Brake Input Device Crash Protection via Slanted Surface
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Solution Overview
Problem
Existing vehicle brake systems with electric boosting devices face challenges in effectively absorbing crash impacts, particularly during oblique or offset crashes, where the engine may not collide with the frangible parts, allowing crash impacts to transmit to the input device and potentially the passenger compartment, compromising occupant safety and layout flexibility.
Innovation Solution
A vehicle brake system design where the input device is attached to a bulkhead with a protective member featuring a slanted surface extending into the power unit room, which creates a lateral force during a frontal crash, tilting the input device and preventing it from moving into the passenger compartment, and utilizing a separate, inexpensive protective member made of stamp-formed sheet metal attached to the input device to enhance impact absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the input device is positioned in the engine room to enhance layout freedom, then the freedom in layout of the brake system is improved, but the input device may transmit crash impact to the passenger compartment
Solution Approach 1:
A protective member is introduced as an intermediary element between the power unit and the input device. This protective member includes a slanted surface that intercepts the rearward movement of the power unit during a crash and redirects it laterally, preventing direct impact transmission to the input device and subsequently to the passenger compartment.
Solution Approach 2:
The protective member is designed as a separate, independently attachable component rather than being integrated into the input device itself. This segmentation allows the protective function to be added without modifying the input device structure, maintaining layout flexibility while providing crash protection.
2Object-affected harmful factors
If a frangible part is provided on the input device to stop impact, then the impact transmission to passenger compartment is reduced, but oblique or offset crashes may bypass the frangible part
Solution Approach 1:
The protective member utilizes a slanted surface that operates in a different dimensional approach compared to traditional frangible parts. Instead of relying on a specific fracture point, the slanted surface creates a lateral redirecting force that works regardless of the crash angle, effectively protecting against oblique and offset crashes that would bypass conventional frangible designs.
3Ease of manufacture
If the protective member is made as a separate attachable component, then the manufacturing cost is minimized, but the attachment must be secure enough to withstand crash forces
Solution Approach 1:
The protective member is designed as a separate, stamp-formed sheet metal component that can be manufactured independently and attached to the input device. This segmentation enables cost-effective production while the attachment mechanism (fasteners and engagement features) provides sufficient strength to withstand crash forces.
Solution Approach 2:
The protective member is constructed from relatively inexpensive stamp-formed sheet metal, treating it as a sacrificial or replaceable component that can be easily manufactured and attached without requiring high-strength, expensive materials, while still providing effective crash protection.
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 design effectively absorbs crash impacts, preventing the input device from entering the passenger compartment and protecting both the input device and electric components, while maintaining layout flexibility and minimizing manufacturing costs.
Implementation Method 1
a free end of the part of the input device extending into the power unit room is fitted with a protective member (70) defining a slanted surface (70a) opposing the power unit and slanting rearward as one moves in a prescribed lateral direction. Owing to the provision of the slanted surface, at the time of a frontal crash, a rearward collision of the power unit... with the input device creates a lateral force to the free end of the input device
Data Source
AI summary
A vehicle brake system comprises an input device (21) attached to a bulkhead (15) separating a power unit room and a passenger compartment of the vehicle from each other, and including a part extending into the power unit room. A free end of the part of the input device extending into the power unit room is fitted with a protective member (70) defining a slanted surface (70a) opposing the power unit and slanting rearward as one moves in a prescribed lateral direction so that the input device is protected from a frontal impact. In particular, the slanted surface aligns with a corner part (83a) of the power unit (83).