Vehicle Chassis Fairing With Embedded Rollers for Side Impact Protection

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Solution Overview

Problem

Existing chassis fairing systems for heavy-duty vehicles provide limited protection against side impacts and rollover events, particularly for vehicles with side-mounted battery packs or hydrogen storage units, which are susceptible to damage and fire hazards during accidents.

Innovation Solution

Integration of vertically arranged shock-absorbing rollers embedded within the chassis fairing system to absorb and distribute impact energy, enhancing safety by reducing the severity of collisions and rollovers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If traditional chassis fairings are used, then aerodynamic drag is reduced, but protection against side impacts and rollover events is insufficient

Engineering Contradiction:

Improveprotection against side impacts and rollover eventsVSAvoidcomplexity of chassis fairing system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The fairing system is divided into multiple functional components: the fairing structure itself and multiple independently arranged rollers. Each roller can rotate independently to absorb impact energy, while the fairing provides aerodynamic protection. This segmentation allows each component to specialize in its function without requiring the entire system to be overly complex.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rollers are designed to rotate dynamically during impact events rather than being fixed. This dynamic response allows the rollers to absorb impact energy through rotation, providing adaptive protection that activates only when needed. The fairing maintains its static aerodynamic shape while the rollers provide dynamic impact absorption.

Inventive Principle:

Principle #15Dynamics

2Strength

If vertically arranged rollers are added to the fairing system, then impact energy is absorbed and distributed, but the device complexity increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidnumber of components in fairing system

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The roller components serve multiple functions: they act as impact absorbers during side collisions, provide rollover protection through their vertical arrangement, and can be integrated into the existing fairing structure. This multi-functionality justifies the added complexity by delivering multiple safety benefits from a single component addition.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The rollers are pre-positioned in vertical arrays on the fairing structure before any impact occurs. Their vertical arrangement and rotational capability are designed in advance to cushion against both side impacts and rollover forces. This prior cushioning design ensures protection is already in place when accidents occur, rather than requiring active deployment mechanisms.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Object-affected harmful factors

If rollers are embedded in the fairing body, then impact forces are distributed over larger area, but manufacturing complexity increases

Engineering Contradiction:

Improveimpact force distributionVSAvoidease of assembling fairing system

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into separate steps: first manufacturing the fairing structure with integrated roller housings, then assembling the roller components into these pre-prepared housings. This segmentation of manufacturing steps makes the overall process more manageable compared to attempting to create fully integrated monolithic structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rollers are nested within the fairing structure, with each roller housed in its own compartment or housing that is integrated into the fairing body. This nesting arrangement allows the rollers to be protected and properly positioned while maintaining the aerodynamic shape of the fairing. The nested structure also simplifies assembly by providing dedicated spaces for each roller component.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 embedded rollers effectively distribute impact forces over a larger area, minimizing damage to the vehicle structure and its components, such as battery packs or hydrogen storage units, while reducing the risk of injury and fire hazards.

Implementation Method 1

a plurality of vertically arranged rollers that are at least partly embedded in a body of the at least one side fairing... the chassis fairing system mitigates the impact of accidents by having the vertical rollers that absorb and distribute energy

Methodology Applied

Scientific EffectEnergy absorption through rotation: Friction

Data Source

PatentEP4663521A1A chassis fairing system for a vehicle

Publication Date: 2025.12.17 VOLVO TRUCK CORP

Figure 1~2A
Figure 2B~2C
Figure 3A~3B

AI summary

A chassis fairing system for a vehicle (10) is provided. The system comprises at least one side fairing (100a, 100b) arranged to be affixed to a longitudinal side (13) of the vehicle (10), and a plurality of vertically arranged shock absorbing rollers (140a-f) that are at least partly embedded in a body (110) of the at least one side fairing (100a, 100b). A vehicle is also provided.