Vehicle Front-End Module Support Structure With Embedded Arms
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Solution Overview
Problem
Existing front panel module support structures in motor vehicles are inadequate in protecting devices during frontal collisions, as current reinforcement methods, such as straight reinforcements and reinforcement plates, deteriorate and fail to ensure the bonnet lock's strength, leading to potential bonnet opening during impacts.
Innovation Solution
A support structure comprising a lower crosspiece, side uprights, and an upper crosspiece made of plastic material with embedded metallic support arms and ribs, where the support arms are connected to the reinforcement plate and embedded in the network of ribs, providing enhanced rigidity and protection without requiring overmolding, and featuring connection elements like riveted fasteners for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If straight reinforcements or reinforcement plates are added to the support structure, then the bonnet lock strength is improved, but the reinforcements are damaged during frontal collision and fail to protect the bonnet lock
Solution Approach 1:
The support arms are nested within the volume of the plastic support structure, specifically received within recesses formed in the crossmembers. This nesting arrangement allows the metal support arms to be protected by the surrounding plastic structure during collision, preventing direct damage to the reinforcements while maintaining bonnet lock strength.
Solution Approach 2:
The support structure combines plastic material (crossmembers with recesses) and metallic material (support arms) to create a composite structure. The plastic provides external protection and structural integration, while the metal provides internal reinforcement for bonnet lock strength, resolving the contradiction between strength enhancement and protection reliability.
2Ease of manufacture
If the support structure is made entirely of robust plastic material, then it complies with safety regulations, but it lacks sufficient rigidity and strength to protect devices during frontal collision
Solution Approach 1:
The invention combines plastic crossmembers with embedded metal support arms to create a composite structure. The plastic material maintains ease of manufacture and compliance with safety regulations, while the metallic support arms provide the additional rigidity and strength needed for collision protection, resolving the contradiction between manufacturability and protective strength.
Solution Approach 2:
Instead of making the entire support structure from high-strength metal (which would be difficult to manufacture), the invention applies metal support arms only in specific locations where additional strength is needed, while the rest of the structure remains in plastic. This localized reinforcement maintains manufacturing ease while providing necessary collision protection strength.
3Strength
If reinforcement plates are positioned on the front side of the support structure, then they connect the hood latch area to the bumper beam, but they are impacted during collision and fail to guarantee hood latch strength
Solution Approach 1:
The support arms are nested within recesses in the plastic crossmembers, positioning them inside the protected volume of the main structure rather than on the external front surface. This nested arrangement shields the metal reinforcements from direct collision impact while they continue to provide structural support for the hood latch, resolving the contradiction between strength provision and impact resistance.
Data Source
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AI summary
The invention relates to a supporting structure (10) for a front-end module of a motor vehicle, said supporting structure comprising a lower crossmember (13), a first side post (11), a second side post (12) and an upper crossmember (14). According to the invention, the supporting structure (10) comprises a first (40, 140, 240) and a second (50, 150, 250) supporting arm received within the supporting structure (10), the first supporting arm (40, 140, 240) being connected via the first end (41, 141, 241) thereof to the first side post (11) and via the second end (42, 142, 242) thereof to the upper crossmember (14), and/or the second supporting arm (50, 150, 250) being connected via the first end (51, 151, 251) thereof to the second side post (12) and via the second end (52, 152, 252) thereof to the upper crossmember (14). The invention also relates to a front-end module comprising such a supporting structure.