Motor Vehicle Front Structure Composite Stiffeners
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Solution Overview
Problem
The front part of a motor vehicle's structure faces challenges in reconciling weight reduction, compact architecture, maximum impact absorption, and simple assembly, while meeting stringent safety and performance requirements, particularly in frontal impacts, and conventional designs are heavy and costly due to numerous metal parts.
Innovation Solution
A structural assembly comprising an outer and inner shell joined to form hollow longitudinal stiffeners, with extensions that fix to the front crossmember using screws, simplifying assembly and optimizing weight reduction through composite materials, allowing for efficient energy absorption and force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal parts assembly is used for front block structure, then structural strength and impact resistance are achieved, but vehicle weight increases significantly
Solution Approach 1:
The patent applies composite materials (specifically thermoplastic composite materials) to manufacture the front block structure, replacing conventional metal parts. This composite material approach maintains the required structural strength and impact resistance while significantly reducing vehicle weight, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent merges multiple separate metal components into a single integrated front block structure manufactured from one piece of composite material. This consolidation eliminates the need for assembling multiple parts while maintaining structural integrity, thereby reducing weight without compromising strength.
2Strength
If multiple metal parts are assembled to form front block structure, then structural requirements are met, but manufacturing and assembly costs increase
Solution Approach 1:
The patent combines multiple separate metal parts into a single integrated front block structure made from thermoplastic composite material. This merging eliminates the need for complex assembly processes and multiple manufacturing steps, significantly reducing both manufacturing and assembly costs while maintaining structural integrity.
Solution Approach 2:
The patent changes the material parameter from metal to thermoplastic composite material, which enables different manufacturing approaches (such as molding) that are more cost-effective for complex geometries compared to traditional metal fabrication and assembly processes.
3Weight of moving object
If front block dimensions are reduced for weight savings, then vehicle consumption decreases, but impact absorption capacity is compromised
Solution Approach 1:
The patent uses thermoplastic composite materials that provide high strength-to-weight ratio, enabling the front block to be lighter while maintaining or even improving energy absorption capacity. The composite material's inherent properties allow for reduced dimensions without compromising impact protection.
Solution Approach 2:
The patent implements local reinforcement strategies within the front block structure, varying the density and fiber orientation of the composite material in different zones to optimize energy absorption where needed while minimizing weight in less critical areas.
Data Source
Figure 1~4
Figure 5~8c
AI summary
The invention relates to a front portion (1) of the structure of a motor vehicle comprising a structural assembly (2) and at least one front crossmember (3), characterised in that the structural assembly (2) comprises at least one outer shell (5, 6) and at least one inner shell (7, 8) contiguous to one another, the shells (5-8) being shaped so as to define, on either side of the vehicle, at least one stiffener (9-10) in the general shape of a sleeve extending substantially in the longitudinal direction (X) of the vehicle, each stiffener (9-10) being closed, at an end resting against the front crossmember (3), by a first extension (18) from one of the two shells defining same, a second extension (20) from the other one of the two shells defining same being stacked at least partially on the first extension (18), said extensions (18) comprising means for attachment to said front crossmember.