Vehicle Front Side Frame with Multiple Break Points

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Solution Overview

Problem

Existing vehicle body structures face challenges in effectively distributing and absorbing impact loads during oblique collisions, often concentrating force on specific points, which can lead to inadequate energy absorption and potential damage.

Innovation Solution

A vehicle body structure design featuring a front side frame with strategically positioned break points, a reinforcing frame, and a bumper beam extension, where the impact load is transmitted through a U-shaped frame configuration to distribute force across multiple break points, preventing concentration and enhancing energy absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single fragile section is provided for impact absorption, then the structure is simple, but the impact load concentrates on that single point causing inadequate energy absorption

Engineering Contradiction:

Improveframe structureVSAvoidimpact energy absorption

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The front side frame is divided into multiple sections with three distinct break points (first, second, and third break points) along its length. Each break point can independently bend under impact load, segmenting the energy absorption process into multiple stages rather than concentrating all deformation at a single location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the frame are designed with varying geometric properties to create controlled weak points. The break points have specific cross-sectional configurations that make them more susceptible to bending than other sections, allowing localized deformation at predetermined locations while maintaining overall structural integrity.

Inventive Principle:

Principle #3Local quality

2Strength

If a gusset is used to couple the frame, then the first break point is reinforced, but the impact load concentrates on the first break point during oblique collision

Engineering Contradiction:

Improveframe coupling strengthVSAvoidimpact load distribution

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The frame cross-section is designed with asymmetric properties along its length. The break points have reduced cross-sectional area or modified geometry compared to other sections, creating intentional weak points that will bend first under load. This asymmetric design ensures controlled deformation at specific locations rather than uniform stress distribution.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The frame geometry is pre-configured with break points that have lower bending resistance before collision occurs. This preliminary design ensures that during impact, these predetermined locations will bend in the intended sequence (second, then first, then third break points), guiding the deformation process rather than allowing random failure modes.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If the frame structure is simplified for ease of manufacture, then production cost decreases, but the ability to absorb impact energy through controlled bending is reduced

Engineering Contradiction:

Improveframe productionVSAvoidimpact energy absorption reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The frame is segmented into distinct sections with clear break points, allowing each section to be manufactured using standard processes while the overall assembly achieves complex energy absorption behavior. The segmentation enables modular manufacturing approaches.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cross-sectional parameters (area, moment of inertia) are varied along the length of the frame to create break points with different bending characteristics. These parameter changes are achieved through geometric modifications rather than material changes, maintaining ease of manufacture while achieving reliable controlled deformation.

Inventive Principle:

Principle #35Parameter changes

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 improves energy absorption during oblique collisions by ensuring that impact loads are distributed across multiple break points, reducing the risk of damage and enhancing the structural integrity of the vehicle body.

Implementation Method 1

the front side frame is bent at first through third break points... the bending of the first to third break points improves the absorption of impact energy

Methodology Applied

Scientific EffectEnergy absorption through bending: Deformation

Data Source

PatentUS9902431B2Vehicle body structure

Publication Date: 2018.02.27 HONDA MOTOR CO LTD

AI summary

A front side frame has a closed section through coupling between a frame main body having a U-shaped section that opens to the outboard side and a back plate that closes the opening of the frame main body. A reinforcing frame having a U-shaped section that opens to the outboard side in a frame widened section of the front side frame is fitted to the inside of the frame main body. A vehicle-width-direction inboard wall of the reinforcing frame is coupled to a vehicle-width-direction inboard wall of the frame main body at a branch point. A portion of the vehicle-width-direction inboard wall in front of the branch point separates from the vehicle-width-direction inboard wall of the frame main body to the outboard side. The opening of the reinforcing frame is closed by the back plate in the front section of the frame widened section.