Adjustable Headlamp Bracket for Pedestrian Safety

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Solution Overview

Problem

Existing headlamp module mounting systems face challenges in managing reaction forces during collisions and assembly tolerances, leading to potential pedestrian injuries and increased repair costs due to rigid structures and variability in vehicle dimensions.

Innovation Solution

A sandwich structure with adjustable mounting brackets between ribs allows for fore/aft and up/down position adjustments, enabling sliding movement under impact forces while maintaining a rigid attachment, thus absorbing collision energy and compensating for assembly tolerances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a rigid headlamp module and mounting structure are used, then the headlamp module maintains stable position and structural integrity, but the hood crumple zone size is limited and pedestrian injury risk increases during collision

Engineering Contradiction:

Improvestructural integrityVSAvoidpedestrian injury risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The mounting system is segmented into a rigid headlamp module, a compliant mounting structure with breakaway features, and a vehicle support structure. This segmentation allows the headlamp module to remain structurally intact while the mounting structure deforms to increase hood crumple zone size and reduce pedestrian injury risk during collision.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If breakaway components are used in headlamp mounting, then the hood crumple zone size increases and pedestrian safety improves, but force control becomes poor and repair costs increase

Engineering Contradiction:

Improvepedestrian safetyVSAvoidrepair costs

Core Design Contradiction:

Object-affected harmful factorsVSEase of repair

Solution Approach 1:

The mounting structure incorporates breakaway features designed as sacrificial elements that can be easily replaced. These inexpensive components are intended to fail during collision to protect pedestrians, while the expensive headlamp module remains intact. The simple breakaway design reduces repair costs compared to repairing damaged headlamp modules.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If multiple distinct interconnection points are used for headlamp module mounting, then the headlamp module is securely attached to the vehicle, but assembly difficulties arise due to dimensional variability and tolerance accumulation

Engineering Contradiction:

Improveattachment securityVSAvoidassembly difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The mounting system uses adjustable mounting positions with compliance features that allow the headlamp module to adapt to dimensional variability in the vehicle support structure. The mounting structure can deform or adjust its position to accommodate tolerance variations, making assembly easier while maintaining secure attachment through multiple connection points.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS8814394B2Adjustable headlamp attachment with pedestrian protection

Publication Date: 2014.08.26 FORD GLOBAL TECH LLC

AI summary

A bracket coupling a headlamp module to a fixed structure is sandwiched between two ribs that constrain the bracket in only the cross-car direction. Internal clearances in the bracket or rib features for accepting attachment bolts are designed to provide fore/aft and up/down position adjustments. The sandwich structure can be locked in (i.e., compressed) for a rigid, final attachment to the vehicle which will nevertheless allow sliding of the bracket within the ribs when subjected to the forces corresponding to an impact.