Vehicle Front Structure Energy Absorption via Segmentation

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Solution Overview

Problem

Existing vehicle body front part structures fail to effectively absorb collision energy in full-overlap and under-ride collisions, potentially deforming critical components like the inverter unit during frontal collisions.

Innovation Solution

A vehicle body front part structure comprising a radiator panel frame, front side frames, sub frames, upper frame reinforcing members, and joint members, which distribute and absorb collision energy through controlled deformation, preventing damage to the inverter unit across various collision types.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional front bumper reinforcement structure is used, then small-overlap collision energy is absorbed, but full-overlap and under-ride collision energy is not effectively absorbed

Engineering Contradiction:

Improvecollision energy absorption capabilityVSAvoidapplicability across collision types

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The front part structure is divided into multiple independent components: upper frame members, lower frame members, front side members, and intermediate members. Each segment can deform independently to absorb collision energy from different directions and collision types, making the structure adaptable to full-overlap, small-overlap, and under-ride collisions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The structure extends in multiple spatial dimensions with upper and lower frame members positioned at different heights, and intermediate members connecting them. This three-dimensional configuration enables the structure to absorb collision energy from various directions (frontal, lateral, and angular impacts) effectively.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the front part structure is made more rigid to protect the inverter unit, then component integrity is maintained, but collision energy absorption capability is reduced

Engineering Contradiction:

Improvestructural rigidityVSAvoidcollision energy absorption

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

Different parts of the structure have different rigidity characteristics. The intermediate members and connection points provide localized reinforcement to protect the inverter unit, while the frame members are designed with controlled deformation zones that can absorb energy through elastic and plastic deformation, achieving both protection and energy absorption.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The structure incorporates predetermined deformation paths and energy-absorbing zones in the frame members. During collision, these zones deform in advance to absorb impact energy before the force reaches the inverter unit, protecting it while efficiently dissipating collision energy.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If a single coupling body structure is used, then manufacturing is simplified, but adaptability to different collision types is limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcollision type coverage

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Instead of a single coupling body, the structure uses multiple separate members (upper frame members, lower frame members, front side members, intermediate members) that are assembled together. This segmentation allows each component to be optimized for specific collision scenarios while maintaining overall manufacturing efficiency through modular assembly.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The structure effectively absorbs collision energy in full-overlap, small-overlap, and under-ride collisions, maintaining the integrity of the inverter unit by distributing energy through controlled deformation and maintaining structural rigidity, thereby preventing deformation of the inverter unit.

Implementation Method 1

distribute and absorb collision energy through controlled deformation

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

absorbs collision energy in full-overlap, small-overlap, and under-ride collisions

Methodology Applied

Scientific EffectEnergy absorption: Absorption (physical)

Data Source

PatentUS20240308594A1Vehicle body front part structure

Publication Date: 2024.09.19 SUBARU CORP

AI summary

A vehicle body front part structure includes a radiator panel frame, front side frames in a pair, sub frames, upper frame reinforcing members in a pair, radiator panel reinforcing members, and joint members. The radiator panel frame includes projections protruding toward the vehicle rear side. The front side frames are joined to the radiator panel frame at front ends. The sub frames are joined to the radiator panel frame at front ends. The upper frame reinforcing members are bent downward toward the vehicle front side to have slope parts and are joined to the radiator panel frame at lower front ends. The radiator panel reinforcing members respectively have first ends joined to an upper side member of the radiator panel frame and second ends joined to upper front sides of the slope parts. The joint members respectively join the upper frame reinforcing members and the front side frames.