Trailer Hitch Mount Structure With Crushable Frame Rail
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Solution Overview
Problem
Existing trailer hitch assemblies for vehicles lack efficient load distribution and energy absorption during impacts, leading to potential structural failures and reduced safety.
Innovation Solution
A trailer hitch assembly design that includes a collar and face plate configuration with a crushable frame rail section, allowing the trailer hitch mount to extend into a hollow frame rail, distributing loads across multiple points and axes, and enabling energy absorption during impacts by crushing the frame rail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional rigid trailer hitch assembly is used, then structural strength is maintained, but energy absorption during impacts is insufficient leading to potential structural failures
Solution Approach 1:
The patent incorporates a crushable section in the frame rail that is designed to deform and absorb impact energy before the force is transmitted to the rigid trailer hitch mount and face plate. This pre-cushioning mechanism protects the structural integrity of the hitch assembly during rear-end collisions or impact events.
Solution Approach 2:
The frame rail is designed with differentiated local properties: a crushable section with reduced wall thickness for energy absorption, and stronger sections for structural support. The trailer hitch mount extends into the hollow frame rail to distribute loads across multiple points, while the face plate provides a rigid mounting surface. This local quality differentiation allows simultaneous energy absorption and structural strength.
2Strength
If the trailer hitch mount extends into the hollow frame rail, then load distribution across multiple points is improved, but device complexity increases
Solution Approach 1:
The patent integrates the trailer hitch mount, collar, and face plate into a unified assembly where the mount extends through the hollow frame rail and is secured by the collar and face plate. This merging of components creates efficient load paths that distribute forces across multiple attachment points (the collar surrounding the mount and the face plate providing additional support), enhancing load-carrying capacity while maintaining structural coherence.
3Reliability
If a crushable frame rail section is added for energy absorption, then safety during impacts is improved, but manufacturing complexity increases
Solution Approach 1:
The frame rail is manufactured with a localized crushable section featuring reduced wall thickness in specific areas. This allows the rail to be produced using standard forming processes with localized modifications, rather than requiring entirely different manufacturing methods. The crushable section is strategically positioned to absorb impact energy while the rest of the frame rail maintains its structural integrity.
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 enhances load-carrying capacity, reduces stack-up during impacts, and increases the crushable length of the frame rail, thereby improving safety and structural integrity.
Implementation Method 1
the frame rail may include a crushable section extending in the vehicle-forward direction from the collar, the crushable section being crushable relative to a section of the frame rail along which the trailer hitch mount extends in the hole
Data Source
AI summary
A vehicle includes a vehicle frame. The vehicle frame includes a frame rail elongated along a vehicle-longitudinal axis that defines a hole. The vehicle includes a trailer hitch mount supported by the frame rail. The vehicle includes a face plate supported by the trailer hitch mount that defines an opening extending through the face plate that is aligned with the hole of the frame rail. The trailer hitch mount extends through the opening and is completely surrounded by the face plate. The trailer hitch mount extends into the hole of the frame rail along the vehicle-longitudinal axis.