Corrugated Plastic Door Bracket for Side Impact Energy Absorption

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing side impact countermeasures in vehicles face challenges with imprecise positioning due to adhesive use and high costs of specially formulated foamed pads, which struggle to balance low reaction force and energy absorption requirements.

Innovation Solution

A corrugated automobile door bracket with an attachment section and a monolithic corrugated section, formed from materials like plastics, is designed to attach to the door bolster, providing improved positioning and energy absorption while maintaining low reaction forces during side impacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If foamed pads are used for side impact resistance, then energy absorption is improved, but positioning precision deteriorates due to adhesive application

Engineering Contradiction:

Improveimpact energy absorptionVSAvoidpositioning precision

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent replaces the adhesive bonding system with a mechanical attachment system using a door bracket. The bracket uses physical fastening methods (screws, clips, or snap-fits) to attach the impact-resistant material to the door structure, eliminating the need for adhesives and thereby achieving precise positioning while maintaining energy absorption capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the attachment method from chemical bonding (adhesive) to mechanical bonding (bracket with fasteners). This parameter change in the attachment mechanism enables precise positioning during assembly while preserving the energy absorption function of the impact-resistant material.

Inventive Principle:

Principle #35Parameter changes

2Strength

If specially formulated foamed pads are used, then impact resistance is improved, but cost increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent segments the impact-resistant component into a standard door bracket structure combined with a detachable impact-absorbing element. This segmentation allows the use of conventional, cost-effective materials and manufacturing processes for the bracket, while the impact-absorbing element can be a simpler, less expensive material that achieves the required performance when properly configured.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a bracket design that uses conventional, inexpensive materials rather than specially formulated expensive foams. The bracket structure itself can be manufactured using standard plastic injection molding or metal stamping processes, significantly reducing material and manufacturing costs while maintaining adequate impact resistance through proper structural design.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If adhesive is used to attach foamed pads, then attachment is simplified, but positioning precision and cure time are problematic

Engineering Contradiction:

Improveattachment simplicityVSAvoidpositioning precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the adhesive attachment system with a mechanical fastening system using a door bracket. This substitution eliminates cure time requirements and allows for precise positioning during assembly through mechanical means such as screws, clips, or snap-fits, while maintaining ease of attachment through standardized fastening procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of energy

If foamed pads are compressed, then energy absorption increases, but reaction force increases which violates safety requirements

Engineering Contradiction:

Improveenergy absorptionVSAvoidreaction force

Core Design Contradiction:

Loss of energyVSForce

Solution Approach 1:

The patent changes the material properties and structural configuration of the impact-resistant component. By using a bracket design with appropriate structural geometry and material selection, the system achieves energy absorption through controlled deformation mechanisms that maintain reaction forces within safety limits, rather than relying solely on foam compression which generates excessive force.

Inventive Principle:

Principle #35Parameter changes

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 corrugated door bracket effectively absorbs impact energy with controlled deformation, meeting governmental and manufacturer standards by maintaining low reaction forces and efficient energy absorption, outperforming traditional foamed pads in side impact tests.

Implementation Method 1

The corrugated section comprises a plurality of corrugations... effectively absorbs impact energy with controlled deformation

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

maintaining low reaction forces and efficient energy absorption

Methodology Applied

Scientific EffectEnergy absorption: Damping

Data Source

PatentUS7708313B2Plastic bracket countermeasure for door side impact

Publication Date: 2010.05.04 INTERNATIONAL AUTOMOTIVE COMPONENTS GROUP NORTH AMERICA INC

AI summary

An automobile door bracket includes an attachment section and a corrugated section. The door bracket is placed within an automobile door assembly to function as a side impact countermeasure.