Upper Crossbar Mounting for Low-Overlap Front Impact Deformation
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Solution Overview
Problem
Existing motor vehicle structures struggle to efficiently deform during low-overlap frontal impacts without compromising the safety of vehicle occupants, particularly due to imbalances in deformation between structural elements.
Innovation Solution
A front structure with an improved upper cross member is integrated between longitudinal structural beams and deformation boxes, using fixing supports sandwiched between these elements, allowing for easy adaptation without modifying existing components, and featuring through openings and tubular elements for secure fixation, along with optional anti-crushing elements for enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an upper cross member is added to stiffen the front structure, then lateral rigidity is improved, but device complexity increases
Solution Approach 1:
The fixing supports are integrated within the space between the longitudinal structural beams and deformation boxes, nesting the cross member attachment mechanism within the existing structural envelope rather than adding external components
Solution Approach 2:
The upper cross member is divided into a cross member element and separate fixing supports, allowing the fixing supports to be positioned at optimal locations between the beams and boxes while keeping the cross member element simple and elongated
2Ease of manufacture
If the upper cross member is integrated into existing structure without modifications, then ease of manufacture is improved, but structural strength may be compromised
Solution Approach 1:
The fixing supports act as intermediary elements between the cross member and the existing structure (beams and boxes), providing secure attachment points without requiring modifications to the pre-existing components while maintaining structural integrity
Solution Approach 2:
The fixing supports are positioned at specific critical locations between the longitudinal beams and deformation boxes, concentrating the strengthening effect where it is most needed for low-overlap impact resistance
3Reliability
If fixing supports are positioned between longitudinal beams and deformation boxes, then balanced deformation is achieved, but device complexity increases
Solution Approach 1:
The fixing supports serve multiple functions: they attach the cross member to the structure, control the deformation pattern during impact, and provide a mounting point for the tubular elements, eliminating the need for separate components for each function
Data Source
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AI summary
The invention relates to a front structure (1) of a motor vehicle, comprising: - two longitudinal structural beams (10) having a generally elongate shape in a direction parallel to the longitudinal axis (X) of the vehicle; - two deformation boxes (14), each deformation box (14) being rigidly attached to one of the longitudinal structural beams (10), respectively; - an upper cross-member (18), the upper cross-member (18) comprising a cross-member element (180) that extends along a transverse axis (Y) of the vehicle, the cross-member element (180) being attached to the rest of the front structure (1) by means of two attachment brackets (182), each attachment bracket (182) being sandwiched between the corresponding longitudinal structural beam (10) and the deformation box (14), respectively.