Motor Vehicle Structural Frame Cross-Brace Design
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Solution Overview
Problem
The transition from internal combustion engines to electric traction motors in vehicles reduces the need for a rigid bulkhead, but maintains the requirement for structural rigidity and safety, while also desiring increased space for occupants without altering the external vehicle size.
Innovation Solution
A structural frame design featuring a pair of spaced pillars joined at an upper region to a roof crossmember and a structural cross-brace that supports suspension connectors, allowing the cross-brace to project beyond the connectors and be accommodated within the occupant compartment, thereby maintaining structural stiffness and space without the need for a bulkhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid bulkhead is used to separate engine compartment from occupant compartment, then structural rigidity and protection are improved, but occupant space is reduced
Solution Approach 1:
The patent removes the traditional bulkhead component entirely from the vehicle structure. Instead of separating the engine and occupant compartments with a rigid wall, the design integrates the suspension connectors directly into the structural frame, allowing the engine compartment space to be eliminated while maintaining structural integrity through the cross-brace and pillar configuration.
Solution Approach 2:
The structural cross-brace serves multiple functions simultaneously: it provides structural rigidity to resist torsional loading, supports the suspension connectors, and defines the occupant compartment boundaries without requiring a separate bulkhead. This multi-functional design eliminates the need for dedicated noise and heat barriers while maintaining structural performance.
2Stability of the object's composition
If structural cross-brace is positioned to support suspension connectors, then structural stiffness is improved, but occupant compartment space may be obstructed
Solution Approach 1:
The structural cross-brace is positioned in the transverse dimension (across the vehicle width) rather than extending into the longitudinal occupant space. By arranging the cross-brace to connect pillars at their rear surfaces and position suspension connectors laterally, the design maintains structural stiffness while keeping the longitudinal path through the occupant compartment clear and unobstructed.
Solution Approach 2:
The cross-brace configuration uses asymmetric positioning where the brace extends beyond the suspension connectors on the engine compartment side but remains clear of the occupant compartment interior. This asymmetric arrangement allows the structural element to perform its support function while being invisible to occupants and not interfering with headroom or legroom.
3Strength
If traditional bulkhead and cowl structure is used, then structural reinforcement is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the functions of the bulkhead, cowl, and suspension support structure into a single integrated structural frame design. The structural cross-brace combines the roles of the traditional bulkhead (compartment separation), cowl (windscreen support), and suspension mounting structure, eliminating multiple separate components and reducing manufacturing complexity while maintaining structural reinforcement.
Data Source
AI summary
Embodiments of the present invention provide a structural frame for a body of a motor vehicle, the structural frame defining, at least in part, an occupant compartment of the vehicle, the structural frame comprising a pair of spaced pillars joined together at an upper region of each pillar to a roof crossmember and further joined together at respective points below the roof crossmember to a structural cross-brace, the structural cross-brace is further arranged to support a pair of spaced apart vehicle suspension connectors and, wherein the structural cross-brace projects from the pillars beyond the suspension connectors so that the space in the occupant compartment between the pillars is substantially unobstructed by the structural cross-brace and, at least a portion of the structural cross-brace is accommodated within the occupant compartment.