Unitary Interface Joint for Motor Vehicle Crash Load Management
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Solution Overview
Problem
Existing interface joints between a crush box and a frame rail in motor vehicles often result in structural discontinuities and require additional fasteners or welding, complicating assembly and potentially increasing mass.
Innovation Solution
A unitary interface joint with plate and flange portions, designed to engage the crush box and frame rail without additional fasteners or welding, and an engine cradle attachment portion, cast from aluminum, iron, or magnesium alloys, minimizing mass and simplifying assembly by providing a common interface for crash load management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners and welding are used to connect the energy absorbing device to the crush box and frame rail, then the connection strength is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The interface joint integrates multiple connection functions into a single unitary component that simultaneously connects the energy absorbing device, crush box, and frame rail. This eliminates the need for separate fasteners and welding operations, reducing assembly complexity while maintaining connection strength through the integrated structural design.
Solution Approach 2:
The unitary interface joint serves multiple functions: it provides structural connection between different components, manages crash loads, and simplifies assembly operations. This multi-functional design replaces traditional multi-component assembly approaches, reducing both device complexity and assembly difficulty while maintaining necessary connection strength.
2Reliability
If additional fasteners and welding components are used, then the connection reliability is improved, but the added mass increases
Solution Approach 1:
By merging the interface joint into a single unitary component, the design eliminates redundant fasteners and welding materials, thereby reducing added mass while maintaining connection reliability through the integrated structural design that provides sufficient load-bearing capacity.
3Adaptability or versatility
If separate components are used to connect the crush box and frame rail, then the adaptability to different geometries is improved, but the structural discontinuities increase
Solution Approach 1:
The unitary interface joint merges multiple connection points into a single integrated component that provides continuous structural support. This eliminates gaps and discontinuities between separate components while maintaining adaptability to different geometries through the designed flange configurations that can accommodate various crush box and frame rail shapes.
Data Source
AI summary
An interface joint for a motor vehicle is provided that serves as a node to connect a longitudinal motor compartment frame rail, an energy absorbing device, referred to as a crush box, and an engine cradle. The interface joint is a unitary component having a plate portion, first and second flange portions, and an engine cradle attachment portion. The first flange portion extends longitudinally from the plate portion and is adapted for engagement with the crush box. The second flange portion extends longitudinally from the plate portion opposite the first flange portion and is adapted for engagement with the frame rail. The engine cradle attachment portion extends between the flange portions and is adapted for attachment to the engine cradle.