Vehicle Body Joint Structure for Frontal Impact Strength
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Solution Overview
Problem
The vehicle body of purpose-built vehicles (PBVs) with a box-type design has weak front frame strength and inadequate impact absorption performance in front collisions due to its design, which compromises safety.
Innovation Solution
A vehicle body coupling structure that enhances the joint strength between the underbody and upper body by incorporating a front back beam assembly, crash box, and multiple mounting and coupling parts made of aluminum and steel materials, distributing collision loads across various sections to improve stability and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a box-type design is used for the front vehicle body to achieve large indoor space, then the interior volume is improved, but the front frame strength and impact absorption performance deteriorate
Solution Approach 1:
The front vehicle body is segmented into a upper body and an underbody (rolling chassis) that can be independently designed and assembled. The underbody includes a front back beam assembly with crash boxes that provide structural strength, while the upper body can be optimized for interior space without compromising the overall front frame strength.
Solution Approach 2:
The front back beam assembly uses composite construction combining aluminum alloy crash boxes with steel or aluminum back beams. This composite structure provides both the weight benefits of aluminum and the strength of steel, achieving high specific strength while maintaining large interior space capability.
2Volume of moving object
If a box-type design is used for the front vehicle body to achieve large indoor space, then the interior volume is improved, but the impact absorption performance deteriorates
Solution Approach 1:
Crash boxes are installed at the front of the underbody structure before collision occurs. These energy-absorbing structures are designed to deform in controlled ways during frontal impacts, absorbing collision energy and protecting the passenger compartment and critical components from damage.
Solution Approach 2:
The crash boxes convert the harmful impact force from collisions into beneficial energy absorption through controlled deformation. The aluminum alloy crash boxes are designed to crumple in predictable ways, transforming the harmful kinetic energy of collision into deformation energy, thereby protecting the overall vehicle structure and occupants.
3Ease of manufacture
If the upper body is mounted on the underbody with simple coupling to ease assembly, then the ease of manufacture is improved, but the joint strength between underbody and upper body deteriorates
Solution Approach 1:
The coupling system is segmented into multiple independent coupling points distributed along the sides of the vehicle. Each coupling point includes corresponding mounting parts on both the underbody and upper body, allowing for modular assembly while distributing structural loads across multiple joints rather than relying on a single weak coupling point.
Data Source
AI summary
An embodiment vehicle body coupling structure of a vehicle that includes an underbody and an upper body coupled to the underbody includes a front back beam assembly provided on a front side of the underbody, a first mounting part provided on a front side member of the upper body and coupled with the front back beam assembly, and a first body coupling part provided on the front back beam assembly and engaged with the first mounting part.