Vehicle Front Load Distribution via Overlapped Connection Members
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Solution Overview
Problem
The existing vehicle front structure connection systems are inefficient in distributing impact loads during frontal collisions, leading to deformation and increased weight and manufacturing costs due to the complexity of approximately 24 members and stiffeners.
Innovation Solution
A load distribution structure comprising a pair of front side members, side sills, front pillars, connection members, and a dash crossmember, where each component is strategically overlapped and joined to absorb and distribute impact loads through a network of reinforcing ribs and abutting walls, reducing the number of components and weight while enhancing crashworthiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connection structure with approximately 24 members and stiffeners is used to maintain stiffness, then structural strength is improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate members and stiffeners into an integrated connection structure. The connection structure includes a main body portion with multiple connection portions formed integrally, eliminating the need for separate stiffeners and reducing the total number of members from approximately 24 to a unified structure, thereby reducing weight while maintaining structural strength
Solution Approach 2:
The connection structure serves multiple functions simultaneously: it provides structural support, connects different vehicle components (front side member, side sill, front pillar), and maintains stiffness through its integrated design with multiple connection portions. This multi-functionality eliminates the need for separate dedicated stiffener components
2Ease of manufacture
If flange coupling is used to connect the connection structure to front side members and front pillars, then ease of assembly is improved, but impact load distribution efficiency deteriorates
Solution Approach 1:
The connection structure incorporates locally optimized features including reinforcing ribs at critical stress areas, specifically positioned connection portions with enhanced geometry, and strategically placed reinforcement portions that locally strengthen the structure without requiring a complete redesign of the entire connection system
Solution Approach 2:
The connection structure utilizes composite construction combining different material properties and structural configurations - the main body portion integrates multiple connection portions with varying geometries and reinforcement patterns, creating a composite structure that optimizes both assembly ease and impact load distribution
3Stability of the object's composition
If a complex connection structure with multiple members is used, then structural stability is improved, but device complexity increases
Solution Approach 1:
The connection structure is segmented into distinct functional portions: a main body portion, multiple connection portions (first, second, third connection portions), reinforcing ribs, and reinforcement portions. This segmentation allows each portion to be optimized for its specific function while being formed as an integrated structure, reducing overall complexity
Data Source
AI summary
A load distribution structure for a vehicle includes: a pair of front side members which are spaced apart from each other in a width direction of the vehicle on a front side of the vehicle; a pair of side sills respectively connected to the front side members; a pair of front pillars respectively connected to front ends of the side sills; a pair of connection members each connecting the front side members and the corresponding side sill along a longitudinal direction of the vehicle; and a dash crossmember transversely connected to the pair of connection members. In particular, each front side member is overlapped and joined to the corresponding connection member, and end portions of the dash crossmember are overlapped and joined to the connection members, respectively.