Vehicle Front Structure Load Distribution via Extension Frame Buckling
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Solution Overview
Problem
Existing vehicle front portion structures face challenges in achieving optimal shock absorption during frontal collisions while minimizing vehicle weight, as they often require complex designs and additional reinforcements that increase weight, and fail to efficiently distribute collision loads between front side frames and extension frames.
Innovation Solution
A vehicle front portion structure where the load from the extension frame is transferred to both the front side frame and suspension cross member, with the extension frames being designed to buckle under collision, distributing the load and reducing the need for increased rigidity or reinforcements, allowing the front side frames to absorb shock through axial compression without complex shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If front side frames are designed with complex shapes and reinforcements to achieve optimal shock absorption characteristics, then shock absorption performance is improved, but vehicle weight increases
Solution Approach 1:
The front portion structure is segmented into multiple functional components: extension frames for early peak formation, front side frames for axial compression, and suspension cross members for load distribution. This segmentation allows each component to be optimized for its specific function rather than requiring the entire structure to be over-engineered, reducing overall weight while maintaining shock absorption performance
Solution Approach 2:
The patent introduces extension frames that extend in the front-to-rear direction below the front side frames, adding a dimensional element to the shock absorption system. This allows the collision load to be distributed across multiple members in three-dimensional space, achieving optimal deceleration characteristics without requiring excessive reinforcement of individual components
2Reliability
If extension frames are given high strength to be resistant to light collision, then the extension frame can form peak during early stages, but the suspension cross member and supporting members need to be increased in rigidity or reinforced, resulting in increased vehicle weight
Solution Approach 1:
The extension frames act as intermediary elements that absorb and distribute collision loads during early stages of impact. By positioning these frames to extend forward below the front side frames, they serve as mediators that transfer and disperse forces to multiple suspension cross members, preventing the need for excessive reinforcement of any single component
Solution Approach 2:
Different members are designed with different rigidity characteristics suited to their specific functions: extension frames have controlled rigidity for peak formation, front side frames are optimized for axial compression, and suspension cross members are designed for load distribution. This localized optimization avoids the need for uniform high-strength design throughout the entire structure
3Strength
If load from extension frame is transferred to suspension cross member only, then the suspension cross member needs to be increased in rigidity, but transferring load to both front side frame and suspension cross member distributes the load efficiently
Solution Approach 1:
The patent merges the load-bearing functions of multiple members: front side frames, extension frames, and suspension cross members work together as an integrated shock absorption system. The connection between extension frames and front side frames creates a combined structural path that distributes collision loads efficiently across multiple components, reducing the complexity burden on any single member
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
This design effectively reduces vehicle weight by distributing collision loads efficiently, ensuring peak deceleration during early stages of a collision without the need for additional reinforcements, and facilitates synchronization of deformation between front side frames and extension frames for enhanced shock absorption.
Implementation Method 1
the extension frames being designed to buckle under collision, distributing the load
Implementation Method 2
front portion structure that is deformed into a predetermined configuration to absorb shock caused by a frontal collision
Implementation Method 3
the front side frame merely needs to serve to absorb shock through axial compression
Implementation Method 4
the front side frame needs to be axially compressed with reliability without being affected by the extension frame
Data Source
AI summary
Front side frames 1 of a vehicle are each vertically connected through a corresponding one of joint members 7 to a cross member 2 configured to support a suspension arm below the front side frame 1. The joint members 7 are each coupled to a back end of a corresponding one of extension frames 4. This allows the front side frames 1 and the cross member 2 to share the load experienced by the extension frames 4 in a frontal collision of the vehicle.