Upper Cross-Member Layout for Small Overlap Front Impacts

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Solution Overview

Problem

Existing motor vehicle structures struggle to effectively deform during small overlap frontal impacts without compromising the structural integrity and occupant safety.

Innovation Solution

A motor vehicle front structure incorporating an upper cross-member with attachment brackets sandwiched between longitudinal structural beams and deformation boxes, enhancing lateral rigidity and controlled deformation of both boxes during impacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If an upper cross-member is added to rigidify the front structure, then lateral rigidity and structural stability are improved, but the deformation capability of longitudinal structural beams is reduced

Engineering Contradiction:

Improvelateral rigidityVSAvoiddeformation capability

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The attachment brackets are designed with local quality differentiation: the first bracket attaches to the longitudinal beam at a position optimized for deformation, while the second bracket attaches to the deformation box at a position optimized for rigidity. This allows different parts of the same component to serve different functions - the longitudinal beam deforms locally to absorb energy while the upper cross-member maintains overall lateral rigidity through its rigid connections to deformation boxes.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If existing attachment elements are modified to integrate the upper cross-member, then structural integration is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural integrationVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The upper cross-member is segmented into distinct components: the cross-member body and separate attachment brackets. The brackets are further segmented into first and second brackets that attach to different elements (longitudinal beam and deformation box respectively). This segmentation allows each component to be manufactured independently using existing processes and then assembled, avoiding the need to modify existing attachment elements while achieving full structural integration.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12606250B2Front structure of a motor vehicle comprising an upper cross-member and vehicle comprising such a front structure

Publication Date: 2026.04.21 STELLANTIS AUTO SAS

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.