Angled Vehicle Deflector Assembly for Small Overlap Impacts
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Solution Overview
Problem
Existing vehicle designs struggle to effectively manage energy during small overlap or offset frontal impacts, which primarily affect the outer portion of the vehicle and lack efficient load distribution and deformation control.
Innovation Solution
A structural assembly featuring angled deflectors and internal bulkheads within the vehicle frame, which are angled forward and secured to the bumper structure, allowing for variable cross-sections and internal cavities, facilitating load transfer and lateral deflection during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional vehicle structures are used for small overlap impacts, then the primary load carrying structure is not affected, but the outer portion of the vehicle cannot effectively manage energy with controlled deformation
Solution Approach 1:
The vehicle structure is segmented into distinct functional zones: an outer crushable structure (deflector) that absorbs initial impact energy, and an inner primary load carrying structure that maintains structural integrity. The deflector is separated from the main frame rails, allowing independent deformation behavior that manages energy absorption while protecting critical components.
Solution Approach 2:
The deflector acts as an intermediary element between the bumper and the primary load carrying structure. It intercepts and absorbs impact forces before they reach the main frame, serving as a protective mediator that controls deformation and protects the underlying structural components from direct impact loads.
2Object-affected harmful factors
If the deflector is positioned further forward relative to the suspension system, then impact loads are redirected away from critical components, but the structural complexity increases
Solution Approach 1:
The deflector is integrated with the bumper structure through attachment mechanisms, merging two protective elements into a unified front-end assembly. This combination allows the deflector to be positioned forward for optimal protection while sharing mounting points and structural support with the existing bumper, thereby reducing overall structural complexity.
Solution Approach 2:
The deflector serves multiple functions: it redirects impact loads away from critical components, provides a mounting surface for the bumper, and contributes to the overall structural rigidity of the front end. This multi-functionality reduces the need for additional separate protective structures, simplifying the overall assembly despite the forward positioning.
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
Enhances the vehicle's ability to distribute and deflect impact loads laterally, protecting critical components like the battery structure by redirecting forces away from the vehicle's center, thereby improving energy management during small overlap collisions.
Implementation Method 1
Each deflector is angled in a forward direction of the vehicle from a location adjacent to the cross beam
Implementation Method 2
Each deflector of the pair of deflectors has a variable cross-section; the rear end of each deflector has a cross-sectional area that is greater than a cross-sectional area of the front end of each deflector
Data Source
AI summary
A structural assembly for a vehicle includes a left frame, a right frame, a cross beam, a bumper structure, and a pair of deflectors. The left frame rail and the right frame rail are spaced apart from each other and extend in a longitudinal direction of the vehicle. The cross beam extends in a transverse direction and connects the left and right frame rails to each other. The bumper structure extends in the transverse direction and is secured to front ends of the left frame rail and the right frame rail. Each deflector includes a rear end secured to an outboard wall of a respective left and right frame rail and a front end secured to a respective end of the bumper structure. Each deflector is angled in a forward direction of the vehicle from a location adjacent to the cross beam.