Vehicle Front Structure with Upper Frame Reinforcers for Collision Energy Distribution

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing vehicle body front part structures fail to effectively absorb collision energy in full-overlap and under-ride collisions, potentially deforming the inverter unit, which is critical for preventing sudden abnormal reactions in hybrid and electric vehicles.

Innovation Solution

A vehicle body front part structure comprising a radiator panel frame, front side frames, a front cross member, upper frame reinforcing members, and radiator panel reinforcing members forms a robust three-dimensional framework that absorbs collision energy through controlled deformation, distributing it across the front chamber components to prevent inverter unit deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

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

Engineering Contradiction:

Improvecollision energy absorption capabilityVSAvoidapplicability across different collision types

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent transitions from a planar front bumper reinforcement structure to a three-dimensional framework by adding upper frame reinforcing members that extend upward and backward from the front cross member. This vertical dimension allows the structure to absorb collision energy from multiple collision types (full-overlap, under-ride, and small-overlap) simultaneously, resolving the contradiction between reliability in specific collision types and adaptability across all collision types.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The front part structure is divided into multiple functional segments: the front cross member for small-overlap collisions, the upper frame reinforcing members for full-overlap and under-ride collisions, and the radiator panel frame for overall structural support. Each segment is optimized for specific collision scenarios, enabling the entire structure to handle various collision types effectively.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the inverter unit is protected from deformation, then sudden abnormal reactions are prevented, but collision energy must be absorbed elsewhere

Engineering Contradiction:

Improveinverter unit integrityVSAvoidstructural strength requirements

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The upper frame reinforcing members act as intermediary elements between the front cross member and the cabin structure. These members absorb and distribute collision energy through their bent parts and strategic positioning, protecting the inverter unit located between the front cross member and the cabin from deformation while maintaining the necessary structural strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The upper frame reinforcing members are positioned and configured in advance to cushion the inverter unit from collision forces. The bent parts of these members are designed to deform preferentially during collision, absorbing energy before it reaches the inverter unit, thereby preventing sudden abnormal reactions while maintaining structural integrity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a robust three-dimensional framework is created, then collision energy is distributed effectively, but structural complexity increases

Engineering Contradiction:

Improvecollision energy distributionVSAvoidframework structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The upper frame reinforcing members serve multiple functions: they strengthen the front part structure, absorb collision energy in full-overlap and under-ride collisions, and protect the inverter unit. This multi-functionality allows the structure to achieve effective collision energy distribution without proportionally increasing complexity, as a single component performs multiple protective roles.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the front cross member, upper frame reinforcing members, and radiator panel frame into an integrated three-dimensional framework. By combining these elements into a unified structure with strategic joinings, the design achieves effective collision energy distribution across multiple components while avoiding the complexity of separate, isolated reinforcement systems.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240300581A1Vehicle body front part structure

Publication Date: 2024.09.12 SUBARU CORP

AI summary

A vehicle body front part structure includes: a radiator panel frame, front side frames; an inverter unit; a front cross member extending in the vehicle width direction ahead of the inverter unit; upper frame reinforcing members in a pair extending in a vehicle longitudinal direction on an upper side of the vehicle; and radiator panel reinforcing members forming a V shape pointing in the vehicle longitudinal direction. In each radiator panel reinforcing member, an apex is joined to an outer part of an upper end of the radiator panel frame; a rear end of an upper side member is joined to a front side part of a bent part of the upper frame reinforcing member; and a rear end of a lower side member is joined to an upper surface of the front side frame ahead of a joint part joining the front cross member and the front side frame.