehicle lower-side edge of the upper toe board overlapping a vehicle upper-side edge of the lower toe board; main frames provided on opposite sides of the vehicle-body front part in a vehicle width direction and extending in a vehicle front-rear direction; and front pillars extending in a vehicle up-down direction on opposite outer sides of the toe board in the vehicle width direction. The toe board has a closed cross section at a position where the upper and lower toe boards are overlapped. The closed cross section includes opposite ends joined to the front pillars in the vehicle width direction. The main frames are joined to the toe board at positions overlapping the closed cross section in a vehicle front view.