Armrest Core Lattice for Side Impact Injury Reduction

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Solution Overview

Problem

Motor vehicle armrests face a challenge in balancing vertical strength with lateral yielding to prevent injury during side impact collisions, as they may be too stiff laterally and unyielding, potentially causing harm to occupants.

Innovation Solution

An armrest core with a lattice structure comprising void channel clusters defined by 3D shaped structures like skeletal ovoids, ellipsoids, polyhedra, and octahedra, aligned along a longitudinal axis, providing greater vertical strength while allowing lateral yielding, covered with a cushion and finish layer for added protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the armrest is made with substantial vertical strength to support loads, then the armrest can support vehicle occupant's arm weight, but the armrest becomes too stiff laterally and unyielding, increasing potential for injury from occupant impact

Engineering Contradiction:

Improvevertical strengthVSAvoidinjury risk from impact

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The lattice structure employs different geometric configurations and material densities in different regions of the armrest. Vertical struts are designed with higher strength characteristics to support load-bearing functions, while lateral regions incorporate more yielding structures that can deform during side impacts, thereby providing localized property optimization to resolve the contradiction between vertical strength and lateral yielding

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The armrest core utilizes a lattice structure with controlled flexibility that allows dynamic response to different types of loads. During normal use, the structure maintains rigidity for support, but during side impact collisions, the lattice can deform in a controlled manner to absorb impact energy, transforming the structure from static to dynamically adaptive behavior that reduces injury risk while maintaining support function

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If the armrest is made yielding in the lateral direction to prevent injury, then the armrest can absorb impact energy, but the armrest loses vertical strength needed to support loads

Engineering Contradiction:

Improveinjury risk from impactVSAvoidvertical strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The armrest core is segmented into a lattice structure composed of discrete struts and nodes rather than a solid continuous structure. This segmentation allows independent optimization of different structural elements - vertical struts can be designed for strength and load-bearing, while lateral connections can be designed for flexibility and energy absorption, thereby resolving the contradiction between overall vertical strength and lateral yielding through distributed functional segmentation

Inventive Principle:

Principle #1Segmentation

3Strength

If the armrest uses a solid structure to ensure strength, then the armrest can support vertical loads, but the armrest increases weight and reduces lateral flexibility

Engineering Contradiction:

Improveload support capacityVSAvoidarmrest weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The armrest core employs a lattice structure that is essentially a controlled porous configuration of material. This porous lattice provides sufficient vertical load-bearing capacity through the distributed strut network while significantly reducing overall material usage and weight compared to a solid structure. The porous architecture also inherently provides lateral flexibility as the void spaces allow for controlled deformation during impacts, thereby resolving the contradiction between strength, weight, and flexibility

Inventive Principle:

Principle #31Porous materials

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

The armrest core effectively absorbs impact in side collisions by offering enhanced vertical support and lateral flexibility, reducing the risk of injury to vehicle occupants.

Implementation Method 1

The armrest core effectively absorbs impact in side collisions by offering enhanced vertical support and lateral flexibility

Methodology Applied

Scientific EffectEnergy absorption through deformation: Deformation

Data Source

PatentUS10286821B1Armrest core, armrest incorporating that armrest core and method of manufacturing that armrest assembly

Publication Date: 2019.05.14 FORD GLOBAL TECH LLC

AI summary

An armrest core includes a lattice having a plurality of void channel clusters. The void channel clusters have a section geometry characterized by a lateral dimension D1 and a vertical dimension D2 where D1<D2. An armrest assembly includes the armrest core and an outer cover overlying the armrest core. A method of manufacturing the armrest assembly is also disclosed.