Canopy Windshield Retention Pillars with Stiffness Gradients

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Solution Overview

Problem

Mass transport vehicles with larger cabin compartments and reduced front end crumple zones face challenges in absorbing frontal crash impacts effectively, as the distance between the front fascia and occupant chamber is smaller, leading to potential windshield damage and inadequate impact absorption.

Innovation Solution

The vehicle incorporates a canopy-style windshield retention system with pillars designed to crumple or crush in a controlled manner, featuring different stiffness zones and a windshield retention beam to absorb impact energy, allowing the windshield to rotate downward and mitigate crash forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If the distance between front fascia and cabin is reduced to achieve larger cabin volume, then the cabin compartment volume is increased, but the crumple zone size is reduced leading to inadequate impact absorption

Engineering Contradiction:

Improvecabin compartment volumeVSAvoidimpact absorption capability

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The pillar is divided into multiple sections with different stiffness characteristics: a first section with higher stiffness near the roof, a second section with lower stiffness in the middle, and a third section with higher stiffness near the base. This segmentation allows the pillar to absorb impact energy through controlled deformation in the softer middle section while maintaining structural integrity at the ends.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the pillar are given different mechanical properties (stiffness values) to perform different functions. The upper and lower portions maintain high stiffness for structural support, while the middle portion has reduced stiffness for energy absorption during crashes.

Inventive Principle:

Principle #3Local quality

2Reliability

If the pillars are made fully rigid to maintain windshield integrity, then the windshield retention is improved, but the crash impact force transmitted to the cabin increases

Engineering Contradiction:

Improvewindshield retentionVSAvoidcrash impact force

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The pillar's stiffness parameter is varied along its length rather than being uniform. The middle section has a lower stiffness parameter to allow controlled deformation and energy absorption, while the end sections maintain high stiffness to preserve windshield retention and overall structural integrity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the interior support structure is made continuous to strengthen the pillar, then the pillar strength is increased, but the controlled crush capability is reduced

Engineering Contradiction:

Improvepillar strengthVSAvoidcrush deformation time

Core Design Contradiction:

StrengthVSDuration of action of moving object

Solution Approach 1:

The interior support structure is selectively removed or reduced in the middle section of the pillar where controlled deformation is desired. This creates a gap or reduced stiffness zone that allows the pillar to crush in a controlled manner during impacts, while the support structure remains intact at the ends to maintain overall strength.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This design enhances the vehicle's ability to absorb frontal crash impacts by increasing the crumple zone size and reducing the force transmitted to the cabin compartment, thereby protecting occupants and maintaining windshield integrity.

Implementation Method 1

The first and second pillars include a portion that is configured to crumple or crush that rotates the windshield downward in a controlled manner

Methodology Applied

Scientific EffectControlled crumple: Deformation

Implementation Method 2

The vehicle includes a canopy style windshield retention system with pillars designed to crumple or crush in a controlled manner, featuring different stiffness zones and a windshield retention beam to absorb impact energy

Methodology Applied

Scientific EffectImpact energy absorption: Absorption (physical)

Implementation Method 3

The first and second pillars include a first stiffness zone and a second stiffness zone, such that the second stiffness zone is closer to the roof than the first stiffness zone. The first portion and the second portion provide different a stiffness as compared to the third portion. The differences in stiffness mitigate an impact received during a crash.

Methodology Applied

Scientific EffectStiffness gradient: Elasticity

Data Source

PatentUS11505259B2Canopy windshield retention

Publication Date: 2022.11.22 FORD GLOBAL TECH LLC

AI summary

The present disclosure relates to a vehicle that includes a windshield and a frame. In addition, the vehicle includes a first pillar that extends from one side of the windshield. The first pillar includes a first wall and a second wall coupled to the first wall. The first pillar also includes a first portion and a second portion. The first portion includes a first interior support coupled to the first wall and a second interior support coupled to the second wall. Further, the first interior support includes a first end which is spaced from a second end in the second portion.